Tufting machine and tufting method

Abstract

A system, apparatus, and method for forming a tufted article may include a hollow needle tufting machine for forming a patterned tufted article including yarns of a plurality of colors. The hollow needle tufting machine may include a series of hollow needles arranged at a stitch pitch along a needle bar and will receive a series of yarns of different colors and / or types from a yarn feed system. A funnel block having a series of funnels configured to receive a series of yarns is to be disposed adjacent to the needle bar for guiding selected yarns to a corresponding or associated hollow needle. The plurality of hollow needles are to reciprocate into and out of the backing to deliver a series of yarns; the plurality of blades can be jointed with the corresponding plurality of blades to form a plurality of yarn piles. The plurality of blades are movable between a non-cutting position and a cutting position to form a plurality of loop pile and cut pile yarn piles in the backing.

Description

[0001] Cross-references

[0002] This patent application claims the benefit of U.S. Provisional Patent Application No. 63 / 401,393, filed on August 26, 2022.

[0003] Incorporated by Reference

[0004] The disclosure and drawings of U.S. Provisional Patent Application No. 63 / 401,393, filed on August 26, 2022, are specifically incorporated by reference into this application as if set forth in its entirety. Technical Field

[0005] The present disclosure relates to tufting machines for producing tufted textile articles such as carpets and other articles; and more particularly to hollow needle tufting machines and methods of tufting using such hollow needle tufting machines. Background Art

[0006] Hollow needle tufting machines, such as those shown in U.S. Pat. No. 4,549,496 to Kile, U.S. Pat. No. 5,588,383 to Davis et al., and U.S. Pat. No. 6,401,639 to Samilo, have been used to produce patterned carpets by implanting yarns of different colors into a backing material. Such hollow needle tufting machines typically have a yarn feeding mechanism that supplies yarns of different colors to each of the hollow needles, the yarns being blown into and through a funnel block associated with each hollow needle and into the central passage of each hollow needle. Typically, an electromagnetically controlled cylinder operates to control the feeding of yarns of different colors through the funnel and into each of the hollow needles. In the past, the number of colors that could be fed to each needle of such a hollow needle tufting machine was generally limited by the needle pitch spacing, and in order to expand the number of colors, the needle pitch spacing between needles was generally increased, for example, doubling the spacing from 1" to 2", which could result in other limitations in the patterns produced and / or the productivity of the machine.

[0007] In addition, many conventional hollow needle tufting machines contain multiple yarn injectors and one or more solenoid valves for each needle, which increases the complexity and expense of manufacturing, maintaining and repairing, and operating such hollow needle tufting machines; typically increasing the amount of energy used by the machine to supply additional air to it as needed during operation of the machine. It is also necessary to control the feed of the yarn in an attempt to achieve as close to uniform a pile height as possible. However, when the yarn is replaced and released from the needle, the yarn may retract due to the inherent elasticity of the corresponding yarn, and this retraction may vary for different yarns with different elasticities.

[0008] Therefore, it can be seen that there is a need for a hollow needle tufting machine that can achieve increased production efficiency and the ability to produce complex patterns, such as patterns utilizing yarns of an increased number of colors. The present disclosure is directed to a hollow needle tufting machine and methods for operating such a hollow needle tufting machine that address the foregoing and other needs and shortcomings present in the prior art. Summary of the invention

[0009] Briefly stated, the present disclosure is directed to a system, apparatus, and method for forming tufted articles such as, but not limited to, carpet, artificial turf and / or grass, area rugs, and other tufted fabrics.

[0010] In an embodiment, the system and apparatus for forming a tufted product disclosed and shown herein may include a tufting machine having a series of needles that reciprocate in and out of a backing to form a plurality of tufts therein. In an embodiment, the tufting machine may further include a yarn feeding system and a yarn selection system, wherein the yarn feeding system feeds a plurality of yarns to each of the needles, and the yarn selection system includes a plurality of drawer modules, each drawer module having a cylinder body and a drawer (jerker), and the drawer can be moved between an extended position and a retracted position for pulling back unselected yarns from the needle. In some embodiments, the drawer module may include a double-acting cylinder with a reduced profile, and may further include a multi-way valve for controlling a pressurized air flow so as to control the extension and retraction of the drawer. In an embodiment, the yarn feeding system may include a plurality of yarn feeding devices, each of which is configured to feed a single yarn to an associated needle in a hollow needle.

[0011] In some embodiments, the apparatus may include a tufting machine having a plurality of hollow needles, a yarn feeding system, a yarn selection system, a yarn cutting system, and a control system having one or more processors and programs configured to collaboratively control the feeding of yarn to the hollow needles through the yarn feeding system, engage one or more drawers of the yarn selection system to pull back unselected yarns, and / or move one or more blades of the yarn cutting system to cut the selected yarns presented by the needles to form a selected pattern.

[0012] Additionally, in embodiments, the methods disclosed and illustrated herein may include a method of forming a patterned tufted article. In embodiments, the method may include displacing a plurality of hollow needles in needle pitch increments. In some embodiments, the method may further include selectively moving one or more blades between a non-engaging or non-cutting position and one or more engaging or cutting positions.

[0013] In an embodiment, the present disclosure relates to an improved hollow needle tufting machine and features and / or components thereof. The improved hollow needle tufting machine may include a control system having a controller, which can be combined with the hollow needle tufting machine. The control system may include instructions or programs that can be executed to control various operating systems or components of the hollow needle tufting machine in a collaborative manner to form patterns using an increased number of colors or types of yarns, which can be formed without expanding the stitch spacing between needles. For example, but not by way of limitation, in an embodiment, a patterned article comprising 4, 8, 16, and possibly more colors of yarn can be formed, wherein the hollow needles of the hollow needle tufting machine are arranged at a stitch spacing of approximately 1", and wherein the yarn is fed to each of the needles substantially uniformly.

[0014] For example, in an embodiment, a hollow needle tufting machine is disclosed which may include a needle bar having a series of hollow needles mounted in a spaced-apart sequence, such as at an exemplary needle pitch spacing of approximately 1" (and in some embodiments, a needle pitch spacing of less than 1" or a needle pitch spacing of greater than 1"). The needle bar may be mounted along a mounting plate, which may include or be connected to a funnel block having a series of funnels, each funnel being associated with a corresponding one of the needles. In some embodiments, each funnel may be configured so that at least about 8 colors can be fed therethrough and fed to each of the hollow needles. For example, in an embodiment, each needle may tuft up to about 8 colors per needle. Yarn may be fed from an upper or inlet portion of each funnel to a tubular outlet, which, in an embodiment, may have a stop defined along it.

[0015] In an embodiment, the inlet portion of each funnel may be configured as a multi-angle circular orifice having a first angled or inclined surface defined adjacent to an upper portion or region of the funnel and having a first angle, and the first angled or inclined surface transitions to a second angled surface having a second angle, which in an embodiment may be different from the first angle. The yarn is directed into and through the funnel, to the tubular outlet of the funnel and into the bore of a corresponding or associated hollow needle located below it.

[0016] In other embodiments, the funnel may have a plurality of slotted yarn flow grooves defined around its periphery adjacent to its upper portion or zone. For example, in an embodiment, the funnel may include 8 slotted yarn flow grooves. In other embodiments, a greater or lesser number of slotted yarn flow grooves may also be provided. In an embodiment, the slotted yarn flow grooves may be arranged around the funnel in a substantially circular arrangement, for example, configured to form a flower pot type design. It is contemplated that other arrangements may also be used in other embodiments as needed to accommodate different numbers and / or types of yarns being fed. In an embodiment, each funnel may be configured to feed more than one yarn per funnel.

[0017] In an embodiment, a hollow needle tufting machine may include a modular configuration of needles and blades. For example, in an embodiment, a plurality of needle modules may be mounted along a needle bar of a hollow needle tufting machine, each needle module including one or more hollow needles. In some embodiments, the needles may be positioned and fixed in place within their modules by a processing fixture and fixed in a desired orientation. In an embodiment, the processing fixture may include a body having an opening, in which the needles are received and against which the needle modules may engage. The openings in the fixture guide the needles to the desired orientation, after which each needle may be fixed in place in the body of its module. Additionally, in an embodiment, a plurality of blade modules may be provided, for example as part of a yarn cutting system or a knife bar system, wherein each blade module has at least one blade or cutting edge.

[0018] In an embodiment, a shifting mechanism may be provided to control the displacement movement of the backing support or shuttle of the hollow needle tufting machine. In an embodiment, a shifting mechanism may be further provided for gradually shifting the needle bars, and therefore the needles, laterally across the backing material. In an optional embodiment, the backing may be displaced or the needle bars may be displaced laterally, or both the backing and the needle bars may be displaced laterally. The shifting mechanism may include a servo motor driven or similar actuator driven shifting mechanism, in an embodiment, it may include a servo controlled rack and pinion shifting mechanism.

[0019] In an embodiment, the needle module may have a reduced profile so that the needles can be installed at about 1" gauge spacing, with each needle receiving about 8 colors of yarn. It is contemplated that other desired gauge spacings of the needles can be used and additional colors can be tufted by shifting the backing, shifting the needles, or both. The needles can also be mounted at closer spacings. The backing, needles, or both can be laterally shifted in single or double gauge jumps or steps as needed to form a selected pattern, rather than having to shift multiple gauges across two, three, or more gauge spacings to form the same pattern.

[0020] In embodiments, the hollow needle tufting machine may incorporate a yarn feed system with improved control. For example, in embodiments, the hollow needle tufting machine may incorporate one or more single-end or double-end yarn feed mechanisms or accessories, such as the Infinity 1000 from Card-Monroe Corp. of Chattanooga, TN. TM or Infinity IIE TM Yarn feeding accessories or yarn feeding mechanisms or systems. Such yarn feeding mechanisms or accessories may include yarn feeding units or modules, each of which may include multiple individual yarn feeding devices that can be individually selectively controlled to feed one or two yarns to a needle, or in some embodiments, more yarns to a needle. In embodiments, one or more yarn feeding mechanisms or accessories of a yarn feeding system may generally be configured to control the feeding of a selected length of yarn for each individual stitch to enable the formation of multiple fabric surfaces and / or multiple fabric pile heights.

[0021] Additionally, in an embodiment, the hollow needle tufting machine may include puller rolls downstream of the yarn feed mechanisms and / or accessories on each side of the hollow needle tufting machine. The rotation of the puller rolls may be controlled by the system controls to control the pulling of yarn from the yarn feed rolls of one or more yarn feed mechanisms or accessories for feeding to its needles along the travel path.

[0022] In some embodiments, the hollow needle tufting machine may further include a yarn selection system. In an embodiment, the yarn selection system may include a series of yarn injectors, which are operable to inject air into a funnel so as to blow or guide the selected yarn fed from the yarn feeding system into the needle. In some embodiments, the yarn selection system may further include a series of drawer modules, which are arranged along the travel path of the yarn from the yarn feeding mechanism or accessories to the needle, and each drawer module generally has a drawer (yarn jerker) connected to an actuator. The drawer can be selectively controlled to extend and retract along a selected length or stroke (e.g., in an embodiment, approximately 2 "stroke, but other distances may also be used) to retract or pull back the yarn from the needle. In an embodiment, this may enable the use of smaller needles and modules that can be arranged at closer spacings (e.g., 1 "stitch spacing).

[0023] In an embodiment, the actuator may include a cylinder formed with a drawer module or incorporated into the drawer module, for example, the drawer module may be formed with a plurality of holes, and each hole accommodates a piston rod therein. Other types of actuators may also be provided. For example, in some embodiments, the drawer module (or its actuator) may include a double-acting cylinder, which is configured to not have a mechanical spring return, and uses the air of the different parts of the hole supplied to the drawer module to cause the piston to move along the selectivity of the hole, so as to control the extension and retraction of the drawer. In an embodiment, owing to not using a spring, the drawer module is provided or formed as a double-acting cylinder that can help increase the timing or the speed of the actuation of the drawer. In addition, the lower air pressure for the operation of the drawer may also be used to operate the double-acting cylinder.

