Tufting machine and tufting method

Abstract

Systems, devices, and methods for forming tufted articles can include a hollow needle tufting machine for forming patterned tufted articles containing multiple colored yarns. The hollow needle tufting machine can include a series of hollow needles arranged along a needle bar at gauge intervals and receive a series of different colored and / or typed yarns from a yarn feed system. A funnel block having a series of funnels configured to receive the series of yarns can be provided adjacent to the needle bar to direct selected yarns to corresponding or associated hollow needles. The hollow needles can be reciprocated in and out of the substrate to deliver a series of yarns that can be engaged by corresponding knives to form tufts of yarn. The knives can be moved between a non-cutting position and a cutting position to form loops and cut pile tufts of yarn in the substrate.

Description

[Technical Field]

[0001] (cross reference) This patent application claims the benefit of U.S. Provisional Patent Application No. 63 / 401,393, filed August 26, 2022.

[0002] (Incorporated by reference) The disclosure and figures of U.S. Provisional Patent Application No. 63 / 401,393, filed August 26, 2022, are specifically incorporated by reference in their entirety into this specification to the same extent as if set forth herein.

[0003] (Technical field) TECHNICAL FIELD This disclosure relates to tufting machines for producing tufted textile goods such as carpets and other articles, and more particularly to hollow needle tufting machines and methods of tufting utilizing such hollow needle tufting machines. [Background technology]

[0004] Hollow needle tufting machines, such as those illustrated in U.S. Patent No. 4,549,496 to Kile, U.S. Patent No. 5,588,383 to Davis et al., and U.S. Patent No. 6,401,639 to Samilo, have been used to produce patterned carpets by embedding different colored yarns into a substrate material. Such hollow needle tufting machines typically have a yarn feed mechanism that feeds different colored yarns into each of the hollow needles, and the yarns are blown into and through a funnel block associated with each hollow needle and into the central passage of each hollow needle. Conventionally, a solenoid-controlled air cylinder is operated to control the feeding of the different colored yarns through the funnels to each of the hollow needles. In the past, the number of colors that could be fed to each needle of such hollow needle tufting machines was generally limited by the gauge spacing, and to expand the number of colors, it was typical to increase the gauge spacing between the needles, for example, doubling the spacing from 1 inch to 2 inches, which could lead to other limitations in terms of the patterns produced and / or the production rate of the machine.

[0005] In addition, many conventional hollow needle tufting machines include multiple injectors and one or more solenoid valves for each needle, which increases the complexity and cost of manufacturing, maintaining, repairing, and operating such hollow needle tufting machines, and often increases the amount of energy used by the machine as needed to supply additional air to the machine during operation. It is also desirable to control the yarn feed to attempt to achieve as close to a uniform pile height as possible. However, when the yarn is changed and released from the needle, it may shrink due to the inherent elasticity of each yarn, and the shrinkage may vary for different yarns having different elasticity.

[0006] It can be seen, therefore, that a need exists for a hollow needle tufting machine that is capable of achieving increased production efficiency and the ability to produce complex patterns, such as patterns that utilize an increased number of colored yarns. The present disclosure is directed to a hollow needle tufting machine and method of operating such a hollow needle tufting machine that addresses the above and other needs and shortcomings that exist in the art. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] U.S. Patent No. 4,549,496 [Patent Document 2] U.S. Patent No. 5,588,383 [Patent Document 3] U.S. Patent No. 6,401,639 Summary of the Invention [Means for solving the problem]

[0008] Briefly, the present disclosure is directed to systems, apparatus, and methods for forming tufting articles, such as, but not limited to, carpets, artificial turf and / or grass, rugs, and other tufting fabrics.

[0009] In embodiments, the systems and apparatuses for forming tufted articles disclosed and illustrated herein may include a tufting machine having a series of needles that are reciprocated in and out of a substrate to form multiple tufts in the substrate. In embodiments, the tufting machine may further include a yarn feed system that feeds multiple yarns to each of the needles, and a yarn selection system including multiple jerker modules, each having a cylinder body and a jerker movable between an extended position and a retracted position to retract unselected yarns from the needle. In some embodiments, the jerker modules may include a double-acting cylinder with a reduced profile and may further include a multi-way valve for controlling the flow of pressurized air to control the extension and retraction of the jerker. In embodiments, the yarn feed system may include multiple yarn feed devices, each configured to feed a single yarn to an associated one of the hollow needles.

[0010] In some embodiments, the apparatus can include a tufting machine having a plurality of hollow needles, a yarn feed system, a yarn selection system, a yarn cutting system, and a control system having one or more processors and programming configured to cooperatively control the feeding of yarns by the yarn feed system to the hollow needles to form a selected pattern, the engagement of one or more jerkers of the yarn selection system to retract unselected yarns, and / or the movement of one or more knives of the yarn cutting system to cut selected yarns presented by the needles.

[0011] Additionally, in embodiments, the methods disclosed and illustrated herein can include methods for forming patterned tufting articles. In embodiments, the methods can include shifting a plurality of hollow needles in gauge increments. In some embodiments, the methods can further include selectively moving one or more knives between a non-engaging or non-cutting position and one or more engaging or cutting positions.

[0012] In embodiments, the present disclosure is directed to an improved hollow needle tufting machine and its features and / or components. The improved hollow needle tufting machine may include a control system having a controller that may be coupled to the hollow needle tufting machine. The control system may include instructions or programming that may be executed to control various operating systems or components of the hollow needle tufting machine in a cooperative manner to form patterns using an increased number of colors or types of yarns, without the need to increase the gauge spacing between the needles. For example, without limitation, in embodiments, patterned articles including yarns of four, eight, sixteen, and potentially more colors may be formed with a substantially consistent feed of yarn to each of the hollow needle tufting machine's hollow needles, with the needles positioned at a gauge spacing of about one inch.

[0013] For example, in embodiments, a hollow needle tufting machine is disclosed that may include a needle bar having a series of hollow needles mounted in series and spaced apart, such as at an exemplary gauge spacing of about 1 inch (in some embodiments, less than 1 inch or greater than 1 inch). The needle bar may be mounted along a mounting plate that may include (or be coupled to) a funnel block, each having a series of funnels associated with a corresponding one of the needles. Each funnel, in some embodiments, may be configured to allow at least about eight colors to be fed therethrough to each of the hollow needles. For example, in embodiments, each needle may be capable of tufting up to about eight colors per needle. The yarn may be fed from the upper or inlet portion of each funnel to a tubular outlet, which, in embodiments, may have a stop defined therethere.

[0014] In embodiments, the inlet portion of each funnel may be defined adjacent an upper portion or region of the funnel and configured as a multi-angled circular orifice having a first angled or beveled surface having a first angle, which in embodiments transitions to a second angled surface having a second angle, which 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.

[0015] In other embodiments, the funnel can have multiple fluted thread channels defined around its circumference adjacent its upper portion or region. For example, in an embodiment, the funnel can include eight fluted thread channels. In other embodiments, a greater or lesser number of fluted thread channels can be provided. In an embodiment, the fluted thread channels can be arranged around the funnel in a generally circular arrangement, for example, configured to form a flowerpot-type design. It is contemplated that other arrangements can be used in other embodiments, as needed, to accommodate different numbers and / or types of threads being fed. In an embodiment, each funnel can be configured to feed two or more threads per flute.

[0016] In embodiments, hollow needle tufting machines can include modular configurations of needles and knives. For example, in embodiments, multiple needle modules, each containing one or more hollow needles, can be mounted along the needle bar of a hollow needle tufting machine. In some embodiments, the needles can be positioned and secured in a fixed position and desired orientation within the modules by a tooling fixture. In embodiments, the tooling fixture can include a body having openings into which the needles are received and into which the needle modules can be engaged. The openings in the fixture guide the needles into a desired orientation, after which each needle can be secured in a fixed position within the body of its module. Additionally, in embodiments, multiple knife modules can be provided, for example, as part of a yarn cutting system or knife bar system, and each knife module can have at least one knife or cutting blade.

[0017] In embodiments, a shift mechanism can be provided to control the shifting movement of the substrate support or shuttle of the hollow needle tufting machine. In embodiments, a shift mechanism can further be provided to shift the needle bar, and therefore the needle, laterally in stages across the substrate material. In optional embodiments, the substrate can be shifted, or the needle bar can be shifted laterally, or both the substrate and the needle bar can be shifted laterally. The shift mechanism can include a servo motor-driven or similar actuator-driven shift mechanism, which in embodiments can include a servo-controlled rack and pinion shift mechanism.

[0018] In embodiments, the needle module can have a reduced profile so that the needles are mounted at approximately 1-inch gauge spacing, with each needle capable of receiving approximately eight colors of yarn. It is envisioned that other desired gauge spacings of needles can be used by shifting the substrate, shifting the needles, or both, and additional colors can be tufted. The needles can also be mounted at closer spacings. The substrate, needles, or both can be shifted laterally in single or double gauge jumps or steps in the lateral direction as needed to form the same pattern, rather than having to shift multiple gauges across two, three, or more needle gauge spacings to form a selected pattern.

[0019] 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 be an Infinity 1000mm tufting machine from Card-Monroe Corp. (Chattanooga, TN). TM or Infinity IIE TM The system may incorporate one or more single or double-ended yarn feed mechanisms or attachments, such as a yarn feed attachment or yarn feed mechanism or system. Such yarn feed mechanisms or attachments may comprise yarn feed units or modules that may include multiple individual yarn feed devices, each of which may be individually selectively controlled to feed one or two yarns, or in some embodiments, more than one yarn, to the needles. In embodiments, the one or more yarn feed mechanisms or attachments of the yarn feed system may generally be configured to control the feeding of a selected length of yarn for each individual stitch to enable the creation of multiple fabric surfaces and / or multiple fabric pile heights.

[0020] Additionally, in embodiments, the hollow needle tufting machine may include puller rolls downstream from the yarn feed mechanisms and / or attachments on either side of the hollow needle tufting machine, the rotation of which may be controlled by a system controller to control the drawing of yarns from the yarn feed rolls of one or more yarn feed mechanisms or attachments for feeding along their travel paths to the needles.

[0021] In some embodiments, the hollow needle tufting machine can further include a yarn selection system. In embodiments, the yarn selection system can include a series of injectors operable to inject air into the funnel to blow or direct selected yarns fed from the yarn feed system into the needles. In some embodiments, the yarn selection system can further include a series of jerker modules arranged along the yarn travel path from the yarn feed mechanism or attachment to the needles, each jerker module generally having a yarn jerk coupled to an actuator. The yarn jerkers can be selectively controlled to extend and retract along a selected length or travel (e.g., in embodiments, about a 2-inch travel, although other distances can be used) to retract or pull back the yarn from the needle. In embodiments, this can enable the use of smaller needles and modules that can be spaced more closely together (e.g., on a 1-inch gauge spacing).