[0024] In an embodiment, the size of the actuator (e.g., drawer module / double-acting cylinder or other selectively controlled actuator) can be reduced. For example, the hole of the drawer module can be reduced from 1 / 2 to 5 / 16 using two four-way solenoid valves and two three-way valves. The drawer module can also be configured with a smaller profile to achieve enhanced design density (e.g., eight drawer modules located at about two inches of spacing), and the high-density module arrangement allows control of feeding and / or pulling back unused yarn from the needle (e.g., using a 2" stroke drawer).

[0025] In an embodiment, each of the drawers may include a body having a proximal end and a key at its distal end, such as a female keyway or a male keyway, the proximal end being configured to engage a yarn passing through a yarn selection system (e.g., through an opening of a yarn guide adjacent to a drawer module). The key may be coupled to an associated actuator in the actuator by engaging and interlocking with a drawer door, and the interlocking arrangement may be configured to limit its rotation. In other embodiments, a guide rod may be used as an alternative anti-rotation mechanism.

[0026] The drawer module can also be formed by a lighter material, such as aluminum or composite material, such as nylon, carbon fiber polymer and / or other moldable materials. In some embodiments, the yarn feed opening formed in the drawer module can also be hard-coated anodized or otherwise processed to promote movement of the yarn through it. A separate pipe or conduit for each yarn can be coupled to the yarn feed opening to supply yarn and supply yarn to needles through the drawer module for forming tufts in the backing.

[0027] In an embodiment, the yarn feeding system may be controlled, for example, by a control system based on a program and a desired pattern being formed. In some embodiments, the control system may include a controller, which may include one or more processors and a memory, which may be configured to receive and store pattern information, and the controller may further include programs or instructions suitable for controlling the operation of the hollow needle tufting machine and its various operating components. For example, in an embodiment, the controller of the control system may include a program or instructions executed by one or more processors for selectively controlling the yarn fed to the needles to achieve substantially consistent yarn feeding to each of the needles, cooperating with the engagement / selective operation of the blades and the drawbar, and / or shifting the backing material and / or the needles based on the received or programmed pattern information to form a desired pattern with multiple colors and / or types of yarns.

[0028] In such embodiments, the control system may include a program adapted to apply dynamic advancement parameters to advance the operation of various operating components of the hollow needle tufting machine based on the operating speed (RPM) of the main shaft of the hollow needle tufting machine. For example, based on the rotation of the machine shaft of the tufting machine, the control system may advance the operation of one or more operating components, such as the engagement of a selected drawer among the drawers, the engagement (e.g., switching on and off) of the blower, the yarn feeding of a selected yarn among the yarns being fed to each needle, the movement, displacement, and other operating elements of the blade between a cutting position and a non-engaged or non-cutting position, before the next stitch placement step or tuft placement step of the pattern.

[0029] In an embodiment, the control system may control the yarn feeding system (e.g., controlling a yarn feeding device or a yarn feeding mechanism or a selected one of its units) to deliver a portion of the yarn length to be fed to each needle during each stitch or individual stitching operation within a portion of a rotation of the main shaft of the hollow needle tufting machine.

[0030] In some embodiments, the hollow needle tufting machine may be configured to provide single level cut-pile tufted fabrics, and the control system may include a program that utilizes yarn feed control to control the formation of multi-level loop pile tufts of yarns without necessarily moving the blade for cutting the yarn loops from a cutting (cylinder extended) position to a looping (cylinder retracted) position.

[0031] In some additional embodiments, the formation of multiple layers of pile height tufts may also be provided, which may include the formation of two layers of cut pile tufts. In such embodiments, the yarn feed control may be utilized in conjunction with a yarn cutting or blade system configured to achieve increased control over the positioning of the blades, including providing for selective movement of selected blades according to the tufting pattern to be formed.

[0032] For example, in some embodiments, the yarn cutting or knife bar system may include a knife bar along which a series of blades are mounted. In embodiments, the yarn cutting or knife bar system may further include a knife bar having a plurality of individually controllable blade modules or blocks mounted along it. Each blade module or block may have a body in which the blades are mounted, and a multi-position actuator, such as a pneumatic cylinder, which may be selectively controlled or activated to move its corresponding or associated blade between a non-cutting position and a cutting position relative to the stroke of the needles of the hollow needle tufting machine.

[0033] In embodiments, the blade may be oriented or aligned to a desired or selected position relative to the needle by an alignment system, which in embodiments may include a plate assembly disposed along the blade bar. In embodiments, the blade may be oriented by the plate assembly to set the angle of orientation of the blade relative to the needle angle of each of its associated or corresponding needles. Adjustment of the blade may also assist in setting or adjusting blade pressure.

[0034] By selectively controlling the blade position, multiple cut heights can be achieved. As a further result, in embodiments, the yarn feed can be controlled in conjunction with the control of the blade positioning to achieve the formation of a multi-pile height tufted article having both cut and loop pile. In some embodiments, the multi-pile height tufts can include cut pile tufts of different pile heights and loop pile tufts of different pile heights, which can be selectively formed to achieve further texturing effects in addition to enabling the formation of various patterns of different colors or types or yarns.

[0035] In an embodiment, a blade positioning system is disclosed in which a multi-position actuator may be provided. The flow of air or other fluid to the multi-position actuator or the air pressure of the supply may be controlled by a control system so that the blade moves between various selected cutting positions for forming cut pile tufts of a selected pile height and non-engaging or non-cutting positions for forming loop pile tufts. For example, in an embodiment, the multi-position actuator may include a 3-position actuator, such as a 3-position pneumatic or hydraulic cylinder or a servo or stepper motor (or other actuator), and may further include a 4-way fluid valve for selectively controlling the supply of fluid (e.g., air) to the 3-position actuator. In an embodiment, at least three positions may be provided for each of the blades, such as a high cutting position, a low cutting position, and a non-cutting or looping position.

[0036] In addition, according to various aspects of the present disclosure, there is provided a tufting machine, which comprises: a backing support; a plurality of needles, the plurality of needles being positioned above the backing support and being configured to penetrate a backing positioned on the backing support when the plurality of needles reciprocate; wherein the plurality of needles comprises a plurality of hollow needles, each hollow needle having an upper end and a lower end, wherein a channel is defined between the upper end and the lower end; a yarn feeding system, the yarn feeding system being used to supply a plurality of yarns; a series of funnels, the series of funnels being connected to the plurality of needles; a yarn selection system, the yarn selection system being connected to an air supply source and being configured to deliver a plurality of selected yarns from a plurality of yarns supplied by the yarn feeding system to one or more of the plurality of needles; wherein the yarn selection system comprises: a series of yarn injectors, the series of yarn injectors being configured to guide the plurality of selected yarns to the plurality of needles, into one or more of the plurality of funnels for feeding to the plurality of needles; a series of A drawer module, wherein the series of drawer modules are arranged along the travel path of multiple yarns from a yarn feeding system to multiple funnels, each of the multiple drawer modules is connected to an air supply source and includes multiple holes in which multiple pistons are accommodated; and a plurality of drawers, wherein the multiple drawers are connected to the multiple pistons and each includes a body having a proximal end and a distal end, wherein the distal end is configured to engage at least one of the multiple yarns supplied by the yarn feeding system; wherein the multiple drawers can be individually moved between an extended position and a retracted position to retract a plurality of unselected yarns from the multiple funnels by selectively controlling the air flow to the multiple holes of the multiple drawer modules; and a cutting assembly, wherein the cutting assembly is arranged below a backing support and includes one or more blades, wherein the one or more blades are configured to cut the selected multiple yarns as the selected multiple yarns are carried into the backing as the multiple needles reciprocate in and out of the backing.

[0037] In an embodiment, the tufting machine further includes a control system configured to control the operation of a yarn feeding system for feeding a selected plurality of yarns to a plurality of needles and the operation of a plurality of drawdowns; wherein the control system includes a program configured to dynamically advance the operation of the yarn feeding system and the plurality of drawdowns before the next needle position step to form a pattern.

[0038] In some embodiments, the control system further includes a program configured to feed a selected plurality of yarns and selectively move the plurality of drawers between their extended and retracted positions based on rotation of a main drive shaft of the tufting machine.

[0039] In an embodiment, a plurality of drawer modules include a plurality of double-acting cylinders having a series of multi-way valves connected to a plurality of holes and configured to control air flow into and through the plurality of holes so that a plurality of pistons move along the plurality of holes for controlling the extension and retraction of a plurality of drawers.

[0040] In an embodiment, the plurality of holes of the plurality of drawer modules have a diameter less than 1 / 2 inch. In some embodiments, the plurality of drawer modules include a plurality of double-acting cylinders having a reduced profile; and the plurality of drawer modules are mounted in one or more groups having a spacing of 8 drawer modules located in about 2 inches.

[0041] In an embodiment, the proximal end of each of the plurality of yarn drawers includes an anti-rotation mechanism configured to resist rotation of the plurality of yarn drawers as the plurality of yarn drawers move between their extended and retracted positions.

[0042] In an embodiment, each of the plurality of funnels comprises an upper end defining an inlet portion and a lower end defining an outlet, the outlet being in communication with an associated needle among the plurality of needles; and wherein the inlet portion comprises a multi-angle orifice comprising a first portion having a first diameter and a second portion having a second diameter, the second diameter being different from the first diameter.

[0043] In an embodiment, the cutting assembly further includes a plurality of blade modules and a plurality of actuators, wherein the plurality of blades are accommodated in the plurality of blade modules, each actuator is connected to one or more of the plurality of blade modules and is in communication with the plurality of blades, and the plurality of actuators can be selectively actuated to control the movement of each of the plurality of blades between a retracted position and a cutting position.

[0044] In an embodiment, the tufting machine further comprises an indexing mechanism connected to the backing support and configured to move the backing support laterally relative to the path of travel of the backing.In some embodiments, the indexing mechanism may comprise a rack and pinion indexing mechanism.

[0045] In an embodiment, a yarn feeding system comprises at least one yarn feeding mechanism having a plurality of yarn feeding devices, each yarn feeding device being configured to control feeding of at least one yarn to a plurality of needles.

[0046] According to other aspects, a tufting machine is provided, which includes: a main drive shaft; a backing support along which a backing is supported; a plurality of needles, the plurality of needles being positioned above the backing support and being configured to penetrate the backing to deliver a selected plurality of yarns during reciprocating motion of the plurality of needles; wherein the plurality of needles include a plurality of hollow needles, each hollow needle having an upper end and a lower end, wherein a channel is defined between the upper end and the lower end; a yarn feeding system, the yarn feeding system being used to supply a plurality of yarns; a series of funnels, the series of funnels being connected to the plurality of needles; a series of drawers, the series of drawers being arranged along a path of travel of the plurality of yarns from the yarn feeding system to the plurality of funnels, each of the plurality of drawers being configured to selectively operate to retracting a plurality of unselected yarns from a plurality of needles; a cutting assembly disposed below a backing support and comprising one or more blade modules, each blade module comprising a blade configured to cut a plurality of selected yarns as the selected yarns are carried into the backing as the plurality of needles reciprocate in and out of the backing; and a control system configured to control the feeding of the selected yarns to the plurality of needles and the movement of a plurality of selected drawers between their extended and retracted positions, the control system comprising a program configured to advance the feeding of the selected yarns by the yarn feeding system and the movement of the plurality of selected drawers based on the rotation of a main drive shaft of the tufting machine before the next row of tufts forming a pattern is stepped.

[0047] In an embodiment, the control system may further comprise a program configured to control the feeding of a selected plurality of yarns of different lengths during rotation of the main drive shaft.

[0048] In an embodiment, the plurality of yarn drawers each include a body having a proximal end and a distal end, wherein the distal end projects and is configured to engage and selectively withdraw a plurality of unselected yarns when the plurality of yarn drawers move from an extended position to a retracted position.

[0049] In an embodiment, the tufting machine further includes a plurality of drawer modules, each of the plurality of drawer modules including a main body having a plurality of holes defined therethrough and connected to an air supply source, a series of pistons being accommodated within the plurality of holes and connected to the plurality of drawers, and the plurality of valves being in communication with the plurality of holes and configured to control a plurality of pressurized air flows entering and passing through the plurality of holes so that the plurality of pistons move along their holes, thereby controlling the movement of the plurality of drawers between their extended positions and retracted positions.

[0050] In some embodiments, the plurality of drawer modules include a plurality of double-acting cylinders having a reduced profile; and the plurality of drawer modules are mounted into one or more groups having approximately 8 drawer modules located within a spacing of approximately 2 inches.

[0051] In an embodiment, the tufting machine further includes an air supply source connected to the plurality of drawer modules and the cutting assembly; and wherein the control system further includes a program configured to perform the following operations: control multiple pressurized air flows from the air supply source to one or more of the plurality of drawer modules for selectively extending and retracting one or more of the plurality of drawers of the plurality of drawer modules, and / or control multiple pressurized air flows from the air supply source to one of the plurality of blade modules of the cutting assembly for selectively moving one or more of the plurality of blades of the plurality of blade modules between a non-engaged position and one or more cutting positions.

[0052] In an embodiment, the tufting machine may further include one or more regulators positioned between the air supply source and the plurality of drawer modules and / or the plurality of blade modules; wherein the plurality of regulators include programs configured to control multiple pressurized air flows to the plurality of drawer modules and / or the plurality of blade modules based on the pattern being tufted.

[0053] In some embodiments of the tufting machine, each of the plurality of funnels includes an upper end defining an inlet portion and a lower end defining an outlet, the outlet being connected to an associated needle among the plurality of needles; and wherein the inlet portion includes a multi-angle orifice, the multi-angle orifice including a first portion having a first diameter and a second portion having a second diameter, the second diameter being different from the first diameter.

[0054] In an embodiment, each of the plurality of blade modules of the cutting assembly further comprises an actuator in communication with its blade; and wherein each actuator of each blade module is selectively actuatable to control movement of the blade between a retracted position and a cutting position.

[0055] In an embodiment, the tufting machine further comprises an indexing mechanism configured to move at least one of the backing support and the plurality of needles laterally relative to a path of travel of the backing.

[0056] In some embodiments, a yarn feeding system includes at least one yarn feeding accessory having a plurality of yarn feeding devices, each yarn feeding device being configured to control feeding of at least one yarn to a plurality of needles.

[0057] Additionally, in some embodiments of the tufting machine, each of the plurality of funnels may include an upper end and a lower end, the lower end defining an outlet communicating with an associated needle among the plurality of needles; and wherein the upper end includes a plurality of yarn flow grooves configured to guide one or more yarns into the funnel to be fed to the associated needle.

[0058] According to another aspect of the present disclosure, there is provided a method for forming a patterned tufted product, comprising: feeding a backing along a travel path; feeding a plurality of yarns through a yarn selection system and feeding them to a plurality of hollow needles; wherein the needle selection system comprises a series of drawer modules, the series of drawer modules being connected to an air supply source and comprising a plurality of holes and a plurality of drawers, the plurality of holes accommodating a plurality of pistons therein, the plurality of drawers being connected to the plurality of pistons and each comprising a body having a proximal end and a distal end; selecting and feeding a backing; feeding a plurality of yarns through a yarn selection system and feeding them to a plurality of hollow needles; wherein the needle selection system comprises a series of drawer modules, the series of drawer modules being connected to an air supply source and comprising a plurality of holes and a plurality of drawers, the plurality of holes accommodating a plurality of pistons therein, the plurality of drawers being connected to the plurality of pistons and each comprising a body having a proximal end and a distal end; selecting and feeding one or more yarns among the plurality of yarns to the plurality of hollow needles, and feeding selected lengths of one or more desired colors or types of yarns to the plurality of hollow needles; and controlling the feeding of a plurality of unselected yarns and moving one or more of the plurality of drawers from an extended position to a retracted position to retract the plurality of unselected yarns or prevent the plurality of unselected yarns from being fed to the plurality of hollow needles; and reciprocating the plurality of hollow needles in and out of a backing to place a plurality of tufts of the one or more yarns into the backing according to a pattern being formed.

[0059] In an embodiment, the method further comprises displacing the backing transversely to its path of travel.

[0060] In an embodiment, the method further includes advancing feeding of the selected plurality of yarns by the yarn feeding system and movement of the plurality of yarn drawers between their extended and retracted positions based on rotation of a main drive shaft of the tufting machine before the next needle position step of forming the pattern.

[0061] In an embodiment, the method further comprises cutting the one or more yarns carried into the backing with the plurality of hollow needles to form a plurality of tufts.

[0062] According to other aspects of the present disclosure, a tufting machine includes: a plurality of hollow needles; a yarn feeding mechanism, the yarn feeding mechanism being configured to control a plurality of selected yarns from a plurality of yarns supplied to the plurality of hollow needles according to a pattern; an air supply source, the air supply source being used to supply pressurized air; a yarn selection system, the yarn selection system being configured to retract a plurality of unselected yarns or prevent a plurality of unselected yarns from being fed to the plurality of hollow needles, the yarn selection system including: a series of yarn injectors, the series of yarn injectors being configured to inject a plurality of selected yarns to the plurality of hollow needles; a series of yarn drawing modules, the series of yarn drawing modules being configured to feed a plurality of yarns from the plurality of hollow needles along the plurality of yarns. A travel path arrangement of a yarn feeding system to multiple funnels, each of a plurality of drawdown modules being connected to an air supply source and comprising a plurality of holes in which a plurality of pistons are accommodated; and a plurality of drawdowns, the plurality of drawdowns being connected to the plurality of pistons and each comprising a body having a proximal end and a distal end, the distal end being configured to engage at least one of a plurality of yarns supplied by the yarn feeding system; wherein the plurality of drawdowns are individually movable between extended and retracted positions to retract a plurality of unselected yarns or prevent a plurality of unselected yarns from being fed to a plurality of hollow needles by selectively controlling pressurized air to the plurality of holes of the plurality of drawdown modules according to a pattern being formed.

[0063] In an embodiment, the tufting machine further includes a cutting assembly disposed below the backing support and comprising one or more blades configured to cut the selected plurality of yarns as the selected plurality of yarns are carried into the backing as the plurality of needles reciprocate in and out of the backing.

[0064] In an embodiment, the tufting machine further includes a control system configured to control the operation of a yarn feeding system for feeding a selected plurality of yarns to a plurality of needles and the operation of a plurality of drawdowns; wherein the control system includes a program configured to dynamically advance the operation of the yarn feeding system and the plurality of drawdowns before the next needle position step to form a pattern.

[0065] In some embodiments of the tufting machine, the control system may further include a program configured to feed a selected plurality of yarns and selectively move the plurality of drawers between their extended and retracted positions based on rotation of a main drive shaft of the tufting machine.

[0066] In some embodiments of the tufting machine, the plurality of drawer modules include a plurality of double-acting cylinders having a reduced profile; and the plurality of drawer modules are mounted into one or more groups having a spacing of 8 drawer modules located within approximately 2 inches.

[0067] In some embodiments of the tufting machine, the proximal end of each of the plurality of drawers may include an anti-rotation mechanism configured to resist rotation of the plurality of drawers as they move between their extended and retracted positions.

[0068] In an embodiment, the tufting machine may further include a plurality of funnels arranged between the yarn selection system and the plurality of hollow needles; wherein the plurality of funnels each include an upper end defining an inlet portion and a lower end defining an outlet, the outlet being connected to an associated needle among the plurality of needles; and wherein the inlet portion includes a multi-angle orifice, the multi-angle orifice including a first portion having a first diameter and a second portion having a second diameter, the second diameter being different from the first diameter.

[0069] In an embodiment, the tufting machine may further include one or more regulators positioned between the air supply source and the plurality of drawer modules; wherein the plurality of regulators contain programs configured to control pressurized air flow to the plurality of drawer modules according to a pattern being tufted.

[0070] In an embodiment, the tufting machine may further include: a backing support, over which the backing moves for insertion of yarn tufts by a plurality of hollow needles; and a rack and pinion shifting mechanism connected to the backing support and configured to move the backing support laterally relative to the travel path of the backing.

[0071] Therefore, embodiments of a hollow needle tufting machine or a system and method for tufting an article using such a hollow needle tufting machine are disclosed for the above needs and other needs. The foregoing and other advantages and aspects of the embodiments of the present disclosure will become apparent and more easily understood from the following detailed description in conjunction with the accompanying drawings. In addition, it should be understood that both the foregoing overview and the following detailed description of the present disclosure are exemplary and are intended to provide further explanation without limiting the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0072] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in this specification and constitute a part thereof, illustrate embodiments of the present disclosure and, together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show the structural details of the present disclosure in more detail and in various ways in which it may be practiced than may be necessary for a basic understanding of the exemplary embodiments discussed herein.

[0073] Figure 1A is an end view of an embodiment of a tufting system or apparatus according to the principles of the present disclosure.

[0074] Figure 1B yes Figure 1AA close-up detail view of the tufting area of ​​a tufting system or machine.

[0075] Figure 2A-2B yes Figure 1A-1B A perspective view of an embodiment of a tufting system or apparatus.

[0076] Figure 3A-3B For example Figures 1A-2B 0026] A front perspective view of a portion of a tufting system or apparatus is shown in FIG. 1 showing yarn being fed through a pulling roll and to needles in accordance with the principles of the present disclosure.

[0077] Figure 4 is an end view of an embodiment of a needle bar having a yarn feed tube for feeding yarn from a drawbar to the needles of a tufting system or apparatus in accordance with the principles of the present disclosure.

[0078] Figure 5 is a side elevation view of an embodiment of a yarn selection system for a tufting system or apparatus according to the principles of the present disclosure.

[0079] Fig. 6A is a side elevation view schematically illustrating yarn being fed to a yarn injector and through a feed tube to a needle bar mounting plate for feeding a series of yarns through a funnel block and to a series of needles arranged along a needle bar of a tufting system or apparatus in accordance with the principles of the present disclosure.

[0080] Figure 6B An embodiment of a needle bar mounting plate to which a yarn feed tube is coupled and which contains yarn injectors for feeding yarn to the needles of a tufting system or apparatus is shown in accordance with the principles of the present disclosure.

[0081] Figures 7A-7C An embodiment of a funnel block for feeding yarn to hollow needles of a tufting system or apparatus according to the principles of the present disclosure is shown.

[0082] Figures 8A-8C Another embodiment of a funnel block for feeding yarn to hollow needles of a tufting system or apparatus according to the principles of the present disclosure is shown.

[0083] Figures 9A-9E An example of a yarn selector system according to the principles of the present disclosure is shown, which includes a series of drawer modules for selectively controlling the feeding of yarn to the needles of a tufting system or apparatus.

[0084] Fig.10 An example implementation of an anti-rotation device or mechanism for limiting rotation of a yarn drawer as it moves along a stroke or travel path in accordance with the principles of the present disclosure is shown.

[0085] Figures 11A-11BAn embodiment of a hollow needle and a positioning assembly for aligning the hollow needle for installation along a needle bar of a tufting system or apparatus is shown in accordance with the principles of the present disclosure.

[0086] Figures 12A-12B Example embodiments of a yarn cutting system or yarn blade system for a tufting system or apparatus according to the principles of the present disclosure are shown. DETAILED DESCRIPTION

[0087] The present disclosure may be more easily understood by reference to the following detailed description, examples, drawings and claims, as well as the descriptions before and after them. However, it should be understood that, unless otherwise specified, the present disclosure is not limited to the specific devices, systems and / or methods disclosed, and therefore, these may certainly vary. It should also be understood that the terms used herein are only for the purpose of describing specific aspects and are not intended to be limiting. Therefore, the following description is provided as an illustration of the principles of the present disclosure rather than a limitation thereof.