[0022] In embodiments, the actuator can include an air cylinder formed with or incorporated into the jerker module; for example, the jerker module can be formed with multiple bores, each receiving a piston rod. Other types of actuators can also be provided. For example, in some embodiments, the jerker module (or its actuator) can comprise a double-acting air cylinder configured without a mechanical spring return and using air supplied to different portions of the bore of the jerker module to cause selective movement of the piston along the bore to control the extension and retraction of the jerker. Providing or forming the jerker module as a double-acting cylinder can, in embodiments, help increase the timing or speed of actuation of the yarn jerker due to the absence of any spring. Additionally, lower air pressure for actuation of the yarn jerker can also be utilized to operate the double-acting cylinder.

[0023] In embodiments, the actuators (e.g., jerker modules / double-acting cylinders or other selectively controlled actuators) can be reduced in size. For example, a jerker module can be reduced in size from 1 / 2 to 5 / 16 with two 4-way solenoid valves and two 3-way valves. Jerker modules can also be configured with smaller profiles (e.g., eight jerker modules spaced approximately 2 inches apart) to allow for increased density designs, with the high density module arrangement allowing for controlled feeding and / or retraction of unused yarn to / from the needles (e.g., using a 2-inch travel jerker).

[0024] In embodiments, each of the yarn jerkers can include a body with a proximal end configured to engage a yarn passing through a yarn selection system, e.g., an opening in a yarn guide adjacent the jerk module, and a key, e.g., a female or male keyway, at its distal end. The key can couple the jerk to an associated one of the actuators by engaging and interlocking with a jerk gate, and the interlocking arrangement can be configured to limit its rotation. In further embodiments, a guide rod can be used as an alternative anti-rotation mechanism.

[0025] The jerker module can also be formed from lighter materials such as aluminum or composites, e.g., nylon, carbon fiber polymers, and / or other moldable materials. In some embodiments, the yarn feed openings formed in the jerker module can be hard-coat anodized or otherwise treated to facilitate movement of the yarns therethrough. Individual tubes or conduits for each yarn can be coupled to the yarn feed openings to feed the yarns through the yarn jerker module to needles to form tufts in the substrate.

[0026] In embodiments, the yarn feeding system can be controlled by a control system or the like based on programming and the desired pattern being formed. In some embodiments, the control system can include a controller that can include one or more processors and a memory that can be configured to receive and store pattern information, and that can further include programming or instructions adapted to control the operation of the hollow needle tufting machine and its various operating components. For example, in embodiments, the controller of the control system can include programming or instructions executed by one or more processors to selectively control the engagement / selective operation of knives and yarn jerkers, and / or shifting of substrate material and / or needles to enable a substantially consistent yarn feeding to each of the needles, based on received or programmed pattern information to form a desired pattern using multiple colors and / or types of yarns.

[0027] In such an embodiment, the control system may include programming adapted to apply dynamic advancement parameters for advancing 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, the control system may advance the operation of one or more operating components, such as engagement of selected ones of the yarn jerkers, engagement (e.g., turning on and off) of an air blower, yarn feed of selected ones of the yarns fed to each needle, movement of a knife between a cutting position and a disengaged or non-cutting position, shifting, and other operating elements, ahead of the next stitch or tuft placement step for the pattern based on the rotation of the machine shaft of the tufting machine.

[0028] In an embodiment, the control system can control the yarn feeding system (e.g., control the yarn feeding device or yarn feeding mechanism or selected units thereof) to deliver a portion of the length of yarn to be fed to each needle during each stitch or individual sewing operation within a portion of a revolution of the main shaft of the hollow needle tufting machine.

[0029] The hollow needle tufting machine, in some embodiments, can be configured to provide a single level cut pile tufting fabric, and the control system can include programming that can utilize yarn feed control to control the formation of multi-level loop pile tufts of yarn without necessarily requiring movement of the knife from a cut (cylinder extended) position to a loop (cylinder retracted) position to cut loops of yarn.

[0030] In some additional embodiments, multi-level pile high tufting may also be provided, which may include the formation of two-level cut pile tufts. In such embodiments, yarn feed control may be provided that may be utilized in conjunction with a yarn cut or knife system configured to allow increased control of knife positioning, including selective movement of selected knives according to the tufting pattern to be formed.

[0031] For example, in some embodiments, the yarn cutting or knife bar system can include a knife bar with a series of knives mounted thereon. In embodiments, the yarn cutting or knife system can further include a knife bar with a plurality of individually controllable knife modules or blocks mounted thereon. Each knife module or block can have a body to which the knives are mounted and a multi-position actuator, such as an air cylinder, that can be selectively controlled or fired to move its corresponding or associated knife between a non-cutting position and a cutting position relative to the needle stroke of the hollow needle tufting machine.

[0032] In embodiments, the knives can be directed or aligned to a desired or selected position relative to the needles by an alignment system, which in embodiments may include a plate assembly positioned along the knife bar. In embodiments, the knives can be directed by the plate assembly to set the angle of knife orientation relative to the needle angle of each of their associated or corresponding needles. Adjusting the knife can also assist in setting or adjusting knife pressure.

[0033] By selectively controlling the knife position, multiple cut heights can be achieved. As a further result, in embodiments, the yarn feed can be controlled in conjunction with controlling the knife positioning to enable the formation of multiple pile height tufted articles having both cut and loop pile. In some embodiments, the multiple pile height tufts can include cut pile tufts of different pile heights and loop pile tufts of different pile heights that can be selectively formed to enable additional textural effects in addition to allowing various patterns of different colors or types of yarns to be formed.

[0034] In embodiments, a knife positioning system is disclosed in which a multi-position actuator may be provided. The pneumatic flow or supply of air or other fluid to the multi-position actuator may be controlled by a control system to move the knife between various selected cutting positions for forming cut pile tufts of selected pile heights and a disengaged or non-cutting position for forming loop pile tufts. For example, in embodiments, the multi-position actuator may include a three-position actuator, such as a three-position pneumatic or hydraulic cylinder or servo or stepper motor (or other actuator), and may further include a four-way fluid valve for selectively controlling the supply of fluid (e.g., air) to the three-position actuator. In embodiments, at least three positions may be provided for each of the knives, e.g., a high-cut position, a low-cut position, and a non-cutting or loop position.

[0035] Additionally, according to various aspects of the present disclosure, there is provided a method for manufacturing a textile machine comprising: a substrate support; a plurality of needles positioned above the substrate support and configured to pierce a substrate positioned on the substrate support upon reciprocal movement of the needles, each of the needles having an upper end and a lower end and comprising a hollow needle with a passageway defined between the upper end and the lower end; a yarn feed system for supplying a plurality of yarns; a series of funnels in communication with the needles; a yarn selection system coupled to an air supply source and configured to deliver selected yarns of the yarns supplied by the yarn feed system to one or more of the needles, the series of injectors configured to direct the selected yarns to the needles and into one or more of the funnels for delivery to the needles; and a series of jerker modules disposed along a path of travel of the yarns from the yarn feed system to the funnels, the jerker modules A tufting machine is provided that includes a yarn selection system comprising: a series of jerk modules, each of which includes a plurality of holes with a piston received therein and communicating with an air supply; a plurality of jerkers coupled to the pistons, each having a body having a proximal end and a distal end configured to engage at least one of the yarns supplied by the yarn feed system, the jerkers being individually movable between an extended position and a retracted position to retract unselected yarns from the funnels into the holes of the jerk module by selective control of air flow; and a cutting assembly including one or more knives disposed below the substrate support and configured to cut the selected yarns as they are carried into the substrate with reciprocating movement of the needles into and out of the substrate.

[0036] In an embodiment, the tufting machine further comprises a control system configured to control operation of the yarn feed system and operation of the jerk to feed selected yarns to the needles, the control system including programming configured to dynamically advance operation of the yarn feed system and the jerk ahead of the next stitch placement step of the pattern being formed.

[0037] In some embodiments, the control system further includes programming configured to feed selected yarns and selectively move the jerkers between their extended and retracted positions based on rotation of a main drive shaft of the tufting machine.

[0038] In an embodiment, the jerk module has a series of multi-way valves in communication with the holes and includes a double-acting cylinder configured to control the flow of air into and through the holes and cause movement of a piston therealong to control the extension and retraction of the jerk.

[0039] In embodiments, the holes in the jerker modules have a diameter of less than ½ inch. In some embodiments, the jerker modules comprise double-acting cylinders with reduced profiles and are mounted in one or more groups of eight jerker modules spaced within about 2 inches of each other.

[0040] In embodiments, the proximal end of each of the jerkers includes an anti-rotation mechanism configured to resist rotation of the jerkers when the jerkers are moved between their extended and retracted positions.

[0041] In an embodiment, the funnels each include an upper end defining an inlet portion and a lower end defining an outlet in communication with an associated one of the needles, the inlet portions having a multi-angled orifice including a first portion having a first diameter and a second portion having a second diameter different from the first diameter.

[0042] In an embodiment, the cutting assembly further comprises a plurality of knife modules in which the knives are received, and actuators each coupled to one or more of the knife modules and in communication with the knives, the actuators being selectively operable to control movement of each of the knives between the retracted position and the cutting position.

[0043] In embodiments, the tufting machine further comprises a shifting mechanism connected to the substrate support and configured to move the substrate support transversely relative to the path of travel of the substrate, hi some embodiments, the shifting mechanism can comprise a rack and pinion shifting mechanism.

[0044] In an embodiment, the yarn delivery system includes at least one yarn delivery mechanism having a plurality of yarn delivery devices each configured to control the delivery of at least one yarn to the needle.

[0045] According to another aspect, a method for manufacturing a textile machine includes a main drive shaft, a substrate support on which a substrate is supported, a plurality of needles positioned above the substrate support and configured to pierce the substrate and deliver a plurality of selected yarns upon reciprocal movement of the needles, each comprising a hollow needle having an upper end and a lower end with a passageway defined between the upper and lower ends, a yarn feed system for supplying the plurality of yarns, a series of funnels in communication with the needles, and a series of jerkers positioned along a path of travel of the yarns from the yarn feed system to the funnels, each jerker configured to be selectively operated to retract unselected yarns from the needles, and a series of jerkers positioned below the substrate support, each However, a tufting machine is provided that includes: a cutting assembly including one or more knife modules equipped with knives configured to cut the selected yarn as the selected yarn is carried into and out of the substrate with the reciprocating movement of the needles into and out of the substrate; and a control system configured to control the feeding of the selected yarn to the needles and the movement of the selected jerkers between their extended and retracted positions, the control system including programming configured to advance the feeding of the selected yarn by the yarn feeding system and the movement of the selected jerkers before the next tuft placement step in the pattern being formed based on rotation of a main drive shaft of the tufting machine.