[0088] By way of example, and as used throughout, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Thus, for example, reference to "a processor" may include two or more such processors unless the context dictates otherwise.

[0089] In this article, ranges can be expressed as from "about" one particular value and / or to "about" another particular value. When such a range is expressed, another aspect includes from the one particular value and / or to the other particular value. Similarly, when values ​​are expressed as approximations, by using the antecedent "about", it is understood that the particular value forms another aspect.

[0090] As used herein, the term "tuft" encompasses both cut and loop tufts or stitches of yarn, and the term "tufting" encompasses both the act of forming cut yarn stitches and the act of forming loop yarn stitches.

[0091] Referring to the drawings, wherein like numerals indicate like parts throughout the several views, Figure 1A-12B Exemplary embodiments of tufting systems or apparatuses constructed in accordance with the principles of the present disclosure and their various operating components and / or features are shown. Figure 1A-5 In the embodiment shown in FIG. 1 , the tufting system or apparatus includes a hollow needle tufting machine 10, which will typically include a plurality of needles, which in embodiments may include hollow needles 12, which are configured to tuft the backing along a travel path P( Figure 2A) penetrates the backing material 14 as it moves through the hollow needle tufting machine 10 to deliver and / or implant a series of yarns Y into the backing for forming a plurality of yarn piles therein.

[0092] In an embodiment, the hollow needle tufting machine 10 may feed a series of different colors and / or types of yarns to each of the hollow needles, which may then be selectively implanted or tufted into a backing material to form a tufted patterned article.

[0093] like Figures 1A-2B As shown in , in an embodiment, the hollow needle tufting machine 10 includes a frame 16 having an upper portion 17A and a lower portion 17B, a tufting area or zone T defined therethrough, and a backing support or shuttle 18 on which the backing moves, which can be positioned along the tufting area. A row of hollow needles 12 can be mounted along a needle bar 20, which is driven in a reciprocating (up and down) motion to cause the needles 12 to penetrate into and out of the backing 14 for implanting yarn piles in the backing as the backing moves through the tufting area or zone.

[0094] In addition, in an embodiment, a yarn cutting system or yarn blade system 21 may be disposed below the backing support or shuttle 18. In an embodiment, the yarn cutting system or yarn blade system 21 may include a series of blade modules 22, each blade module including a blade 23. In some embodiments, one or more of the blades 23 may be individually controlled to move between a non-cutting or non-engaging position and one or more cutting positions for selectively cutting the yarn when the yarn is implanted in the backing. The hollow needle tufting machine 10 may generally further include a yarn feeding system 25 for supplying a length of yarn to the needle from a yarn supplier such as a creel or warp beam (not shown).

[0095] Furthermore, in an embodiment, the hollow needle tufting machine will include a control system 30. In an embodiment, the control system 30 may include a controller 31 having one or more processors and programs for controlling the operation of the hollow needle tufting machine 10 and various operating systems and / or operating components of the hollow needle tufting machine to produce patterned tufted products according to a selected pattern. The control system may be further configured to control the pressurized air from an air supply source S (e.g., Figure 1A The blower indicated in the figure, or other pressurized air source) is supplied to various operating systems or components of the operating system or components of the hollow needle tufting machine. In an embodiment, for example, Figure 3BAs shown in the figure, the pressurized air supply source may also include a distribution device 26 or be connected to the distribution device 26, which is, for example, a manifold and can be divided into rows or sections 26A, 26B, etc. The rows or sections 26A, 26B can be configured to supply different groups or sections of various operating parts of the hollow needle tufting machine, such as but not limited to the yarn selection system 75 The drawer module and the yarn injector segment, the blade module 22 of the cutting assembly 21 and / or other components.

[0096] In embodiments, the length, needle spacing, and number of needles of the hollow needle tufting machine may vary depending on the product to be produced and the desired production rate. For example, in embodiments, the hollow needle tufting machine may be configured to produce carpets, turf, rugs, or other products of a selected size or size range.

[0097] In embodiments, the backing material 14 may be advanced longitudinally through the reciprocating needle by a backing feed system 35, which in embodiments may include a feed roller 36, which may further include a spike roll, and may be driven by a motor 37 (e.g., a servo or stepper motor, or other drive). The backing feed system 35 will typically be controlled (e.g., by a control system 30), and in embodiments may be provided with a backing feed controller that is programmed and configured to advance the backing 14 ( Figure 2A ) is fed under the needle 12 and through the tufting area T of the hollow needle tufting machine 10.

[0098] The backing feeding system can be controlled so that the backing 14 moves in a controlled manner (e.g., in an embodiment, in a stepping motion), and the backing can be further displaced. When the needle reciprocates in and out of the backing, a series of yarns Y are inserted into the backing by the needle to form a yarn pile. In an embodiment, the yarn pile may include loop pile tufting, cut pile tufting, or a combination thereof. In some embodiments, the tufting may be formed with different or varying pile heights to provide texturing or other effects. Various colors and / or types of yarns may be selectively provided to each of the needles for forming tufted products, such as carpets, rugs, artificial turf or grass and other tufted fabrics. In an embodiment, such tufted products may be formed with a selected design, which may include but is not limited to yarns of different colors or types, textures, and / or other pattern effects.

[0099] The hollow needle tufting machine 10 may include a needle bar drive system 40 configured and operable to reciprocate the needle bars, carrying the needles 12 in and out of the backing 14. In an embodiment, the needle bar drive system may include a push rod 41 ( Figure 4-5 ), the push rod 41 is connected to the needle bar at its lower end, and is connected to the main shaft 42 ( Figure 1Aand 2B ). For example, the upper end of the push rod may be connected to a cam member carried on and driven by the main shaft. In an embodiment, the main shaft may be located off-center from each cam member and may be supported by bearings. Each push rod may extend through a guide or bearing to help guide its vertical reciprocating motion.

[0100] like Figure 1A and 2A -2B, the main drive shaft 42 and in some embodiments the needle bar drive system 40 can be driven by one or more motors 42A, which are operably connected to the opposite ends of the main drive shaft and mounted to the opposite ends of the frame of the hollow needle tufting machine for rotating the main drive shaft. In the case of driven rotation of the main shaft at an operating speed, the one or more motors are configured to operate under the control of the control system. For example, in an embodiment, the motor 42A can rotate the main drive shaft at a speed of up to about 1000 rpm or more to achieve high product delivery.

[0101] In operation, each rotation of the main drive shaft may cause the needle to penetrate the backing and then be withdrawn from the backing. In other words, each rotation of the main drive shaft may cause one needle reciprocating cycle, also known as a tufting cycle, which includes a downstroke and an upstroke of the needle. In embodiments, the control of various operating systems or components may further depend on the rotation or position of the main shaft.

[0102] like Figure 4 As shown in , the lower end of the push rod may be further connected to a needle bar mounting plate 44, which is connected to the laterally extending needle bar 20 and supports the laterally extending needle bar. The needles 12 may be mounted to the needle bar 20 and arranged in a spaced-apart sequence along the needle bar or at least a portion thereof. For example, each of the needles may be located at a selected or desired spacing from an adjacent needle, for example, in an embodiment, at a 1" needle spacing across the width of the tufting machine. Other needle spacing distances may also be used. As the spindle rotates, the reciprocating movement of the spindle is imparted to the push rod, which correspondingly drives the needle bar in a similar reciprocating (up and down) movement, so that the needles 12 repeatedly penetrate into and are withdrawn from the backing 14, introducing the yarn into the backing for forming multiple tufts in the backing.

[0103] In an embodiment, the needle bar mounting plate 44 may be rectangular in cross-section, and for each needle, one or more channels 46 may be provided, extending from an inlet 47 at the top of the needle bar mounting plate 44 to a funnel block 48 connected to each needle 12, such as Figure 3A-3B and 6A. A plurality of yarn guide tubes 49 ( Figure 4-5) can be connected to each of the corresponding inlets 47 in the top of the needle bar mounting plate for supplying multiple yarns to the inlets and their corresponding needles 12. Each funnel block 48 can generally include a funnel extending from the inlet to the outlet at the bottom of the needle bar mounting plate and configured to receive and guide the yarn fed from the yarn feeding system. As shown, the funnel block is configured to receive and guide each of the yarns fed from the yarn head system to the needle below it.

[0104] like Figure 1B , 6A As shown in FIGS. 11A-11B , each of the needles 12 may generally have an elongated hollow body 51 defining a central passage 52 through which the yarn is fed, such as Figure 5 , and having a first inlet or distal end 53 that can be received within a module or mounting block 54, which in embodiments may include an elongated body 54A configured to be attached to the needle shaft 20. Alternatively, in some embodiments, the needles may be individually attached to the needle shaft, mounted in a spaced-apart sequence along the needle shaft. The needles will further include an open second or distal end 56 terminating at a top end 57. As shown in FIG. Figures 11A-11B As further shown in the figure, in an embodiment, the proximal end of each of the needles may generally further include a cutting edge or surface 58, which may include an angled surface extending upward from the top end 57 to a midpoint along the body of each needle, and in some embodiments, may further include a groove at its upper end, which may be configured to help hold or capture the yarn during cutting.

[0105] In an embodiment, the needles 12 may be mounted in a spaced-apart sequence along their modules or mounting blocks 54, wherein one or more modules or mounting blocks are mounted to the needle shaft. Figures 11A-11B As shown in , a fixture 61 may be provided for aligning or orienting each of the needles within its module to generally secure the needles in place with the cutting surfaces of the needles oriented in an appropriate or selected orientation or arrangement for engagement by the blades 23 of the yarn cutting or blade system 22 thereunder. In an embodiment, as indicated in 11A-11B, the fixture 61 may include a body 62 which may have a stepped profile 63 at its upper end which will be configured to receive a module or mounting block / support bar 54 for the needles thereon, and the body 62 may further include a series of needle receiving holes 64.

[0106] like Fig. 11BAs shown in , in an embodiment, the needle 12 can be inserted through the needle mounting opening 55A defined in the module or mounting block 54 and inserted into the needle receiving hole 64 of the clamp. In some embodiments, the module or mounting block 54 may further include one or more longitudinal slots or separation areas 55A, and the needle mounting opening is spaced along the one or more longitudinal slots or separation areas 55A; and the needle 12 will be guided, such as causing the needle 12 to rotate or otherwise orientate, wherein its cutting surface is aligned in a selected position for engagement with the blade of the yarn cutting system or yarn blade system. In an embodiment, a set screw 65 or similar fastener may be further provided for adjusting the rotation, travel and / or orientation of the cutting surface of the needle within the channel of the clamp.

[0107] Once the needle 12 has been placed in the proper selected alignment, it may be secured along the module or mounting block by engaging a fastener 59, such as a set screw or other fastener, which is similarly disposed along the side surface of the module or mounting block, such as Fig. 11B , to secure the needle in position and in the desired alignment for engagement with the blade 23 of the yarn cutting or blade system 22, and generally without requiring additional movement or rotation of the needle and / or blade during operation of the hollow needle tufting machine. For example, in an embodiment, when the fastener 59 is engaged against the side surface of the module or mounting bar 54, the slot 55A can be closed against the body of the needle to secure the needle in the desired orientation.

[0108] like Figure 1A-6A As shown in FIG. 1 , a series of different colors or types of yarns Y are fed to each of the needles in the yarn feeding system 25 of the hollow needle tufting machine 10. In an embodiment, the yarn feeding system of the hollow needle tufting machine may include one or more yarn feeding mechanisms or accessories 65 ( Figure 1A and 2A -2B). In an embodiment, such a yarn feeding mechanism or accessory 65 may be mounted on the opposite side of the tufting machine. Figure 1A and 2B As shown in , one or more yarn feed attachments may be located on both sides of the hollow needle tufting machine, for example, mounted to and supported on a frame of the hollow needle tufting machine along the upstream and downstream sides of the hollow needle tufting machine.