[0046] In an embodiment, the control system may further include programming configured to control the feeding of different lengths of the selected yarn during rotation of the main drive shaft.

[0047] In an embodiment, the jerkers each include a body having a proximal end and a protruding distal end configured to engage and selectively retract unselected yarns when the jerkers are moved from the extended position to the retracted position.

[0048] In an embodiment, the tufting machine further comprises a plurality of jerk modules, each of the jerk modules comprising a body having a plurality of holes defined therethrough and coupled to an air supply source, a series of pistons received within the holes and coupled to the jerkers, and valves in communication with the holes and configured to control the flow of pressurized air into and through the holes to cause movement of the pistons along the holes and to control movement of the jerkers between their extended and retracted positions.

[0049] In some embodiments, the jerker modules comprise double-acting cylinders with reduced profiles and are mounted in one or more groups of about eight jerker modules spaced within about two inch intervals.

[0050] In an embodiment, the tufting machine further comprises an air supply in communication with the jerk module and the cutting assembly, and the control system further comprises programming configured to control the flow of pressurized air from the air supply to one or more of the jerk modules to selectively extend and retract one or more of the jerkers of the jerk module, and / or to one of the knife modules of the cutting assembly to selectively move one or more of the knives of the knife module between a disengaged position and one or more cutting positions.

[0051] In embodiments, the tufting machine may further include one or more regulators positioned between the air supply and the jerker module and / or knife module, the regulators including programming configured to control the flow of pressurized air to the jerker module and / or knife module according to the pattern being tufted.

[0052] In some embodiments of the tufting machine, the funnels each include an upper end defining an inlet portion and a lower end defining an outlet in communication with an associated one of the needles, the inlet portion having a multi-angled orifice including a first portion therethrough having a first diameter and a second portion having a second diameter different from the first diameter.

[0053] In embodiments, each of the knife modules of the cutting assembly further includes an actuator in communication with its knife, each actuator of each knife module being selectively actuatable to control movement of the knife between the retracted position and the cutting position.

[0054] In embodiments, the tufting machine further comprises a shifting mechanism configured to move at least one of the substrate support and the needles transversely relative to the path of travel of the substrate.

[0055] In some embodiments, the yarn delivery system includes at least one yarn delivery attachment having a plurality of yarn delivery devices each configured to control the delivery of at least one yarn to the needle.

[0056] Additionally, in some embodiments of the tufting machine, each of the funnels has an upper end and a lower end, the lower end can define an outlet in communication with an associated one of the needles, and the upper end includes a plurality of yarn passage channels configured to guide one or more yarns into the funnel for feeding to the associated needle.

[0057] According to a further aspect of the present disclosure, there is provided a method for forming a patterned tufting article, the method including: feeding a substrate along a travel path; feeding a plurality of yarns to a plurality of hollow needles through a yarn selection system, the needle selection system including a series of jerker modules including a plurality of holes with pistons received therein in communication with an air supply source, and a plurality of jerkers coupled to the pistons, each jerker having a body having a proximal end and a distal end; selecting one or more yarns from the plurality of yarns being fed to the hollow needles, feeding selected lengths of one or more desired colors or types of yarn to the hollow needles; controlling the feeding of unselected yarns, moving one or more of the jerkers from an extended position to a retracted position to retract the unselected yarns or inhibit the feeding of the unselected yarns to the hollow needles; and reciprocating the hollow needles in and out of the substrate to place tufts of the one or more yarns in the substrate according to a pattern being formed.

[0058] In an embodiment, the method further comprises shifting the substrate laterally relative to its path of travel.

[0059] In an embodiment, the method further includes advancing the feeding of selected yarns by the yarn feeding system and the movement of the jerkers between their extended and retracted positions in advance of the next stitch placement step of the pattern being formed based on rotation of the main drive shaft of the tufting machine.

[0060] In embodiments, the method further comprises cutting one or more yarns carried into the substrate with a hollow needle to form tufts.

[0061] According to another aspect of the present disclosure, a tufting machine includes a plurality of hollow needles, a yarn feeding mechanism configured to control feeding of selected yarns from a plurality of yarns fed to the hollow needles according to a pattern, an air supply source for supplying pressurized air, a yarn selection system configured to retract or inhibit feeding of unselected yarns to the hollow needles, a series of injectors configured to inject the selected yarns into the needles of the hollow needles, and a series of jerker modules positioned along a path of travel of the yarns from the yarn feeding system to the funnel, each of the jerker modules being connected to the air supply source. a yarn selection system comprising: a series of jerker modules including a plurality of holes with pistons received therein; and a plurality of jerkers coupled to the pistons and each having a body having a proximal end and a distal end configured to engage at least one of the yarns supplied by the yarn feeding system, the jerkers being individually movable between an extended position and a retracted position, and retracting or retaining unselected yarns from being fed into the hollow needles by selective control of pressurized air to the holes in the jerker modules according to a pattern being formed.

[0062] In embodiments, the tufting machine further comprises a cutting assembly including one or more knives positioned below the substrate support and configured to cut the selected yarn as it is carried into the substrate with the reciprocating movement of the needles in and out of the substrate.

[0063] In an embodiment, the tufting machine further comprises a control system configured to control operation of the yarn feed system and operation of the jerk to feed selected yarns to the needles, the control system including programming configured to dynamically advance operation of the yarn feed system and the jerk ahead of the next stitch placement step of the pattern being formed.

[0064] In some embodiments of the tufting machine, the control system may further include programming configured to feed selected yarns and selectively move the jerkers between their extended and retracted positions based on rotation of a main drive shaft of the tufting machine.

[0065] In some embodiments of the tufting machine, the jerker modules comprise double-acting cylinders having reduced profiles, and the jerker modules are mounted in one or more groups with eight jerker modules spaced within about two inches of each other.

[0066] In some embodiments of the tufting machine, the proximal end of each of the jerkers may include an anti-rotation mechanism configured to resist rotation of the jerkers when the jerkers are moved between their extended and retracted positions.

[0067] In embodiments, the tufting machine may further include a plurality of funnels disposed between the yarn selection system and the hollow needles, each of the funnels including an upper end defining an inlet portion and a lower end defining an outlet in communication with an associated one of the needles, the inlet portion having a multi-angled orifice including a first portion having a first diameter and a second portion having a second diameter different from the first diameter.

[0068] In embodiments, the tufting machine may further include one or more regulators positioned between the air supply and the jerker module, the regulators including programming configured to control the flow of pressurized air to the jerker module according to the pattern being tufted.

[0069] In embodiments, the tufting machine may further comprise a substrate support over which the substrate is moved for insertion of tufts of yarn by hollow needles, and a rack and pinion shift mechanism connected to the substrate support and configured to move the substrate support transversely relative to the path of travel of the substrate.

[0070] Thus, disclosed are embodiments of a hollow needle tufting machine or system and a method for tufting an article utilizing such a hollow needle tufting machine that address the needs discussed above and others. The foregoing and other advantages and aspects of embodiments of the present disclosure will become apparent and more readily understood from the following detailed description considered in conjunction with the accompanying drawings. Furthermore, it is to be understood that both the foregoing summary of the present disclosure and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the present disclosure. [Brief explanation of the drawings]

[0071] The accompanying drawings, which are included to provide a further understanding of embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure, and together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show structural details of the present disclosure in more detail than may be necessary for a basic understanding of the exemplary embodiments discussed herein and various ways in which they may be practiced.

[0072] [Figure 1A] FIG. 1A is an end view of one embodiment of a tufting system or apparatus according to the principles of the present disclosure.

[0073] [Figure 1B] FIG. 1B is an enlarged detail view of the tufting zone of the tufting system or apparatus of FIG. 1A.

[0074] [Figure 2A] 2A-2B are perspective views of an embodiment of the tufting system or apparatus of FIGS. 1A-1B. [Figure 2B] 2A-2B are perspective views of an embodiment of the tufting system or apparatus of FIGS. 1A-1B.

[0075] [Figure 3A]3A-3B are front perspective views of a portion of a tufting system or apparatus such as that illustrated in FIGS. 1A-2B showing yarns being fed to needles through a puller roll according to the principles of the present disclosure. [Figure 3B] 3A-3B are front perspective views of a portion of a tufting system or apparatus such as that illustrated in FIGS. 1A-2B showing yarns being fed to needles through a puller roll according to the principles of the present disclosure.

[0076] [Figure 4] FIG. 4 is an end view of an embodiment of a needle bar with a yarn feed tube for feeding yarn from a yarn jacker to the needles of a tufting system or apparatus according to the principles of the present disclosure.

[0077] [Figure 5] FIG. 5 is a side elevational view of one embodiment of a yarn selection system for a tufting system or apparatus according to the principles of the present disclosure.

[0078] [Figure 6A] FIG. 6A is a side elevation view diagrammatically illustrating a series of yarns being fed to a syringe, through a feed tube, and to a needle bar mounting plate for feeding the series of yarns through a funnel block according to the principles of the present disclosure to a series of needles disposed along the needle bar of a tufting system or apparatus.

[0079] [Figure 6B] FIG. 6B illustrates one embodiment of a needle bar mounting plate having a yarn feed tube coupled thereto and including an injector for feeding yarn to the needles of a tufting system or apparatus in accordance with the principles of the present disclosure.

[0080] [Figure 7A] 7A-7C illustrate one 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. [Figure 7B]7A-7C illustrate one 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. [Figure 7C] 7A-7C illustrate one 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.

[0081] [Figure 8A] 8A-8C illustrate 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. [Figure 8B] 8A-8C illustrate 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. [Figure 8C] 8A-8C illustrate 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.

[0082] [Figure 9A] 9A-9E illustrate an example yarn selector system including a series of jerker modules for selectively controlling the feeding of yarns to the needles of a tufting system or apparatus according to the principles of the present disclosure. [Figure 9B] 9A-9E illustrate an example yarn selector system including a series of jerker modules for selectively controlling the feeding of yarns to the needles of a tufting system or apparatus according to the principles of the present disclosure. [Figure 9C] 9A-9E illustrate an example yarn selector system including a series of jerker modules for selectively controlling the feeding of yarns to the needles of a tufting system or apparatus according to the principles of the present disclosure. [Figure 9D] 9A-9E illustrate an example yarn selector system including a series of jerker modules for selectively controlling the feeding of yarns to the needles of a tufting system or apparatus according to the principles of the present disclosure. [Figure 9E]9A-9E illustrate an example yarn selector system including a series of jerker modules for selectively controlling the feeding of yarns to the needles of a tufting system or apparatus according to the principles of the present disclosure.