[0109] In an embodiment, the yarn feed attachment or mechanism 65 may include a single-end or double-end yarn feed mechanism or attachment, such as the Infinity 1000 manufactured by Carder-Monroe Corporation of Chattanooga, Tennessee. TM or Infinity IIE TM Current feeding attachment. Each of the yarn feeding mechanisms or attachments 65 may include a housing 66 in which a plurality of yarn feeding devices 67 may be received. Figure 1A ,2A As shown in FIG. 2B , each of the yarn feeding devices 68 may include a motor 69 driving at least one driven yarn feeding roller 71, wherein one or more guide roller feeding rollers 72 are driven by the rotation of the driving roller 71. Each of the yarn feeding devices may feed 1-2 (or possibly more) yarns to an associated needle of the hollow needle tufting machine. Each of the yarn feeding devices may further be individually controlled by the control system of the hollow needle tufting machine so as to selectively control the feeding of individual yarns to its needles.

[0110] In an embodiment and as Figure 2A , 2B As shown in FIGS. 6A and 6A , the yarn feed devices may be configured to feed at least one yarn to the needles, wherein each of the yarn feed devices feeds at least one yarn of a different color or type. In an embodiment, a series or group of yarn feed devices may selectively feed their yarns to individual associated needles. For example, but not by way of limitation, a group of eight yarn feed devices may be associated with the needles, and each yarn feed device may feed a different color or type of yarn to the associated needle via the yarn selection system 75 and via the yarn guide tube 49, which extends from the yarn selection system 75 to the inlet 47 of the needle bar mounting plate 44, as shown in FIGS. Figure 5 As shown in . Different groups or series of yarn feeding devices (e.g., multiple groups of 8 or more yarn feeding devices) of each yarn feeding mechanism or accessory mounted on opposite sides of the frame of the tufting machine can feed yarn (e.g., 8 or more yarns) to corresponding ones of the needles. For example, the yarn feeding devices of the yarn feeding mechanisms or accessories located on the front side of the tufting machine can feed their yarns to every other needle, while the yarn feeding devices of the yarn feeding mechanisms or accessories mounted along the back side of the tufting machine can feed their yarns to the needles in between.

[0111] like Figure 5 As shown in FIG. 4 , the yarns will be fed into a funnel block 48 through a channel 46 defined through a needle bar mounting plate 44. Each yarn will typically be fed through a separate yarn guide tube 49 that will be coupled to one of the inlets 47 associated with each needle. Figure 6B An example embodiment of a needle bar mounting plate 44 is shown having multiple sets of inlets arranged along it. Figure 6B As shown in , in an embodiment, multiple groups of 8 inlets 47 may be provided, wherein each group generally contains an inlet for each color or type of yarn (e.g., 8 colors of yarn) supplied to the needles associated therewith, the inlets being spaced around a central hole 76 configured to enable insertion of a yarn injector 77 therethrough. It is contemplated that additional or fewer inlets may also be provided. Fig. 6AAs further shown in the , in an embodiment, each of the channels 46 extends from its entrance 47 through the needle bar mounting plate to an opening at the lower end of the needle bar support plate. In an embodiment, a lip or edge may be defined at the lower end of the channel to provide a stop 78 for inserting the yarn guide tube therethrough, thereby preventing the yarn guide tube from extending all the way or being pulled through the needle bar mounting plate.

[0112] Figures 7A-8C An example embodiment of a hopper block 48 for use with a hollow needle tufting machine 10 is shown. The hopper block may include a body, which is typically formed of a hardened material such as metal (e.g., steel or aluminum) or other similar durable material, and each hopper block will contain a series of hoppers 80. Figure 7C and 8C As shown in FIG. 1 , each of the funnels 80 may generally include a first or upper end 81 and a sidewall 82 that tapers downwardly to a second or lower end 83, terminating at an opening 84 along the bottom surface of the funnel block, and the needle is coupled to the opening 84. When a selected one of the yarns is fed and ejected into each funnel, the selected yarn will be guided to and into the hollow bore of the needle for delivery or implantation of the yarn into a backing.

[0113] In a first embodiment, if Figures 7A-7C As shown in , the funnel may include a multi-angle circular orifice 85, which has a first entrance portion at the upper end 81 of the funnel, the first entrance portion having a first diameter and gradually tapering downward along the first wall section 82' toward a second orifice portion 86 having a second diameter. The side wall 82" of the second orifice portion 86 extends downward, gradually tapering toward the opening 84 at the bottom end of the funnel. In an embodiment, the first diameter or the first orifice portion will be greater than the second diameter of the second orifice portion. In an embodiment, the taper of the wall 82' of the first orifice portion may have a smaller or flatter taper angle than the taper angle of the wall 82" of the second orifice portion. For example, in an embodiment, the taper angle of the wall of the first orifice portion may be approximately 1° to approximately 25°, while the taper angle of the wall of the second orifice portion may be approximately 25° to approximately 45°. Other angles are also contemplated. When the yarn is fed into the funnel, the yarn can be guided through the first aperture portion with a smaller angle to the second aperture portion, which guides the yarn to the center of the funnel so that the yarn can be fed into and through the funnel more smoothly.

[0114] Figures 8A-8C Another alternative embodiment of the funnel block 48 is shown. Fig. 8AAs shown in FIG, in this embodiment, the funnel 80 is formed with a slotted design having a plurality of grooves 88 arranged in series around the periphery of the upper open end of the funnel. Each of the grooves may define a yarn receiving groove that slopes downwardly toward the lower orifice of the funnel for guiding individual yarns into an associated hollow needle. Fig. 8A and 8B A slotted funnel design with approximately 8 grooves is shown, but those skilled in the art will appreciate that fewer or more grooves may also be used. In addition, in embodiments, multiple yarns may be fed to each groove so that each groove may be used to guide one or more yarns supplied from a yarn feeding system to an associated hollow needle.

[0115] In addition, in an embodiment, an air tube may be connected to the yarn injector 77 for selectively supplying air to the yarn injector so as to blow out pressurized air to maintain the position of the plurality of yarns in the needle bar 42, for reasons described below. Preferably, as shown, the lower end of each yarn injector is located at the outlet of the needle bar 42 and in the inlet of the needle 12. The yarn injector preferably includes a plurality of nozzles or openings 49. The yarn injector may have a larger diameter than the internal passage of the needle 12 to ensure sufficient air flow into the needle 12. Each yarn injector may be fed with air from an air supply tube 50, which is fed with air from an air supply source, and in an embodiment, the air supply tube may also include an air manifold 52, through which the supply of pressurized air may be distributed to the yarn injectors.

[0116] Multiple yarns may be provided within the funnel block for feeding into the needle. During the threading process of inserting the yarn into the needle, the selected yarn is forced into the needle 12 by the air yarn injector. During the tufting process, the yarn being stitched and other yarns within the needle are held in the needle by air pressure from the yarn injector 48 acting on the yarn and by controlling the feeding and supply of the yarn by the yarn feeding system and the yarn selection system.

[0117] During each tufting cycle, the hollow needles may reciprocate between a raised or top position and a lowered or bottom position. The backing may be positioned between the top position and the bottom position of the tufting cycle that penetrates the backing. In one cycle, the tip of each hollow needle may travel from the top position to the bottom position and back to the top position. Between the top position and the bottom position, the hollow needles may penetrate the backing and implant the yarn tufts therein. The movement of the hollow needles between the top position and the bottom position is the downstroke of the cycle, and the movement of the needles from the bottom position to the top position is the upstroke of the cycle.

[0118] As described above, each yarn fed to each needle may have a separate yarn feeding device, which may be operated by a system control (e.g., each yarn feeding device or a group of yarn feeding devices may have its own controller or be linked to a yarn feeding system controller, which may be configured to control a series of yarn feeding devices) so that the length of each yarn fed to the needle for each selected stitch of the pattern can be controlled to enable enhanced feeding accuracy of each yarn selected to form a corresponding tuft in the backing, while unselected yarns can be controlled and, in an embodiment, pulled back (e.g., by operation of a drawbar associated with such unselected yarns).

[0119] In addition, a series of pulling rollers 95 may be provided along the upstream and downstream sides of the tufting area, along the front and rear sides of the hollow needle tufting machine. The rotation of the pulling rollers may be controlled by the control system to ensure substantially consistent feeding of the yarn to the needles. The feeding of each of the yarns by the yarn feeder may be controlled based on the rotation of the spindle to substantially match the feed rate of the yarn from the yarn feeder, thereby delivering a desired amount or length of yarn within the rotational portion of the spindle to help ensure substantially consistent yarn delivery by the pulling rollers.

[0120] For example, in an embodiment, the yarn feeding device may be controlled by the control system 30 so as to supply a total stitch length of selected yarn (e.g., the length of yarn required to perform tufting to a substantially selected or desired length) within each stitching cycle or portion of a revolution of the main shaft of the hollow needle tufting machine. In an embodiment, different lengths or amounts of yarn that constitute the total stitch length of each selected yarn to be fed for tufting to form a desired pile height may be fed at increasing or decreasing rates at different times during different portions of the tufting cycle or based on the rotation or position of the main shaft (e.g., in an embodiment, the yarn feeding device of the yarn feeding system may be operable to feed different percentages or amounts of yarn in view of the position of the main shaft in its revolution, rather than feeding a substantially consistent amount of yarn during a revolution of the main drive shaft).

[0121] In an embodiment, the pulling rollers may be driven at a rate and synchronized with the feed rollers of the yarn feeding device to substantially prevent the yarn from being wrapped around the feed rollers. In some embodiments, the pulling rollers may also be driven at a rate and / or a combination of rate and position relative to the rotation of the main drive shaft so that they feed primarily in synchronization with the feeding of different amounts or percentages of yarn within different portions of the rotation of the main drive shaft. By way of example only, if during the initial 120° of rotation of the main drive shaft, the yarn fed as the yarn of the selected color is approximately 4", the pulling rollers may be operated to feed slightly more than 4" of the selected yarn during the 120° of rotation of the main drive shaft. During the remaining 240°, the pulling rollers and / or feed rollers of the yarn feeding device for the selected yarn may be used to slow down and / or speed up the feeding of such selected yarn to the needle as needed (to help minimize additional tension on the yarn). Still further, in embodiments, the yarn feed rate used to form the first and / or last stitch of a selected color or type of yarn may be adjusted in view of an upcoming tuft row color change in the pattern design being formed.

[0122] Such control of the delivery of yarn by each of the yarn feeding devices can achieve delivery of yarn to the pulling rollers disposed along the front and rear sides of the tufting machine at a rate that is selected and controlled to substantially maintain consistency in the feeding of the yarn to the needles. In an embodiment, the pulling rollers are operable to rotate at a different rate than the yarn feeding rollers. For example, in an embodiment, the pulling rollers can be driven at a rate that is substantially synchronized with the feeding of the yarn and sufficient to substantially keep the yarn pulled from the yarn feeding rollers to minimize winding of the yarn on the yarn feeding rollers.

[0123] like Figure 1A As shown in FIG. 7 , the yarn selection system 75 for the hollow needle tufting machine 10 can be positioned along the path of each yarn from the yarn feed device of the yarn feed system through the pulling rollers into the yarn feed conduit that feeds the yarn to the needles. Fig.9A As shown in , the yarn selection system 75 can be positioned adjacent to the pulling roller 95, and in an embodiment, will typically include a plurality of drawer modules 101, which can be attached to a support plate 102 at their upper ends as part of a drawer assembly or modular drawer system that can be attached or mounted along the frame of the hollow needle tufting machine. A yarn feed guide 103 can be positioned adjacent to the lower end of the drawer module, and the yarn feed guide 103 can include a plurality of holes or openings 104 through which the yarn passes to guide the individual yarns to the yarn conduit for feeding to the needles.