[0083] [Figure 10] FIG. 10 illustrates an exemplary embodiment of an anti-rotation device or mechanism for limiting rotation of a jerk as it moves along a stroke or path of travel in accordance with the principles of the present disclosure.

[0084] [Figure 11A] 11A-11B illustrate an embodiment of a hollow needle and a locating assembly for aligning the hollow needle for mounting along a needle bar of a tufting system or device in accordance with the principles of the present disclosure. [Figure 11B] 11A-11B illustrate an embodiment of a hollow needle and a locating assembly for aligning the hollow needle for mounting along a needle bar of a tufting system or device in accordance with the principles of the present disclosure.

[0085] [Figure 12A] 12A-12B illustrate an exemplary embodiment of a yarn cutting or knife system for a tufting system or apparatus according to the principles of the present disclosure. [Figure 12B] 12A-12B illustrate an exemplary embodiment of a yarn cutting or knife system for a tufting system or apparatus according to the principles of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0086] The present disclosure may be more readily understood by reference to the following detailed description, examples, drawings, and claims, as well as their foregoing and following descriptions. It is to be understood, however, that the present disclosure is not limited to the specific devices, systems, and / or methods disclosed, unless otherwise specified, and as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Thus, the following description is provided as an illustration of the principles of the present disclosure, and not as a limitation thereof.

[0087] For example, as used throughout, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a "processor" can include two or more such processors unless the context indicates otherwise.

[0088] Ranges can be expressed herein 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 use of the antecedent "about," it will be understood that the particular value forms another aspect.

[0089] As used herein, the term "tuft" encompasses both cut and loop pile tufts or stitches of yarn, and the term "tufting" encompasses both the act of forming cut and loop yarn stitches.

[0090] Referring to the drawings, in which like numerals indicate like parts throughout the several views, Figures 1A-12B illustrate exemplary embodiments of a tufting system or apparatus and its various operative components and / or features constructed in accordance with the principles of the present disclosure. In embodiments such as those shown in Figures 1A-5, The tufting system or apparatus includes a hollow needle tufting machine 10, which will generally include a plurality of needles, the hollow needle tufting machine 10 including hollow needles 12, which, in embodiments, are configured to penetrate a substrate material 14 to deliver and / or embed a series of yarns Y into the substrate as the substrate moves along a travel path P (FIG. 2A) through the hollow needle tufting machine 10 to form a plurality of tufts of yarns within the substrate.

[0091] In embodiments, the hollow needle tufting machine 10 can feed a series of different colors and / or types of yarns to each of the hollow needles, which yarns can then be selectively embedded or tufted into a substrate material to form a tufted patterned article.

[0092] 1A-2B, in an embodiment, hollow needle tufting machine 10 includes a frame 16 having an upper portion 17A and a lower portion 17B, a tufting zone or region T defined through frame 16, and a substrate support or shuttle 18 over which a substrate is moved, which may be positioned along the tufting zone. An array of hollow needles 12 may be mounted along needle bar 20 which is driven in a reciprocating (up and down) motion to cause needles 12 to penetrate in and out of substrate 14 to embed tufts of yarn within the substrate as it moves through the tufting zone or region.

[0093] Additionally, in embodiments, a yarn cutting or knife system 21 can be provided below the substrate support or shuttle 18. In embodiments, the yarn cutting or knife system 21 can include a series of knife modules 22, each including a knife 23. In some embodiments, one or more of the knives 23 can be individually controlled to be moved between a non-cutting or non-engaging position and one or more cutting positions for selectively cutting the yarn as it becomes embedded in the substrate. The hollow needle tufting machine 10 can also generally include a yarn feed system 25, which feeds lengths of yarn from a yarn supply source (such as a creel or beam, not shown) to the needles.

[0094] Still further, in embodiments, the hollow needle tufting machine includes a control system 30, which in embodiments may include a controller 31 having one or more processors and programming that will control the operation of the hollow needle tufting machine 10 and its various operating systems and / or components to produce a patterned tufted article according to a selected pattern. The control system may be further configured to control the supply of pressurized air from an air supply S (e.g., a blower or other pressurized air source such as that shown in FIG. 1A) to various of the hollow needle tufting machine's operating systems or components. For example, in an embodiment such as that shown in FIG. 3B, the source of pressurized air may also include or be in communication with a distribution device 26, such as a manifold, which may be divided into banks or portions 26A, 26B, etc., and configured to supply different groups or portions of various operating components of the hollow needle tufting machine (such as, but not limited to, the jacker module and injector portions of the yarn selection system 75, the knife module 22 of the cutting assembly 21, and / or other components).

[0095] In embodiments, the length, needle spacing, and number of needles in the hollow needle tufting machine can vary depending on the product to be produced and the desired production rate. For example, in embodiments, the hollow needle tufting machine can be configured to produce carpet, turf, rug, or other articles of a selected size or a range of sizes.

[0096] In embodiments, the substrate material 14 may be advanced longitudinally past the reciprocating needles by a substrate feed system 35, which may, in embodiments, include a feed roller 36, may further include a spike roll, and may be driven by a motor 37 (e.g., a servo or stepper motor or other drive device). The substrate feed system 35 is generally controlled (e.g., by the control system 30) and, in embodiments, may include a substrate feed controller that is programmed and configured to feed the tensioned substrate 14 (FIG. 2A) beneath the needles 12 and through the tufting zone T of the hollow needle tufting machine 10.

[0097] The substrate feed system can be controlled to move the substrate 14 in a controlled motion, for example, in embodiments, in a stepwise motion, and the substrate can be further shifted. As the needles are reciprocated in and out of the substrate, a series of yarns Y are inserted into the substrate by the needles to form yarn tufts. In embodiments, the yarn tufts can comprise loop pile tufts, cut pile tufts, or a combination thereof. In some embodiments, the tufts can be formed with different or varying pile heights to provide texture or other effects. Various colors and / or types of yarn can be selectively provided to each of the needles to form tufted articles such as carpets, rugs, artificial turf or grass, and other tufted fabrics. In embodiments, such tufted articles can be formed with selected designs that can include, but are not limited to, different colors or types of yarns, textures, and / or other pattern effects.

[0098] The hollow needle tufting machine 10 can include a needle bar drive system 40 configured and operable to reciprocate the needle bars and carry the needles 12 in and out of the substrate 14. In embodiments, the needle bar drive system can include push rods 41 (FIGS. 4-5) coupled at their lower ends to the needle bars and coupled to a main shaft 42 (FIGS. 1A and 2B) of the hollow needle tufting machine 10. For example, the upper ends of the push rods can be connected to cam members, which are supported on and driven by the main shaft. In embodiments, the main shafts can be located offset from the centers of the cam members, and the main shafts can be supported by bearings. Each push rod can extend through a guide or bearing to help guide the vertical reciprocating motion of each push rod.

[0099] 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 electric motors 42A, which are operatively connected to both ends of the main drive shaft and mounted on both ends of the frame of the hollow needle tufting machine to rotate the main drive shaft. The one or more motors that drive rotation of the main shaft at an operating speed are configured to operate under the control of a control system. For example, in embodiments, the motor 42A can rotate the main drive shaft at speeds of up to about 1,000 rpm or more for high product throughput.

[0100] In operation, each rotation of the main drive shaft can cause the needles to pierce and then retract from the substrate. In other words, each rotation of the main drive shaft can cause one needle reciprocation cycle, also referred to as a tufting cycle, which includes a needle downstroke and an needle upstroke. In embodiments, control of various operating systems or components can be further tied to the rotation or position of the main shaft.

[0101] As shown in FIG. 4 , the lower end of the push rod can be further connected to a needle bar mounting plate 44, which is connected to and supports the laterally extending needle bar 20. The needles 12 can be mounted to the needle bar 20 and spaced consecutively along or at least a portion of the needle bar. For example, each of the needles can be located at a selected or desired spacing from an adjacent needle, e.g., in embodiments, at 1-inch gauge spacing across the width of the tufting machine. Other needle spacing distances can also be used. Upon rotation of the main shaft, reciprocating movement of the main shaft is imparted to the push rod, which correspondingly drives the needle bar in a similar reciprocating (up and down) movement, causing the needles 12 to repeatedly penetrate and withdraw from the substrate 14 to introduce yarn into the substrate to form multiple tufts therein.

[0102] In an embodiment, as shown in FIGS. 3A-3B and 6A , the needle bar mounting plate 44 may be rectangular in cross section, and one or more passageways 46 may be provided for each needle, 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. A plurality of yarn conduits 49 ( FIGS. 4-5 ) may be coupled to each of the respective inlets 47 at the top of the needle bar mounting plate to supply a plurality of yarns to the inlets and to their respective needles 12. Each funnel block 48 may generally include a funnel extending from an inlet to an outlet at the bottom of the needle bar mounting plate, the funnel configured to receive and direct yarns fed from the yarn feed system. As shown, the funnel block is configured to receive each of the yarns fed from the yarn feed system and direct them to the needles below.

[0103] As illustrated in FIGS. 1B, 6A, and 11A-11B, each of the needles 12 can generally have an elongated, hollow body 51 defining a central passageway 52 through which the textile yarn is fed, as shown in FIG. 5, and each of the needles 12 has a first entrance or distal end 53 that can be received in a module or mounting block 54, which in embodiments can include an elongated body 54A configured to attach to the needle bar 20. Alternatively, in some embodiments, the needles can be separately attached to the needle bar and mounted sequentially at spaced intervals along the needle bar. The needles may further include an open second or distal end 56 that terminates in a pointed tip 57. The following is further illustrated in Figures 11A-11B: in embodiments, the proximal end of each of the needles can generally include a cutting edge or surface 58, which can have an angled surface that extends upwardly along the body of each needle from the tip 57 to a midpoint, and in some embodiments, the cutting edge or surface 58 can further include a recess at its upper end, which can be configured to help hold or capture the yarn during cutting.

[0104] In embodiments, needles 12 are mounted sequentially at spaced intervals along their modules or mounting blocks 54, and one or more modules or mounting blocks can be mounted to a needle bar. For example, in embodiments such as those shown in FIGS. 11A-11B, a jig 61 is generally provided for aligning or orienting each of the needles in their modules to secure the needles in place, so that their cutting surfaces can be oriented in an appropriate or selected orientation or configuration for engagement by knives 23 of knife system 22 or yarn severing below them. In embodiments such as those shown in FIGS. 11A-11B, jig 61 can include a body 62 that can have a stepped profile 63 at its upper end configured to receive a needle module or mounting block / support bar 54 thereon and can further include a series of needle-receiving holes 64.