[0124] like Figures 9C-9EAs shown in , in an embodiment, each of the drawer modules 101 may include a double-acting cylinder 105 having a housing or cylinder body 107 in which a series of piston holes 108 and a series of air passages 109 are formed. A piston 112 may be received in each of the piston holes. Air ports 113 ( Fig.9A and 9B ) can be connected to the upper end of the piston bore. The air port can include a fitting or connector connected to an air line or conduit that is linked to an air supply source (e.g., one or more blowers) and is configured to supply air flow from the air supply source to the double-acting cylinder 105. The air flow entering the port and entering the individual piston bores of the double-acting cylinder or drawer module can be controlled (e.g., increased or decreased) to selectively drive the piston along the piston bore in a first direction and a second direction to cause the drawer 115 to selectively move between an extended position and a retracted position, such as Fig. 9B The drawer 115 can engage with individual yarns so that such yarns can be retracted or pulled back, while the feeding of such yarns is controlled by the yarn feeding device to pull unselected or unwanted yarns back and out of the funnel of the hollow needle.

[0125] In an embodiment where the drawer module includes a double-acting cylinder, the drawer module can be operated with a valve 110 such as a multi-way valve (e.g., a four-way solenoid valve or two to three air valves) to apply a pressurized air flow or other fluid flow through an air connection for driving the piston along a path of travel in a first direction and a second direction of the piston without requiring a spring return of the piston. For example, but not limiting, the air pressure can be controlled so that an increased air pressure can be supplied to a first port in the port, which is sufficient to drive the selected piston along the piston hole of the selected piston in the piston in the first direction. For example, in an embodiment, an increased air pressure can be provided, which is sufficient to overcome the basic or substantially constant air pressure supplied through the second port and through the air channel cylinder block, which basic or substantially constant air pressure pushes the piston to a retracted position, causing the drawer to extend; and once such pressure-increased air flow is substantially stopped or reduced, the piston can move in its second direction along the return stroke to retract its associated drawer.

[0126] The cylinder block or body 107 of the drawer module can be further configured with a reduced profile, which allows the drawer module to be placed at a higher density than the yarn selection assembly; for example, in an embodiment, the drawer modules can be arranged in groups or groups, wherein approximately 8 drawer modules can be positioned in a space of approximately two inches or less. Other arrangements and / or spacings of the drawer modules can also be used, including various numbers of drawer modules arranged at different spacings. In addition, the holes of the drawer modules can be reduced from approximately 1 / 2 inch to approximately 5 / 16 inch, which further achieves the following advantages. Figure 5 and 9A -A more compact, denser design as shown in the 9E.

[0127] In addition, in an embodiment, the drawer module can also be formed with reduced weight, for example, in an embodiment, the drawer module can be formed by a lighter material, such as aluminum or a composite material, such as nylon, carbon fiber polymer and / or other moldable materials. In some embodiments, the yarn feed opening formed in the drawer module can also be anodized or otherwise processed through a hard coating to promote movement of the yarn through it.

[0128] like Figure 9B-9E As shown in , each of the drawers 115 may generally include an elongated body 116 having an upper or proximal end 117 and a lower or distal end 118. In an embodiment, as shown in Fig.9D and 9E As shown in , the distal end of the drawer may have a hooked or angled configuration. Figures 9B-9C As shown in , the distal end of the drawer may include a substantially straight or flat distal end. In an embodiment, it can be seen that the drawer module may further include an anti-rotation mechanism or device 120 ( Fig. 9C and 10 ), the anti-rotation mechanism or device is configured to limit or substantially prevent the rotation or pivoting of the drawer as the drawer moves along a stroke or travel path between a retracted position and an extended position.

[0129] In an embodiment, the anti-rotation mechanism 120 may include an interlocking key located at the proximal or upper end of the drawer. Fig. 9C and 10As shown in, the proximal end 117 of the drawer 115 can be keyed and locked together (e.g., alternate drawers in the drawer can include male or female keyways 119A / 119B), so that the drawers can move cooperatively with each other in a substantially linear motion, wherein excessive twisting or rotation of the drawer is substantially prevented, further achieving a more compact configuration and modularity of design. The male and female keyways adjacent to the drawer further act as anti-rotation devices or mechanisms to limit the rotation or pivoting movement of the drawer when extended and retracted.

[0130] In some embodiments, the anti-rotation mechanism may include a guide rod. In addition to or as an alternative to the male and female keyways of the drawer, a guide rod may be used to help limit the rotation of the drawer during its extension and retraction movements.

[0131] The yarn drawer may further be coupled at its proximal end to an associated piston, such as Fig. 9C , for example, by forming a connector or gate key 119A / 119B at the proximal end of each drawer. Each of the keys may include an elongated head 122, and in embodiments, may include a male or female key 119A / 119B, and may include an opening through which the distal end of the associated piston 112 may be received and secured.

[0132] like Figures 12A-12B As further generally shown in FIG. 1 , a yarn cutting system or yarn blade system 21 may be arranged below the backing and along the tufting area. In an embodiment, the cutting system or blade system 21 may include a series of blade modules 22 mounted along a cutter bar 24, which will carry the blade modules and their blades in a reciprocating movement toward and away from the needles as the needles reciprocate in and out of the backing. The blade modules may also be configured with a reduced profile and may be arranged along the cutter bar at a needle pitch spacing similar to the needle pitch, such as Fig. 12B Each of the blade modules 22 will typically include a blade or cutting edge 23 having a cutting edge 125 adjacent its upper end. Each of the blades 12 can be received within a holder or support 126, wherein the blades are typically positioned or oriented so that their cutting edges 125 are aligned with the cutting edge or cutting surface of the needle, such as Figure 7B-9C as shown in .

[0133] In an embodiment, the blade alignment system may include a plate assembly 130 disposed along the cutter bar, the plate assembly 130 being used to or position the cutting edge of the blade with the cutting surface of the needle. The blade may be aligned via the assembled plate alignment piece and fixed in place in its holder. Each of the blade modules may be installed along the cutter bar, rather than the blade having to be installed separately along the hollow needle tufting machine. In an embodiment, the cutter bar may be further combined with an alignment plate assembly so that the blade may be installed in the hollow needle tufting machine, and the plate assembly may then be used to align or set the blade to a desired or selected cutting angle relative to the alignment or orientation of the cutting surface of its corresponding or associated needle. For example, in an embodiment, the cutting edge of the blade may be set to a zero-degree cutting angle relative to the cutting surface of the needle, but other cutting angles may also be used as needed to ensure proper cutting engagement or contact with the cutting surface of the needle. Adjustment of the blade position and / or orientation may further achieve adjustment of the blade pressure for engagement between the blade and the cutting surface of the needle.

[0134] Each of the blade modules will typically further include an actuator, such as a cylinder 121. In an embodiment, the actuator of the blade module may typically include a multi-position actuator or cylinder. The multi-position actuator will each receive a pressurized air flow from the air supply source of the hollow needle tufting machine under the control of the control system for selectively moving each of the blades between a series of positions. The position of the blade can be controlled so that the blade can be moved between a lowered or non-cutting position in which the loop pile tufts of the selected yarn can be formed in the backing according to the pattern of the tufted product being formed and a plurality of elevated cutting positions or ridges for cutting the yarn implanted or delivered to the backing by the needle to form a cut pile tuft. Such tufts can be further formed with varying pile heights.

[0135] For example, in an embodiment, the multi-position actuator may include a 3-position actuator, such as a 3-position pneumatic or hydraulic cylinder or a servo or stepper motor (or other actuator), and may further include a 4-way fluid valve for selectively controlling the supply of fluid (e.g., air) to the 3-position actuator. In an embodiment, at least three positions may be provided for each of the blades, such as a high cutting position, a low cutting position, and a non-cutting or coiling position.

[0136] The positioning or location of the blade between its non-cutting position and the cutting position can be controlled by the system controls and cooperates with the delivery of the selected yarn to each of the needles to form such cut pile tufts and loop pile tufts, as well as tufts for forming tufts of varying pile heights depending on the pattern of the tufted article being formed. In addition, a solenoid can be provided for controlling the feed of air to each of the cylinders that drive the movement of the blades. A pressurized air supply source can be connected to the cylinder of each of the blade modules to supply a pressurized air flow thereto, which can be controlled by a solenoid or other actuator to control the movement of the blades.

[0137] During each tufting cycle, the blades may be configured to cooperate with the needles by sliding over the respective tips of the needles in a shearing-like motion to cut the yarn inserted or implanted by the needles. Thus, with one or more of the blades moved into a position in which their cutting edges are raised to a cutting position, the cutting edge of each of the one or more blades may contact the cutting surface of its associated needle as the needles reciprocate into the backing to form a cut-pile tuft in the backing. Conversely, when one or more blades are moved into a position in which their distal tips are furthest from the tips and cutting edges of the associated needles (i.e., a non-engaged or non-cutting position), the cutting edges of the one or more blades will not contact or will not be in sufficient contact with the cutting surface of the associated needles as the needles reciprocate into the backing, thereby allowing loop pile tufts to be formed in the backing.

[0138] Additionally, in embodiments, the backing support or shuttle may be displaced transversely to the feed direction of the backing along the path of travel of the backing through the hollow needle tufting machine. Figure 2A and 2B As shown in FIG. 1 , the shifting mechanism 38 may be coupled to the backing support or shuttle 18 and may be controlled to shift the backing 14 relative to the travel path P ( Figure 2A ) to laterally displace or move the backing. Additionally, in embodiments, multiple displacing mechanisms may be used (e.g., positioned on opposite sides of the hollow needle tufting machine); and in some embodiments, one or more displacing mechanisms may be coupled to the needle bar for displacing the needles 12 separately from and / or in conjunction with the backing support or shuttle to form a tufting pattern.

[0139] In embodiments, the displacement mechanism may include a displacement mechanism driven by one or more servo motors or other actuators under the control of the control system 30. For example, one or more displacement mechanisms 38 may be provided for laterally displacing the backing rod, and in embodiments, the one or more displacement mechanisms include a servo motor driven rack and pinion screen mechanism, such as the SmartTech manufactured by Carder-Monroe Corporation of Chattanooga, Tennessee. TM Shifting mechanism.

[0140] In an embodiment, the backing can be shifted in steps consisting of one or more stitch lengths. The modular design of the needle modules of the hollow needle tufting machine and the use of a reduced profile drawer module of the yarn selection system can enable eight or more yarns to be fed to each needle, with each needle being spaced approximately one inch apart. Thus, shifting steps or jumps based on the stitch length spacing of the needles within a stitch length of approximately 1", for example, one or more steps or jumps for implanting 8, 16, 24, etc., yarns of different colors and / or types, whereas a conventional hollow needle machine may require at least two or more jumps or steps to present or implant 8, 16, 24, or more yarns.

[0141] In addition, in some embodiments, a displacement mechanism may be provided for displacing the needle. For example, the displacement mechanism may be coupled to the needle shaft and controlled by a control system for displacing the needle relative to the backing.

[0142] Optionally, and as Figure 2A , 3A -3B and 4, one or more presser feet 13 can be arranged transversely across the hollow needle tufting machine 10 adjacent to the needles and slightly above the backing to help prevent the needles from lifting the backing when the needles are removed from the backing during the tufting cycle. The one or more presser feet can be connected to an elongated track member that can be connected to the underside of the frame 11 by an arm to secure the presser foot to the frame 11.

[0143] The control system 30 of the tufting hollow needle tufting machine 10 ( Figure 2B ) may include one or more processors and memory. In an embodiment, the control system 30 may receive programs or instructions from an operator and / or pattern file input (separate from operator instructions) for making a specific tufted product, such as a patterned carpet. In other embodiments, the control system may include programs or instructions stored in a memory for forming a tufted patterned product. In use, as further described herein, the control system may control various subsystems of the tufting equipment, including the feeding of the backing, the reciprocating motion of the needles based on or in view of the operating speed of the hollow needle tufting machine (e.g., the rotation of the spindle), the selective engagement of the blades of the yarn cutting or blade system, and the feeding of the yarn to the needles by the yarn feeding system. The control system may further control the displacement of the backing (and in some embodiments, the displacement of the needles) according to the stored or received instructions to make the desired product.