[0105] 11B, in embodiments, needles 12 can be inserted through needle mounting openings 55A defined in module or mounting block 54, which in some embodiments may further include one or more longitudinal slots or separate areas 55A, with needle mounting openings spaced along the longitudinal slots or separate areas 55A, so that needles 12 enter needle-receiving holes 64 of the fixture and are guided and rotated or otherwise oriented, e.g., with their cutting surfaces aligned at a selected position for engagement with a knife of a yarn cutting or knife system. In embodiments, set screws 65 or similar fasteners can further be provided to adjust the rotation, advancement, and / or orientation of the needles' cutting surfaces within the fixture passages.

[0106] Once the needle 12 is installed in the proper selected alignment, the needle may be secured along the module or mounting block by engaging fasteners 59 (such as set screws or other similar devices located along the side surface of the module or mounting block), as shown in FIG. 11B, to secure the needle in place and in the desired alignment for yarn severing or engagement with the knives 23 of the knife system 22, generally without requiring additional movement or rotation of the needle and / or knife during operation of the hollow needle tufting machine. For example, in an embodiment, when fasteners 59 are engaged against the side surface of the module or mounting bar 54, slots 55A may be closed against the body of the needle, securing the needle in the desired orientation.

[0107] As shown in Figures 1A-6A, a series of different colors or types of yarns Y are fed to each of the needles in the yarn feed system 25 of the hollow needle tufting machine 10. In embodiments, the yarn feed system of the hollow needle tufting machine can include one or more yarn feed mechanisms or attachments 65 (Figures 1A and 2A-2B). In embodiments, such yarn feed mechanisms or attachments 65 can be mounted on both sides of the tufting machine. For example, as illustrated in Figures 1A and 2B, one or more yarn feed attachments can be located on both sides of the hollow needle tufting machine, e.g., along the upstream and downstream sides, that are mounted to and supported on the frame of the hollow needle tufting machine.

[0108] In an embodiment, the yarn feed attachment or mechanism 65 is an Infinity yarn feed attachment or mechanism such as that produced by Card-Monroe Corp. (Chattanooga, Tennessee). TM or Infinity IIE TMThe hollow needle tufting machine may include a single-ended or double-ended yarn feed mechanism or attachment, such as the present feed attachments of the present invention. Each yarn feed mechanism or attachment 65 may include a housing 66 in which multiple yarn feed devices 67 may be received. As shown in FIGS. 1A, 2A, and 2B, each yarn feed device 68 includes a motor 69 that drives at least one driven yarn feed roll 71, and one or more idler feed rolls 72 may be driven by rotation of the drive roller 71. Each yarn feed device may feed one to two (or potentially more) yarns to associated ones of the needles of the hollow needle tufting machine. Each yarn feed device may further be individually controlled by the control system of the hollow needle tufting machine to selectively control the feeding of individual yarns to those needles.

[0109] In embodiments, as shown in FIGS. 2A, 2B, and 6A, the yarn feed devices are configured to feed at least one yarn to the needles, each capable of feeding at least one different color or type of yarn. In embodiments, a series or set of yarn feed devices can selectively feed their yarns to their associated needles. For example, without limitation, eight sets of yarn feed devices can be associated with the needles, each capable of feeding a different color or type of yarn to the associated needle through a yarn selection system 75 and a yarn conduit 49 extending from the yarn selection system 75 to an inlet 47 in the needle bar mounting plate 44, as shown in FIG. 5. A different set or series of yarn feed devices (e.g., a set of eight or more yarn feed devices) on each of the yarn feed mechanisms or attachments mounted on both sides of the tufting machine frame can feed a yarn (e.g., eight or more yarns) to each of the needles. For example, a yarn feed mechanism or attachment yarn feed device on the front of the tufting machine may feed the yarns to every other needle, while a yarn feed mechanism or attachment yarn feed device mounted along the back side of the rear face of the tufting machine may feed the yarns to those in between the needles.

[0110] As shown in FIG. 5 , the yarns will be fed into the funnel block 48 through passages 46 defined through the needle bar mounting plate 44. Each yarn will typically be fed through an individual yarn conduit 49, which will be coupled to one of the inlets 47 associated with each needle. FIG. 6B illustrates an exemplary embodiment of the needle bar mounting plate 44 along which sets of inlets are arranged. As shown in FIG. 6B , in an embodiment, eight sets of inlets 47 are provided, each set may generally include an inlet for the color or type of yarn to be supplied to the needle associated with each set (e.g., eight colors of yarn), each set spaced around a central bore 76 configured to allow insertion of a syringe 77 therethrough. It is envisioned that additional or fewer inlets may also be provided. As further shown in FIG. 6A , in an embodiment, each of the passages 46 extends from its inlet 47 through the needle bar mounting plate to an opening at the bottom end of the needle bar support plate. In an embodiment, a lip or edge may be defined at the lower end of the passageway to provide a stop 78 for insertion of the yarn conduit through the passageway and prevent the yarn conduit from extending or being pulled all the way through the needle bar mounting plate.

[0111] 7A-8C illustrate an exemplary embodiment of a funnel block 48 for use with the hollow needle tufting machine 10. The funnel block may typically include a body formed from a hardened material, such as metal (e.g., steel or aluminum) or other similar durable material, and each will include a series of funnels 80. As shown in FIGS. 7C and 8C, each of the funnels 80 may generally include a first or upper end 81 and a sidewall 82 that tapers downward to a second or lower end 83 and terminates in an opening 84 along the bottom surface of the funnel block, to which the needles are attached. As selected ones of the yarns are fed and injected into each funnel, the selected yarns will be guided into the hollow bores of the needles for delivery of the yarns to or embedding into a substrate.

[0112] In a first embodiment, shown in FIGS. 7A-7C , the funnel can include a multi-angled circular orifice 85 having a first entrance portion at the funnel's upper end 81, the first portion of the multi-angled circular orifice 85 having a first diameter and tapering downward along a first wall portion 82′ to a second orifice portion having a second diameter. A sidewall 82″ of the second orifice portion 86 extends downward and tapers to an opening 84 at the funnel's bottom end. In an embodiment, the first diameter of the first orifice portion will be greater than the second diameter of the second orifice portion. In an embodiment, the taper of the first orifice portion wall 82′ can have a shallower, flatter taper angle than the taper of the second orifice portion wall 82″. For example, in embodiments, the angle of taper of the wall of the first orifice portion can be from about 1° to about 25°, while the angle of taper of the wall of the second orifice portion can be from about 25° to about 45°. Other angles are also contemplated. As the yarn is fed into the funnel, the shallower angle of the first orifice portion can guide the yarn toward the second orifice portion, which guides the yarn toward the center of the funnel and allows for smoother feeding of the yarn into and through the funnel.

[0113] 8A-8C illustrate another alternative embodiment of the funnel block 48. As shown in FIG. 8A, in this embodiment, the funnel 80 is formed with a fluted design having a plurality of flutes 88 arranged continuously around the circumference of the funnel's upper open end. Each of the flutes can define a yarn-receiving channel that slopes downward toward the funnel's lower orifice to guide individual yarns into an associated hollow needle. While FIGS. 8A and 8B illustrate a fluted funnel design with approximately eight flutes, it will be understood by those skilled in the art that fewer or greater numbers of flutes can also be used. Additionally, in embodiments, it is possible to feed multiple yarns into each flute, whereby each flute can be used to direct one or more yarns supplied from a yarn feed system to an associated hollow needle.

[0114] Additionally, in embodiments, air tubes may be connected to syringes 77, for reasons described below, which selectively supply air to the syringes to deliver a burst of pressurized air to maintain the position of the yarns within the needle bar 42. Preferably, as shown, the lower end of each syringe is at the outlet of the needle bar 42 and the inlet of the needle 12. The syringes preferably include multiple jets or openings 49. The syringes may have a larger diameter than the internal passage of the needle 12 to ensure proper air flow into the needle 12. Each syringe may be fed with air from an air supply tube 50, which in embodiments may also include an air manifold 52, through which a supply of pressurized air may be distributed to the syringes.

[0115] A plurality of yarns can be placed in the funnel block for feeding into the needles. During the needle threading process, the yarns are inserted into the needles by the needle threading process, and selected yarns are forced into the needles 12 by the air injector. During the tufting process, the yarn being sewn and other yarns in the needles are held in the needles by air pressure acting on the yarns from the injector 48 and by control of yarn feed and supply by the yarn feed system and yarn selection system.

[0116] During each tufting cycle, the hollow needles can reciprocate between a raised or top position and a lowered or bottom position. The substrate can be positioned between the top and bottom positions of the tufting cycle to penetrate the substrate. In one cycle, the tip of each hollow needle can advance from the top position to the bottom position and return to the top position. Between the top and bottom positions, the hollow needles can penetrate the substrate and embed yarn tufts into the substrate. The movement of the hollow needles between the top and bottom positions 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.

[0117] As described, each yarn fed to each needle can have a separate yarn feeding device, which can be operated by a system controller (e.g., each yarn feeding device or set of yarn feeding devices can have its own controller or can be coupled to a yarn feeding system controller that can be configured to control a series of yarn feeding devices), whereby the length of each yarn fed into the needle for each selected stitch of the pattern can be controlled to allow for improved precision in the feeding of each yarn, and each yarn can be selected to form a corresponding tuft in the substrate, while non-selected yarns can be controlled, and in embodiments, pulled back (e.g., by operation of a yarn jerk associated with such non-selected yarns).

[0118] Additionally, a series of puller rolls 95 can be provided along the front and back sides of the hollow needle tufting machine, and along the upstream and downstream sides of the tufting machine. The rotation of the puller rolls can be controlled by a control system to ensure a substantially consistent feed of yarn to the needles. Each feed of yarn by the yarn feed device can be controlled based on the rotation of the main shaft to essentially match the rate of yarn feed from the yarn feed device to deliver a desired amount or length of yarn within a portion of a revolution of the main shaft to help ensure a substantially consistent yarn delivery by the puller rolls.

[0119] For example, in embodiments, the yarn feed devices can be controlled by the control system 30 to feed the total stitch length of a selected yarn (e.g., the length of yarn required to perform a tuft to a base selected or desired length) within a portion of each stitch cycle or revolution of the main shaft of the hollow needle tufting machine. In embodiments, different lengths or amounts of yarn that produce the total stitch length of each selected yarn to be fed to form a tuft of a desired pile height can be fed at increased or decreased rates during different portions of the tufting cycle, or at different times based on the rotation or position of the main shaft (e.g., in embodiments, the yarn feed devices of a yarn feed system can be operated to feed different percentages or amounts of yarn depending on where the main shaft is in its revolution, as opposed to feeding a substantially consistent amount of yarn during a revolution of the main drive shaft).

[0120] In embodiments, the puller rolls are driven at a rate in sync with the feed rolls of the yarn feed device to generally prevent the yarn from wrapping around the yarn roll. In some embodiments, the puller rolls can also be driven at a rate relative to the rotation of the main drive shaft and / or a combination of rate and position, so that they primarily feed in sync with the yarn feed at different amounts or percentages within different portions of the rotation of the main drive shaft. By way of example only, if the yarn feed for a selected color yarn is approximately 4 inches during the first 120° of rotation of the main drive shaft, the puller rolls can be operated to feed a little more than 4 inches of the selected yarn during the 120° of rotation of the main drive shaft. During the remaining 240°, the puller roll and / or feed roll of the yarn feed device for the selected yarn can be used to slow down and / or re-accelerate the feed of such selected yarn to the needles as needed (to help minimize excess tension on the yarn). Still further, in embodiments, the yarn feed rate for forming the first and / or last stitch of a selected color or type of yarn can be adjusted to account for the next tuft row color change in the pattern design being formed.

[0121] Such control of yarn delivery by each of the yarn feed devices can provide for yarn delivery to puller rolls provided along the front and back sides of the tufting machine at a rate selected and controlled to substantially maintain consistency in yarn delivery to the needles. In embodiments, the puller rolls can be operated to rotate at a different rate than the yarn feed rolls. For example, in embodiments, the puller rolls can be driven at a rate that is substantially synchronized with the yarn feed and is generally sufficient to keep the yarns clear of the yarn feed rolls to minimize wrapping of the yarns around the yarn feed rolls.

[0122] As shown in FIG. 1A, a yarn selection system 75 for the hollow needle tufting machine 10 can be positioned along the travel path of each yarn from the yarn feed device of the yarn feed system, through the puller rolls, and into the yarn feed conduits that feed the yarns to the needles. 9A, the yarn selection system 75 can be located adjacent the puller roll 95 and, in embodiments, generally includes multiple jerker modules 101 that can be attached to a support plate 102 at their upper ends as part of a yarn jerker assembly or modular yarn jerker system that can be mounted or mounted along the frame of the hollow needle tufting machine. A yarn feed guide 103 can be located adjacent the lower end of the jerker module and can include multiple holes or openings 104 through which the yarns pass to guide individual yarns into yarn conduits for feeding to the needles.

[0123] As shown in FIGS. 9C-9E, in an embodiment, each of the jerk modules 101 can include a double-acting cylinder 105 having a housing or cylinder body 107 in which a series of piston bores 108 and a series of air passages 109 are formed. A piston 112 can be received in each of the piston bores. An air port 113 (FIGS. 9A and 9B) can be connected to an upper end of the piston bore. The air port can include a fitting or connector that connects to an air line or conduit coupled to an air supply source (e.g., one or more blowers) configured to supply a flow of air from the air source to the double-acting cylinder 105. The flow of air into the ports and into the individual piston bores of the double-acting cylinder or jerk module can be controlled (e.g., increased or decreased) to selectively drive the pistons along the piston bores in first and second directions to selectively move the jerk 115 between an extended position and a retracted position, as shown by arrows 114 / 114' in FIG. 9B. The jerkers 115 can engage individual yarns so that such yarns can be retracted or pulled back in conjunction with the control of the feeding of such yarns by the yarn feeding device, pulling unselected or unwanted yarns back out of the funnel for the hollow needle.

[0124] In embodiments in which the jerk module comprises a double-acting cylinder, the jerk module can be operated in conjunction with a multi-way valve, e.g., a valve 110 such as a four-way solenoid valve or two or three air valves, for applying a flow of pressurized air or other fluid through an air connection to drive the pistons along their travel paths in their first and second directions without requiring a spring return for the pistons. For example, without limitation, air pressure can be controlled so that increased air pressure sufficient to drive selected ones of the pistons along their piston bores in a first direction can be supplied to a first one of the ports. For example, in embodiments, increased air pressure can be provided through a second port sufficient to overcome base or substantially constant air pressure supplied through an air passage in the cylinder block, causing the pistons to move toward a retracted position and extend their jerkers. When such increased pressure air flow is substantially stopped or reduced, the pistons can be moved along their return stroke in their second direction, retracting their associated jerkers.

[0125] The cylinder block or body 107 of the jerker module can further be configured with a reduced profile, which allows for increased density of jerker module placement than the yarn selection assembly; for example, in an embodiment, the jerker modules can be arranged in groups or sets where approximately eight jerker modules can be positioned within a space of approximately 2 inches or less. Other arrangements and / or spacings of the jerker modules can also be used, including various numbers of jerker modules spaced at different intervals. Additionally, the holes in the jerker modules can be reduced from approximately 1 / 2 inch to approximately 5 / 16 inch, which further allows for a more compact, higher density design as illustrated in FIGS. 5 and 9A-9E.

[0126] Additionally, in embodiments, the jerker module can also be formed with reduced weight, for example, in embodiments, the jerker module can be formed from lighter materials such as aluminum or composite materials, e.g., nylon, carbon fiber polymer, and / or other moldable materials. In some embodiments, the yarn feed openings formed in the jerker module can also be hard coat anodized or otherwise treated to facilitate movement of the yarns therethrough.

[0127] As shown in Figures 9B-9E, each of the jerkers 115 can generally include an elongated body 116 having an upper or proximal end 117 and a lower or distal end 118. In embodiments such as those shown in Figures 9D and 9E, the distal end of the jerker can have a hook-like or angled configuration. Optionally, in other embodiments, the distal end of the jerker can include a substantially straight or flat distal end, as shown in Figures 9B-9C. In embodiments, it is contemplated that the jerker modules may further include an anti-rotation mechanism or device 120 (Figures 9C and 10) configured to limit or substantially prevent rotation or pivoting of the jerkers as they are moved along their stroke or travel path between the retracted and extended positions.

[0128] In embodiments, the anti-rotation mechanism 120 can include interlocking keys at the proximal or upper ends of the jerkers. As shown in Figures 9C and 10, the proximal ends 117 of the jerkers 115 can engage and lock together using a key (e.g., alternating ones of the jerkers can include male or female keyways 119A / 119B), allowing the jerkers to cooperatively move in a substantially linear motion relative to one another, and excessive twisting or pivoting of the jerkers can be substantially prevented, further allowing for a more compact configuration and modularity of the design. The male and female keyways of adjacent jerkers further serve as an anti-rotation device or mechanism to limit the rotational or pivotal movement of the jerkers as they are extended and retracted.

[0129] In some embodiments, the anti-rotation mechanism can include a guide rod, which can be used in addition to or as an alternative to the male and female keyways of the jerkers to help limit rotation of the jerkers during their extension and retraction movements.

[0130] The jerkers may be further coupled at their proximal ends to associated pistons, as shown in FIG. 9C, by connectors or gate keys 119A / 119B or the like formed at the proximal end of each jerker. Each of the keys may include an elongated head 122, and in embodiments, each of the keys may comprise a male or female key 119A / 119B, and each of the keys may include an opening into which the distal end of the associated piston 112 may be received and secured.

[0131] Further, generally, as illustrated in FIGS. 12A-12B, a yarn cutting or knife system 21 can be positioned below the substrate, along the tufting zone. In embodiments, the cutting or knife system 21 can include a series of knife modules 22 mounted along a knife bar 24 that carries the knife modules and their knives in a reciprocating motion toward and away from the needles as the needles are reciprocated in and out of the substrate. The knife modules can also be configured with a reduced profile and can be arranged along the knife bar at gauge spacing similar to the needle spacing as shown in FIG. 12B. Each of the knife modules 22 will generally include a knife or cutting blade 23 having a cutting edge 125 adjacent its upper end. Each of the knives 12 is received in a holder or support 126, and the knives can be positioned or oriented so that their cutting edges 125 are aligned with the cutting edges or surfaces of the needles, as generally shown in FIGS. 7B-9C.

[0132] In embodiments, the knife alignment system may include a plate assembly 130 provided along the knife bar for positioning the knife's cutting edge with the needle's cutting surface. The knives may be aligned via the plate alignment assembly and then secured in place within their holders. Each of the knife modules may be mounted along the knife bar, rather than requiring the knives to be individually mounted along the hollow needle tufting machine. In embodiments, the knife bar may further incorporate an alignment plate assembly, whereby the knives may be mounted within the hollow needle tufting machine, and the plate assembly may then be used to align or set the knives to a desired or selected cutting angle relative to the alignment or orientation of their respective or associated needle's cutting surface. For example, in embodiments, the knife's cutting edge may be set at a zero-degree cutting angle relative to the needle's cutting surface, although other cutting angles may be used as needed to ensure proper cutting engagement or contact with the needle's cutting surface. Adjusting the knife location and / or orientation may further allow for adjustment of the knife pressure of engagement between the knife and the needle's cutting surface.

[0133] Each of the knife modules will generally further include an actuator, such as an air cylinder 121. In embodiments, the knife module actuators may generally comprise multi-position actuators or cylinders. The multi-position actuators will each receive a flow of pressurized air from the hollow needle tufting machine's air supply under the control of a control system to selectively move each of the knives through a series of positions. The knife positions can be controlled so that the knives can be moved between a lowered or non-cutting position, where loop pile tufts of selected yarns can be formed within the substrate according to the pattern of the tufting article being formed, and multiple raised cutting positions or elevations for cutting yarns embedded or delivered into the substrate by the needles to form cut pile tufts. Such tufts can further be formed at various pile heights.

[0134] For example, in embodiments, the multi-position actuator can include a three-position actuator, such as a three-position pneumatic or hydraulic cylinder or servo or stepper motor (or other actuator), and can further include a four-way fluid valve for selectively controlling the supply of fluid (e.g., air) to the three-position actuator. In embodiments, at least three positions can be provided for each of the knives, e.g., a high-cut position, a low-cut position, and a non-cutting or loop position.

[0135] The positions or locations of the knives between their non-cutting and cutting positions can be controlled by a system controller in cooperation with the delivery of selected yarns to each of the needles to form such cut and loop pile tufts, and to form tufts of various pile heights according to the pattern of the tufting article being formed. Additionally, solenoids can be provided to control the delivery of air to each of the cylinders that drive the movement of the knives. A pressurized air supply can be coupled to and supply a flow of pressurized air to each cylinder of the knife modules, which flow of air can be controlled by a solenoid or other actuator to control the movement of the knives.