[0144] like Figure 2B As shown in , in an embodiment, the control system 30 may include a controller 31, which may be linked to a control interface 32, and in some embodiments, the controller 31 may be disposed in a control cabinet connected to or combined with the hollow needle tufting machine. Figure 2BAs shown in , in an embodiment, the controller 31 may be housed in a control cabinet located adjacent to and linked to the hollow needle tufting machine; or may be supported on a frame of the hollow needle tufting machine or otherwise combined with the hollow needle tufting machine.

[0145] In an embodiment, the controller 31 of the control system 30 may be linked to an operating system or component of the hollow needle tufting machine, such as to various controllers / control systems for it. For example, the controller 31 of the control system 30 may be linked to at least one of the following: a backing feed controller 33 for controlling a motor that drives the feeding of the backing through the tufting area, a yarn feeding device for controlling the yarn feeding system to control each yarn feeding to the needle as needed to form a tufting pattern. One or more yarn feed controllers 34, a yarn cutting or blade system controller 36 for controlling the action of a selected blade in its blade; and may be further linked to and control a shifting mechanism for shifting the needle bar and / or shifting the backing. In an embodiment, the controller 31 may receive pattern inputs and display operating conditions from each of the operating elements or components.

[0146] The various controllers and operator interfaces may include at least one computing device (e.g., a personal computer, a laptop computer, a tablet computer, a smart phone, a programmable logic controller, a programmable automation controller, at least one servo drive, at least one hardware interface device, etc.), at least one computing device being programmed with operator utility software and runtime software, and generally storing yarn color pattern information and controlling the operation of a yarn feeding device of the yarn feeding system according to a selected multi-color tufting pattern.

[0147] The control system 30 can control and coordinate the operation of the operating system or components of the hollow needle tufting machine 10 to drive the backing conveying system 16, drive the needle bar drive system via the main drive shaft 42, and drive the yarn feeding device of the yarn feeding system, the displacement of the needle and / or backing, etc., to jointly form a pattern with multiple colors and / or multiple types of yarns. For example, a sensor such as an encoder or other similar sensor configured to monitor the rotation of the main drive shaft can be used to generate data representing the position and speed of the movement of the main drive shaft, and transmit such data to the control system 30, which can use the data to control the operation of one or more of the controllers for operating elements based on the position of the main drive shaft, the operating elements are, for example, a yarn feeding system (in an embodiment, including a separate yarn feeding device), a cutting assembly, a yarn selection system, and one or more shifting mechanisms.

[0148] The control system program or instructions may also include functions such as selecting a pattern file such as a stored pattern file from a pattern input, decompressing or compressing a pattern file, changing pattern colors, setting a yarn rack, and performing diagnostic functions through yarn control input / output. Alternatively, a conventional multi-color pattern scanning device may be used to scan a pattern of the carpet, such as a multi-color pattern, convert the pattern into a pattern file, and download it to a disk, flash drive, or hard drive of the controller 31 or control system. An operator may enter instructions through the operator control interface 256 for the timing of the tufting operation.

[0149] In the operation of the hollow needle tufting machine, the controller 31 of the control system 30 can receive pattern information from the operator through an operator interface, such as a network connection, a disk or other input, or can be instructed to run a pattern that has been programmed and stored in its memory. The hollow needle tufting machine 10 is generally operable to produce multi-color patterned tufted products, such as carpets, rugs, artificial turf or grass, or other tufted products, and at least eight different colors or types of yarns can be delivered to each needle, wherein the needles are arranged approximately one inch in spacing or needle spacing. The hollow needle tufting machine can also be operated to form a tufting pattern using more than eight different color types of yarns, for example, 16 or 24 different color patterns can also be formed. In addition, the hollow needle tufting machine can produce patterned tufted products with both cut pile tufting and loop pile tufting, such as carpets, and in an embodiment, the cut pile tufting and loop pile tufting can be arranged to form a separate or independent pattern or a separate or independent section of the overall pattern. Furthermore, hollow needle tufting machines can produce tufted articles having piles with varying pile heights, which can provide a variety of texturizing effects.

[0150] To form a selected multi-color tufting pattern, the backing is fed through the tufting area at a controlled rate, such as in discrete steps or incremental movements, as the needles reciprocate in and out of the backing. The yarn feeding device of the yarn feeding system can be selectively controlled so that a series of yarns of different colors or textures can be selectively fed to each of the needles so that the desired color or type of yarn for each selected stitch of the pattern is fed to each of the needles while limiting the feeding of unselected yarns (e.g., yarns that are not tufted for such stitch locators). In conjunction with the control of the yarn feeding to the needles, the drawers of the yarn selection system are configured to be cooperatively controlled so as to extend or retract selected ones of the drawers, the drawers engaging and pulling back multiple yarns in the yarn or allowing multiple yarns in the yarn to be fed.

[0151] For example, for the yarn to be fed to be placed in the backing, the selected yarn drawer associated with this type of selected yarn in the yarn drawer can be extended, so as not to interfere with the feeding of the yarn to the needle. The other yarn drawers associated with unselected yarn in the yarn drawer can be retracted, so as to engage and pull back unselected yarn, causing the unselected yarn to be removed from the funnel of its corresponding or distributed needle. In addition, the control system can be operated and coordinated with the feeding of the yarn, the operation of the yarn drawer and the feeding of the backing material according to the displacement of the pattern control needle. In addition, the control system can control the movement of the single blade in the blade below the tufting area, so that the single or selected blade in the blade is positioned in various positions, including the cutting position for forming the loop pile loop or tufting and the various cutting positions for forming the cut pile tufting.

[0152] In addition, in an embodiment, an air conduit may also be provided, which may be communicated with a yarn injector for each needle. In an embodiment, pressurized air may be blown through the air conduit by a corresponding tube connected to a pressurized air supply source, and may be guided through the conduit and into the needle hole as the needle is withdrawn from the backing. When the needle is subsequently opened, this pressurized air flow may force the cut end of the yarn (which usually forms the last back stitch and is no longer connected to the needle) to enter the backing downward. In an embodiment, such operation may be performed in cooperation with the operation of the yarn drawer of the yarn selection system to substantially pull back the yarn that is not selected from the needle. This may further eliminate the excess yarn on the back of the backing and prevent the yarn from forming a back stitch higher than the surface of the backing material. Optionally, each yarn feeding conduit may be arranged at an angle relative to the axis of the corresponding needle in the needle.

[0153] Furthermore, in embodiments, the operation of various operating systems or components of the hollow needle tufting machine may be dynamically cooperatively controlled. In some such embodiments, the timing of the activation of the operation of various operating systems or components may be advanced based on the machine speed or rotational rate (RPM) of the main shaft of the hollow needle tufting machine. The system control may be provided with instructions or programs that may include dynamic advancement parameters determined or programmed for each of the operating systems or components of the hollow needle tufting machine.

[0154] For example, at an initial machine speed or RPM, the extension or retraction of a selected drawer can be advanced based on the position or rotation of the main drive shaft, and the activation of other operating components can also be determined, such as turning on a blower to supply air to the drawer module and to the blade module for moving the blade to a desired cutting position or non-cutting position, and starting and stopping the yarn feed drive for each yarn. Additional dynamic propulsion parameters can be determined for advancing the operation of such operating systems or components at other different machine speeds. In an embodiment, some dynamic propulsion parameter values ​​can be predetermined and stored in a memory of a system control, and in an embodiment, the dynamic propulsion value parameters can be checked by the system control and / or used as initial or guiding parameter values ​​for the selected machine operating speed.

[0155] Thereafter, when the hollow needle tufting machine is running or operating at different machine speeds, the system controls may determine or interpolate dynamic advancements for various selected operating systems or components of the hollow needle tufting machine to improve the precision and consistency of operation of the hollow needle tufting machine even as the operating speeds vary. Thus, even as the operating speed of the hollow needle tufting machine varies, for example, when the machine is started and ramped up from an initial or slow mode to a desired full operating speed, operating systems or components such as drawbringers, blowers, blades, modules, yarn feed drives and / or other components may be controlled to advance their operation as needed to ensure consistent operation of the machine and thereby consistent production of patterned tufted articles produced at substantially any operating speed of the machine.

[0156] In addition, in an embodiment, the control system may include a program, and the program is configured to control the flow or pressurized air to various operating components (for example, one or more drawer modules and / or other components to be supplied with pressurized air flow), so as to selectively open / close the pressurized air flow to groups or separate drawer modules and / or other components. For example, in an embodiment, when some unselected yarns (for example, yarns of a specific color or type) are not used in the pattern of positive tufting, the pressurized air flow of the section or group supplied to the drawer module and / or other components can be cut off to enable air consumption to be reduced. In addition, in some embodiments, a programmable regulator or a valve can be used for controlling the pressurized air flow to various operable components. Such a regulator may include a program, including, for example, preset on / off or start and stop parameters, the volume of air to be supplied and other parameters based on a specific pattern to be tufted. In an embodiment, such preset parameters may be incorporated into the pattern file of a pattern and / or stored as a part of the pattern file of a pattern.

[0157] like Figures 12A-12BAs shown in , in embodiments, the yarn cutting assembly or blade system can be arranged along the tufting area, positioned below the backing support or shuttle and backing 14, and can include one or more blade assemblies. In embodiments, the blade assembly can include a module having multiple blades therein, while in other embodiments, the blade assembly can include a single blade having an actuator coupled thereto.

[0158] The present disclosure has been described herein with respect to examples that illustrate the principles and aspects of the present disclosure. However, it will be appreciated by those skilled in the art that a number of additions, deletions, changes, and modifications (whether subtle or gross) may be made to the examples presented without departing from the spirit and scope of the present disclosure. All such modifications that do not depart from the spirit of the present disclosure are intended to be included within the scope of any aspect and / or claim provided by the present disclosure.

Claims

1. A tufting machine, characterized in that: The tufting machine comprises: a backing support; a plurality of needles positioned above the backing support and configured to penetrate a backing positioned on the backing support upon reciprocation of the plurality of needles; wherein the plurality of needles comprises a plurality of hollow needles, each hollow needle having an upper end and a lower end, wherein a channel is defined between the upper end and the lower end; a yarn feeding system for supplying a plurality of yarns; a series of funnels in communication with the plurality of needles; a yarn selection system coupled to the air supply and configured to deliver a selected plurality of yarns from the plurality of yarns supplied by the yarn feeding system to one or more of the plurality of needles; The yarn selection system comprises: a series of yarn injectors configured to direct the selected plurality of yarns to the plurality of needles into one or more of the plurality of funnels for feeding to the plurality of needles; a series of drawer modules arranged along a travel path of the plurality of yarns from the yarn feeding system to the plurality of funnels, each of the plurality of drawer modules being in communication with the air supply source and each comprising a plurality of holes in which a plurality of pistons are housed; and a plurality of drawers coupled to the plurality of pistons and each of the drawers including a body having a proximal end and a distal end, the distal end configured to engage at least one of a plurality of yarns supplied by the yarn feeding system; wherein the plurality of drawers are individually movable between extended and retracted positions to retract a plurality of unselected yarns from the plurality of funnels by selectively controlling air flow to the plurality of apertures of the plurality of drawer modules; and A cutting assembly is disposed below the backing support and includes one or more blades configured to cut the selected plurality of yarns as the selected plurality of yarns are carried into the backing as the plurality of needles reciprocate in and out of the backing.

2. The tufting machine according to claim 1, characterized in that: The tufting machine also includes a control system configured to control the operation of the yarn feeding system for feeding the selected multiple yarns to the multiple needles and the operation of the multiple drawers; wherein the control system includes a program configured to dynamically advance the operation of the yarn feeding system and the multiple drawers before the next needle position step to form a pattern.

3. The tufting machine according to claim 2, characterized in that: The control system also includes a program configured to feed the selected plurality of yarns and selectively move the plurality of yarn drawers between their extended and retracted positions based on rotation of a main drive shaft of the tufting machine.

4. The tufting machine according to claim 1, characterized in that: The plurality of drawer modules include a plurality of double-acting cylinders having a series of multi-way valves connected to the plurality of holes and configured to control the air flow into and through the plurality of holes so that the plurality of pistons move along the plurality of holes for controlling the extension and retraction of the plurality of drawers.

5. The tufting machine according to claim 4, characterized in that The plurality of holes of the plurality of drawdown modules have a diameter of less than 1 / 2 inch.

6. The tufting machine according to claim 1, characterized in that: The plurality of drawer modules include a plurality of double-acting cylinders having a reduced profile; and the plurality of drawer modules are mounted into one or more groups having a spacing of 8 drawer modules located at approximately 2 inches.

7. The tufting machine according to claim 1, characterized in that: A proximal end of each of the plurality of yarn drawers includes an anti-rotation mechanism configured to resist rotation of the plurality of yarn drawers as the plurality of yarn drawers move between their extended and retracted positions.

8. The tufting machine according to claim 1, characterized in that Each of the plurality of funnels includes an upper end defining an inlet portion and a lower end defining an outlet, the outlet being in communication with an associated needle of the plurality of needles; and wherein the inlet portion includes a multi-angle orifice including a first portion having a first diameter and a second portion having a second diameter, the second diameter being different from the first diameter.

9. The tufting machine according to claim 1, characterized in that: The cutting assembly also includes a plurality of blade modules and a plurality of actuators, wherein the plurality of blades are accommodated in the plurality of blade modules, each of the actuators is connected to one or more of the plurality of blade modules and is in communication with the plurality of blades, and the plurality of actuators can be selectively actuated to control the movement of each of the plurality of blades between a retracted position and a cutting position.

10. The tufting machine according to claim 1, characterized in that The tufting machine also includes an indexing mechanism connected to the backing support and configured to move the backing support laterally relative to a path of travel of the backing.

11. The tufting machine according to claim 10, characterized in that The shifting mechanism comprises a rack and pinion shifting mechanism.

12. The tufting machine according to claim 1, characterized in that The yarn feeding system includes at least one yarn feeding accessory having a plurality of yarn feeding devices, each of the yarn feeding devices being configured to control feeding of at least one yarn to the plurality of needles.

13. A tufting machine, characterized in that: The tufting machine comprises: Main drive shaft; a backing support along which the backing is supported; a plurality of needles positioned above the backing support and configured to penetrate the backing upon reciprocating motion of the plurality of needles to deliver a selected plurality of yarns; wherein the plurality of needles comprises a plurality of hollow needles, each hollow needle having an upper end and a lower end, wherein a channel is defined between the upper end and the lower end; a yarn feeding system for supplying a plurality of yarns; a series of funnels in communication with the plurality of needles; a series of drawers disposed along a path of travel of the plurality of yarns from the yarn feed system to the plurality of funnels, each of the plurality of drawers being configured to selectively operate to retract a plurality of unselected yarns from the plurality of needles; a cutting assembly disposed below the backing support and comprising one or more blade modules, each of the blade modules including a blade configured to cut the selected plurality of yarns as the selected plurality of yarns are carried into the backing with the reciprocating motion of the plurality of needles into and out of the backing; and A control system configured to control the feeding of the selected plurality of yarns to the plurality of needles and the movement of the plurality of selected drawers between their extended and retracted positions, the control system comprising a program configured to advance the feeding of the selected plurality of yarns by the yarn feeding system and the movement of the plurality of selected drawers based on the rotation of the main drive shaft of the tufting machine before the next needle position stepping to form a pattern.

14. The tufting machine according to claim 13, characterized in that The control system also includes a program configured to control the feeding of the selected plurality of yarns of different lengths during rotation of the main drive shaft.

15. The tufting machine according to claim 13, characterized in that Each of the plurality of yarn drawers includes a body having a proximal end and a distal end, the distal end being configured to engage and selectively withdraw the plurality of unselected yarns when the plurality of yarn drawers are moved from an extended position to a retracted position.

16. The tufting machine according to claim 13, characterized in that The tufting machine also includes a plurality of drawer modules, each of which includes a main body, a series of pistons and a plurality of valves, the main body having a plurality of holes defined therethrough and connected to an air supply source, the series of pistons being accommodated within the plurality of holes and connected to the plurality of drawers, the plurality of valves being in communication with the plurality of holes and configured to control the flow of pressurized air entering and passing through the plurality of holes so that the plurality of pistons move along their holes, thereby controlling the plurality of drawers to move between their extended positions and retracted positions.

17. The tufting machine according to claim 16, characterized in that The plurality of drawer modules include a plurality of double-acting cylinders having a reduced profile; and the plurality of drawer modules are mounted into one or more groups having approximately 8 drawer modules located within a spacing of approximately 2 inches.

18. The tufting machine according to claim 13, characterized in that The tufting machine also includes an air supply source connected to the multiple drawer modules and the cutting assembly; and wherein the control system also includes a program configured to perform the following operations: control the pressurized air flow from the air supply source to one or more of the multiple drawer modules for selectively extending and retracting one or more of the multiple drawers of the multiple drawer modules, and / or control the pressurized air flow from the air supply source to one of the multiple blade modules of the cutting assembly for selectively moving one or more of the multiple blades of the multiple blade modules between a non-engaged position and one or more cutting positions.

19. The tufting machine according to claim 18, characterized in that The tufting machine also includes one or more regulators, which are positioned between the air supply source and the multiple drawer modules and / or the multiple blade modules; wherein the multiple regulators contain programs, which are configured to control the pressurized air flow to the multiple drawer modules and / or the multiple blade modules according to the pattern being tufted.

20. The tufting machine according to claim 13, characterized in that Each of the plurality of funnels includes an upper end defining an inlet portion and a lower end defining an outlet, the outlet being in communication with an associated needle of the plurality of needles; and wherein the inlet portion includes a multi-angle orifice including a first portion having a first diameter and a second portion having a second diameter, the second diameter being different from the first diameter.

21. The tufting machine according to claim 13, characterized in that Each of the multiple blade modules of the cutting assembly also includes an actuator, which is connected to its blade; and each actuator of each blade module is capable of selectively actuating to control the movement of its blade between a retracted position and a cutting position.

22. The tufting machine according to claim 13, characterized in that The tufting machine includes an indexing mechanism configured to move at least one of the backing support and the plurality of needles laterally relative to a path of travel of the backing.

23. The tufting machine according to claim 13, characterized in that The yarn feeding system includes at least one yarn feeding accessory having a plurality of yarn feeding devices, each of the yarn feeding devices being configured to control feeding of at least one yarn to the plurality of needles.

24. The tufting machine according to claim 13, characterized in that Each of the plurality of funnels includes an upper end and a lower end, the lower end defining an outlet communicating with an associated needle of the plurality of needles; and wherein the upper end contains a plurality of yarn flow grooves configured to guide one or more yarns into the funnel to be fed to the associated needle.

25. A method of forming a patterned tufted product, characterized in that: The method comprises: feeding a backing along a travel path; feeding a plurality of yarns through a yarn selection system and into a plurality of hollow needles; wherein the yarn selection system comprises a series of drawer modules, the series of drawer modules being in communication with an air supply source and comprising a plurality of apertures having a plurality of pistons received therein and a plurality of drawers coupled to the plurality of pistons and each comprising a body having a proximal end and a distal end; selecting one or more yarns of the plurality of yarns to be fed to the plurality of hollow needles, and feeding a selected length of the one or more yarns to the plurality of hollow needles; controlling feeding of a plurality of unselected yarns to the plurality of hollow needles, and moving one or more of the plurality of drawers from an extended position to a retracted position to retract the plurality of unselected yarns or to prevent the plurality of unselected yarns from being fed to the plurality of hollow needles; and The plurality of hollow needles are reciprocated in and out of the backing to place a plurality of tufts of the one or more yarns into the backing according to a formed pattern.

26. The method according to claim 25, characterized in that The method also includes displacing the backing transversely to its path of travel.

27. The method according to claim 25, characterized in that The method also includes advancing the feeding of the selected plurality of yarns by the yarn feeding system and the movement of the plurality of yarn drawers between their extended and retracted positions based on the rotation of the main drive shaft of the tufting machine before the next needle position step of forming the pattern.

28. The method according to claim 25, characterized in that The method also includes cutting the one or more yarns carried into the backing with the plurality of hollow needles to form the plurality of tufts.

29. A tufting machine, characterized in that: The tufting machine comprises: Multiple hollow needles; a yarn feeding system configured to control feeding of a selected plurality of yarns among the plurality of yarns supplied to the plurality of hollow needles according to a pattern; an air supply source, the air supply source being used to supply pressurized air; A yarn selection system configured to retract a plurality of unselected yarns or prevent a plurality of unselected yarns from being fed to the plurality of hollow needles, the yarn selection system comprising: a series of yarn injectors configured to inject the selected plurality of yarns to the plurality of hollow needles; a series of drawer modules arranged along a path of travel of the plurality of yarns from the yarn feeding system to the plurality of hollow needles, each of the plurality of drawer modules being in communication with the air supply source and comprising a plurality of holes in which a plurality of pistons are received; and a plurality of drawers coupled to the plurality of pistons and each of the drawers comprising a body having a proximal end and a distal end, the distal end being configured to engage at least one of the plurality of yarns supplied by the yarn feeding system; Wherein the plurality of drawers are capable of individually moving between extended and retracted positions to retract the plurality of unselected yarns or prevent the plurality of unselected yarns from being fed to the plurality of hollow needles by selectively controlling pressurized air to the plurality of holes of the plurality of drawer modules according to a formed pattern.

30. The tufting machine according to claim 29, characterized in that The tufting machine also includes a backing support along which the backing moves and a cutting assembly disposed below the backing support and comprising one or more blades configured to cut the selected plurality of yarns as the selected plurality of yarns are carried into the backing by the reciprocating motion of the plurality of needles in and out of the backing.

31. The tufting machine according to claim 29, characterized in that The tufting machine also includes a control system configured to control the operation of the yarn feeding system for feeding the selected multiple yarns to the multiple needles and the operation of the multiple drawers; wherein the control system includes a program configured to dynamically advance the operation of the yarn feeding system and the multiple drawers before the next needle position step to form a pattern.

32. The tufting machine according to claim 31, characterized in that The control system also includes a program configured to feed the selected plurality of yarns and selectively move the plurality of yarn drawers between their extended and retracted positions based on rotation of a main drive shaft of the tufting machine.

33. The tufting machine according to claim 29, characterized in that The plurality of drawer modules include a plurality of double-acting cylinders having a reduced profile; and the plurality of drawer modules are mounted into one or more groups having a spacing of 8 drawer modules located at approximately 2 inches.

34. The tufting machine according to claim 29, characterized in that The proximal end of each of the plurality of yarn drawers includes an anti-rotation mechanism configured to resist rotation of the plurality of yarn drawers as the plurality of yarn drawers move between their extended and retracted positions.

35. The tufting machine according to claim 29, characterized in that The tufting machine further includes a plurality of funnels disposed between the yarn selection system and the plurality of hollow needles; wherein each of the plurality of funnels includes an upper end defining an inlet portion and a lower end defining an outlet, the outlet being in communication with an associated needle of the plurality of needles; and Wherein the inlet portion comprises a multi-angle orifice having a first portion having a first diameter and a second portion having a second diameter, the second diameter being different from the first diameter.

36. The tufting machine according to claim 29, characterized in that The tufting machine also includes one or more regulators positioned between the air supply source and the plurality of drawer modules; wherein the plurality of regulators include a program configured to control pressurized air to the plurality of drawer modules according to the pattern being tufted.

37. The tufting machine according to claim 29, characterized in that The tufting machine also includes a backing support over which a backing moves for insertion of yarn tufts through the plurality of hollow needles, and a rack and pinion shifting mechanism connected to the backing support and configured to move the backing support laterally relative to a path of travel of the backing.

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