[0136] During each tufting cycle, the knife blades can be configured to cooperate with the needles by sliding over their respective tips in a shearing action to cut the yarns inserted or embedded by the needles. Thus, when one or more of the knives are moved to a position where their cutting edges are raised to the cutting position, the cutting edge of each of such one or more knives can contact the cutting surface of their associated needle as the needle is reciprocated into the substrate, forming cut pile tufts within the substrate. Conversely, when one or more knives are moved to a position where their distal ends are furthest from the tips and cutting edges of their associated needles, i.e., a disengaged or non-cutting position, the cutting edge of one or more knives will not contact or will not fully contact the cutting surface of the associated needle as the needle is reciprocated into the substrate, thus allowing loop pile tufts to be formed within the substrate.

[0137] Additionally, in embodiments, the substrate support or shuttle can be shifted laterally relative to the direction of feed of the substrate along its path of travel through the hollow needle tufting machine. In embodiments, as shown in Figures 2A and 2B, a shift mechanism 38 can be coupled to the substrate support or shuttle 18 and controlled to shift or move the substrate laterally relative to the path of travel P of the substrate 14 through the hollow needle tufting machine 10 (Figure 2A). Additionally, in embodiments, multiple shift mechanisms can be used (e.g., positioned on both sides of the hollow needle tufting machine), and in some embodiments, one or more shift mechanisms can be coupled to the needle bars to shift the needles 12 separately and / or in conjunction with the substrate support or shuttle to form the tufting pattern.

[0138] In embodiments, the shifting mechanism may include a shifting mechanism driven by one or more servo motors or other actuators under the control of control system 30. For example, in embodiments, a SmartTech TM One or more shifting mechanisms 38, including servo motor driven rack and pinion shifting mechanisms, such as a shifting mechanism, can be provided for shifting the substrate bar laterally.

[0139] In embodiments, the substrate can be shifted in one or more gauge steps. The modular design of the needle module of the hollow needle tufting machine and the use of a reduced-profile jerker module in the yarn selection system allow for eight or more yarns to be fed to each needle, and each needle can be spaced at approximately one-inch gauge intervals. As a result, shift steps or jumps based on needle gauge spacing within approximately one-inch stitch gauge, e.g., one or more steps or jumps to embed yarns of different colors and / or types, such as eight, sixteen, twenty-four, etc., as opposed to conventional hollow needle machines that may require at least two or more jumps or jumps to provide or embed eight, sixteen, twenty-four, or more yarns.

[0140] Additionally, in some embodiments, a shifting mechanism can be provided to shift the needle, for example, the shifting mechanism can be coupled to the needle bar and controlled by the control system to shift the needle relative to the substrate.

[0141] Optionally, as shown in Figures 2A, 3A-3B, and 4, one or more presser feet 13 can be positioned laterally across the hollow needle tufting machine 10 adjacent to the needles and slightly above the substrate to help prevent the needles from lifting the substrate when they are removed from the substrate during a tufting cycle. The one or more presser feet can be connected to an elongated rail member that can be connected to the underside of the frame 11 with arms to secure the presser feet to the frame 11.

[0142] The control system 30 (FIG. 2B) of the tufting hollow needle tufting machine 10 can include one or more processors and memory. In embodiments, the control system 30 can receive programming or instructions from an operator and / or pattern file input (separate from operator instructions) to create a particular tufted article, such as a patterned carpet. In other embodiments, the control system can include programming or instructions for forming a tufted patterned article stored in memory. In use, as further described herein, the control system can control various subsystems of the tufting apparatus, including substrate feeding, needle reciprocation based on or taking into account the operating speed of the hollow needle tufting machine (e.g., main shaft rotation), selective engagement of knives of a yarn cutting or knife system, and yarn feeding to the needles by a yarn feed system. The control system can further control substrate shifting (and, in some embodiments, needle shifting) according to stored or received instructions to create a desired product.

[0143] As shown in Figure 2B, in embodiments, control system 30 may comprise / include controller 31, which may be coupled to control interface 32 and, in some embodiments, may be provided within a control cabinet connected to or associated with the hollow needle tufting machine. For example, as shown in Figure 2B, in embodiments, controller 31 may be housed within a control cabinet located adjacent to and coupled to the hollow needle tufting machine, or may be supported on a frame of the hollow needle tufting machine, or may otherwise be associated with the hollow needle tufting machine.

[0144] In an embodiment, the controller 31 of the control system 30 can be coupled to the operating systems or components of the hollow needle tufting machine (such as those coupled to various controllers / control systems for them). For example, the controller 31 of the control system 30 can be coupled to at least one of a substrate feed controller 33 for controlling a motor driving the feed of the substrate through the tufting zone; one or more yarn feed controllers 34 for controlling yarn feed devices of the yarn feed system for controlling the feeding of each yarn to the needles as needed to form the tufting pattern; and a yarn cut or knife system controller 36 for controlling the action of selected ones of the knives, and can further be coupled to and control a shift mechanism for shifting the needle bar and / or shifting the substrate. In an embodiment, the controller 31 can receive pattern inputs and display operating conditions from each of the operating elements or components.

[0145] The various controllers and operator interfaces may comprise at least one computing device (such as a personal computer, a laptop computer, a tablet, a smartphone, a programmable logic controller, a programmable automation controller, at least one servo drive, at least one hardware interface device, etc.) programmed with operator utility software and runtime software, and generally storing yarn color pattern information and controlling operation of the yarn feed devices of the yarn feed system in accordance with a selected multi-color tufting pattern.

[0146] The control system 30 can control and coordinate the operation of the operating systems or components of the hollow needle tufting machine 10 for driving the substrate transport system 16, the needle bar drive system via the main drive shaft 42, and the yarn feed devices of the yarn feed system, needles, and / or substrate shifting, which cooperate to form patterns having multiple colors and / or 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 representative of the position and speed of movement of the main drive shaft and communicate such data to the control system 30, which can be used by the control system to control the operation of one or more of the controllers for operating elements, such as the yarn feed system (which, in embodiments, includes individual yarn feed devices), the cutting assembly, the yarn selection system, and one or more shifting mechanisms, based on the position of the main drive shaft.

[0147] The programming or instructions for the control system may also include functions such as selecting a pattern file from pattern inputs such as stored pattern files, unzipping or compressing pattern files, changing pattern colors, setting the yarn creel, and performing diagnostic functions using yarn control inputs / outputs. Optionally, patterns such as multi-color patterns for carpets can be scanned using a conventional multi-color pattern scanning device, converted to pattern files, and downloaded onto a disk, flash drive, or hard drive of the controller 31 or control system. An operator can input instructions through the operator control interface 256 regarding the timing of the tufting operations.

[0148] In operation of the hollow needle tufting machine, the controller 31 of the control system 30 can receive pattern information from an operator through an operator interface, such as a network connection, disk, or other input, or can be instructed to activate a pattern that has been programmed and stored in its memory. The hollow needle tufting machine 10 can generally be operable to produce multicolored patterned tufted articles, such as carpet, rug, artificial turf or grass, or other tufted articles, delivering at least eight different colors or types of yarn to each needle, which can be spaced at approximately one-inch intervals or gauge spacing. The hollow needle tufting machine can also be operable to form tufting patterns utilizing more than eight different color types of yarn; for example, 16-color or 24-color patterns can be formed. Additionally, hollow needle tufting machines can produce patterned tufted articles such as carpets having both cut pile and loop pile tufts, and in embodiments, the cut pile and loop pile tufts can be arranged to form separate or independent patterns or portions of an overall pattern. Still further, hollow needle tufting machines can produce tufted articles having tufts of various pile heights that can provide a variety of texture effects.

[0149] To form a selected multi-colored tufting pattern, the substrate will be fed through the tufting zone at a controlled rate, e.g., in discrete steps or incremental movements, as the needles are reciprocated in and out of the substrate. The yarn feeding device of the yarn feeding system can be selectively controlled so that a series of different colors or textures of yarn can be selectively fed to each of the needles to feed the desired color or type of yarn for each selected stitch of the pattern to each of the needles while limiting the feeding of non-selected yarns (e.g., yarns that should not be tufted for such stitch locator). In conjunction with controlling the yarn feed to the needles, the jerkers of the yarn selection system are configured to be cooperatively controlled to extend or retract selected ones of the jerkers, which engage some of the yarns and retract or allow them to feed therefrom.

[0150] For example, with respect to a yarn to be fed for placement into the substrate, selected ones of the jerkers associated with such selected yarns can be extended so as not to interfere with the feeding of the yarn to the needles. Others of the jerkers associated with non-selected yarns can be retracted to engage and pull back the non-selected yarns, allowing the non-selected yarns to be removed from the funnels of their corresponding or assigned needles. Additionally, a control system can control the shifting of the needles according to a pattern in operative cooperation with the feeding of the yarns, the operation of the jerkers, and the feeding of the substrate material. Furthermore, the control system can control the movement of individual ones of the knives below the tufting zone to position individual ones or selected ones of the knives at various positions, including non-cutting positions for forming loop pile loops or tufts and various cutting positions for forming cut pile tufts.

[0151] Additionally, in embodiments, an air conduit may be provided that can communicate with a syringe for each needle. In embodiments, pressurized air may be blown through the air conduit by a corresponding tube connected to a pressurized air source and directed through the conduit into the needle eye as the needle is removed from the substrate. This flow of pressurized air may push the cut end of the yarn (generally forming the final backstitch and no longer connected to the needle) down into the substrate as the needle makes the subsequent opening. Such action may, in embodiments, be performed in cooperation with the action of a jerk in the yarn selection system to substantially pull back the unselected yarn from the needle. This may eliminate excess yarn on the back surface of the substrate and further prevent the yarn from forming a backstitch elevated above the surface of the substrate material. Optionally, each yarn feed conduit may be positioned at an angle relative to the axis of a respective one of the needles.

[0152] Still further, in embodiments, the operation of the various operating systems or components of the hollow needle tufting machine can be dynamically and cooperatively controlled. In some such embodiments, the timing of the initiation of operation of the various operating systems or components can be advanced, which can be based on the machine speed or rotation rate (RPM) of the main shaft of the hollow needle tufting machine. The system controller can include instructions or programming that can include determined or programmed dynamic advancement parameters for each of the operating systems or components of the hollow needle tufting machine.

[0153] For example, at an initial machine speed or RPM, a selected jerk extension or retraction can be advanced based on the position or rotation of the main drive shaft, while the initiation of other operational components, such as turning on the air blower to supply air to the jerk module and into the knife module for movement of the knives to the desired cutting or non-cutting positions, and starting and stopping the yarn feed drives for each yarn, can also be determined. Additional dynamic advance parameters can be determined to expedite the operation of such operational systems or components at other different machine speeds. In embodiments, some dynamic advance parameter values ​​can be predetermined and stored in the system controller's memory, and in embodiments, the dynamic advance parameter values ​​can be checked by the system controller and / or used as initial or guide parameter values ​​for the selected machine operating speed.

[0154] The system controller can then determine or interpolate dynamic advances for various selected operating systems or components of the hollow needle tufting machine when the hollow needle tufting machine is run or operated at different machine speeds, allowing for improved precision and consistency of operation of the hollow needle tufting machine even when the operating speed varies. As a result, even when the operating speed of the hollow needle tufting machine is varied, for example, when the machine is started and progresses from an initial or jog mode to a full desired operating speed, operating systems or components such as jerkers, air blowers, knives, modules, yarn feed drives, and / or other components can be controlled to advance their operation as needed to ensure consistent operation of the machine and consistent production of pattern tufted articles being produced thereby at virtually any operating speed of the machine.

[0155] Additionally, in embodiments, the control system may include programming configured to selectively turn on / off the flow of pressurized air to groups or individuals of the jerker modules and / or other components, e.g., to control the flow or pressurized air to various operating components, such as one or more of the jerker modules and / or other components to be supplied with the pressurized air flow. For example, in embodiments, the pressurized air flow supplied to portions or groups of the jerker modules and / or other components may be shut off when certain non-selected yarns (e.g., particular colors or types of yarns) are not used in the pattern being tufted, allowing for reduced air consumption. Additionally, in some embodiments, programmable regulators or valves may be used to control the pressurized air flow to the various operating components. Such regulators may include programming including, for example, preset on / off or start and stop parameters, volumes of air to be supplied, and other parameters based on the particular pattern to be tufted. In embodiments, such preset parameters may be incorporated into and / or stored as part of a pattern file for the pattern.

[0156] 12A-12B, in embodiments, the yarn cutting assembly or knife system may be disposed along the tufting zone, positioned below the substrate support or shuttle and substrate 14, and may comprise one or more knife assemblies. In embodiments, the knife assembly may include a module with multiple knives, while in other embodiments, the knife assembly may comprise individual knives with associated actuators.

[0157] The present disclosure is described herein in terms of examples that illustrate the principles and aspects of the disclosure. However, those skilled in the art will understand that a wide range of additions, deletions, alterations, and modifications, both subtle and gross, can be made to the examples presented without departing from the spirit and scope of the disclosure. All such modifications that do not depart from the spirit of the disclosure are intended to be included within the scope of any of the aspects and / or claims provided by the disclosure.

Claims

1. A tufting machine, comprising: a substrate support; a plurality of needles positioned above the substrate support, the plurality of needles configured to pierce a substrate positioned on the substrate support upon reciprocal movement of the needles; the needles comprising hollow needles, each of the hollow needles having an upper end and a lower end, a passageway defined between the upper and lower ends; a yarn feed system for supplying a plurality of yarns; a series of funnels in communication with said needles; a yarn selection system coupled to an air supply; Equipped with the yarn selection system is configured to deliver selected ones of the yarns supplied by the yarn delivery system to one or more of the needles; The yarn selection system comprises: a series of injectors configured to direct the selected yarns into one or more of the funnels for delivery to the needles; a series of jerker modules disposed along a path of travel of the yarn from the yarn feed system to the funnel, each of the jerker modules communicating with the air supply and including a plurality of bores, pistons received within the plurality of bores; a plurality of jerkers coupled to the piston, each of the plurality of jerkers comprising a body having a proximal end and a distal end, the distal end configured to engage at least one of the yarns supplied by the yarn delivery system; a plurality of jerkers, each of the jerkers being individually movable between an extended position and a retracted position, for selectively controlling airflow to retract unselected yarns from the funnels into the holes in the jerker module; a cutting assembly including one or more knives positioned below the substrate support; Equipped with The one or more knives are configured to cut the selected yarn as it is carried into the substrate with the reciprocating movement of the needles into and out of the substrate.

2. 10. The tufting machine of claim 1, further comprising a control system configured to control operation of the yarn feed system and operation of the jerker to feed the selected yarn to the needles, the control system including programming configured to dynamically advance operation of the yarn feed system and the jerker ahead of a next stitch placement step in a pattern being formed.

3. 3. The tufting machine of claim 2, wherein the control system further includes programming configured to feed the selected yarns and selectively move the jerkers between their extended and retracted positions based on rotation of a main drive shaft of the tufting machine.

4. 2. The tufting machine of claim 1, wherein the jerk module comprises a double-acting cylinder having a series of multi-way valves in communication with the holes, the series of multi-way valves configured to control the flow of air into and through the holes and cause movement of the piston along the holes to control extension and retraction of the jerk.

5. 5. The tufting machine of claim 4, wherein the holes in the jerker module have a diameter of less than 1 / 2 inch.

6. 10. The tufting machine of claim 1, wherein the jerker modules comprise double-acting cylinders having reduced profiles and are mounted in one or more groups of eight jerker modules spaced within approximately two inches of each other.

7. 2. The tufting machine of claim 1, wherein a proximal end of each of the jerkers includes an anti-rotation mechanism configured to resist rotation of the jerkers when the jerkers are moved between their extended and retracted positions.

8. 2. The tufting machine of claim 1, wherein the funnels each include an upper end defining an inlet portion and a lower end defining an outlet in communication with an associated one of the needles, the inlet portions comprising multi-angled orifices, the multi-angled orifices including a first portion having a first diameter and a second portion having a second diameter different from the first diameter.

9. 2. The tufting machine of claim 1, wherein the cutting assembly further comprises a plurality of knife modules in which the knives are received, and actuators each coupled to one or more of the knife modules and in communication with the knives, the actuators selectively actuable to control movement of each of the knives between a retracted position and a cutting position.

10. The tufting machine of claim 1 , further comprising a shifting mechanism connected to the substrate support and configured to move the substrate support transversely relative to a path of travel of the substrate.

11. The tufting machine of claim 10, wherein the shifting mechanism comprises a rack and pinion shifting mechanism.

12. 10. The tufting machine of claim 1, wherein the yarn feeding system comprises at least one yarn feeding attachment having a plurality of yarn feeding devices, each configured to control the feeding of at least one yarn to the needle.

13. A tufting machine, comprising: a main drive shaft; a substrate support on which a substrate is supported; a plurality of needles positioned above the substrate support, the plurality of needles configured to pierce the substrate and deliver a plurality of selected yarns upon reciprocal movement of the needles; the needles comprising hollow needles, each of the hollow needles having an upper end and a lower end, a passageway defined between the upper and lower ends; a yarn feed system for supplying a plurality of yarns; a series of funnels in communication with said needles; a series of jerkers disposed along a path of travel of the yarn from the yarn feed system to the funnel, each of the jerkers configured to be selectively operated to retract unselected yarns from the needles; a cutting assembly disposed below the substrate support and including one or more knife modules, each of the one or more knife modules comprising a knife configured to cut a selected yarn as the selected yarn is carried into the substrate with reciprocating movement of the needle into and out of the substrate; a control system configured to control the feeding of the selected yarn to the needles and the movement of the selected jerkers between their extended and retracted positions; Equipped with The control system includes programming configured to advance the feeding of the selected yarn by the yarn feeding system and the movement of the selected jerker earlier than the next stitch placement step of a pattern being formed based on rotation of a main drive shaft of the tufting machine.

14. 14. The tufting machine of claim 13, wherein the control system further includes programming configured to control feeding of different lengths of the selected yarn during rotation of the main drive shaft.

15. 14. The tufting machine of claim 13, wherein the jerkers each comprise a body having a proximal end and a protruding distal end, the distal ends configured to engage and selectively retract the unselected yarns when the jerkers are moved from an extended position to a retracted position.

16. 14. The tufting machine of claim 13, further comprising a plurality of jerk modules, each of said jerk modules comprising: a body having a plurality of holes defined therethrough and coupled to an air supply; a series of pistons received in said holes and coupled to said jerkers; and valves in communication with said holes, said valves configured to control the flow of pressurized air into and through said holes to cause movement of said pistons along their holes and to control movement of said jerkers between their extended and retracted positions.

17. 17. The tufting machine of claim 16, wherein the jerker modules comprise double-acting cylinders having reduced profiles and are mounted in one or more groups of about eight jerker modules spaced within about two inch intervals.

18. 14. The tufting machine of claim 13, further comprising an air supply in communication with the jerker modules and the cutting assembly, the control system further comprising programming configured to control a flow of pressurized air from the air supply to one or more of the jerker modules to selectively extend and retract one or more of the jerkers of the jerker modules and / or to one of the knife modules of the cutting assembly to selectively move one or more of the knives of the knife module between a disengaged position and one or more cutting positions.

19. 19. The tufting machine of claim 18, further comprising one or more regulators positioned between the air supply and the jerker module and / or the knife module, the regulators including programming configured to control the flow of the pressurized air to the jerker module and / or the knife module according to a pattern being tufted.

20. 14. The tufting machine of claim 13, wherein the funnels each include an upper end defining an inlet portion and a lower end defining an outlet in communication with an associated one of the needles, the inlet portions comprising multi-angled orifices, the multi-angled orifices including a first portion having a first diameter and a second portion having a second diameter different from the first diameter.

21. 14. The tufting machine of claim 13, wherein each of the knife modules of the cutting assembly further comprises an actuator in communication with the knife of each knife module, each actuator of each knife module selectively operable to control movement of the knife of each knife module between a retracted position and a cutting position.

22. The tufting machine of claim 13 further comprising a shifting mechanism configured to move at least one of the substrate support and the needles laterally relative to a path of travel of the substrate.

23. 14. The tufting machine of claim 13, wherein the yarn feeding system comprises at least one yarn feeding attachment having a plurality of yarn feeding devices each configured to control the feeding of at least one yarn to the needle.

24. 14. The tufting machine of claim 13, wherein each of the funnels has an upper end and a lower end, the lower end defining an outlet in communication with an associated one of the needles, and the upper end including a plurality of yarn channels configured to guide one or more yarns into the funnel for feeding to an associated needle.

25. 1. A method of forming a patterned tufting article, said method comprising: feeding the substrate along a travel path; feeding a plurality of yarns to a plurality of hollow needles through a yarn selection system; the needle selection system comprising a series of jerk modules in communication with an air supply, the series of jerk modules comprising a plurality of cavities with pistons received therein and a plurality of jerkers coupled to the pistons, each of the plurality of jerkers comprising a body having a proximal end and a distal end; selecting one or more yarns from the plurality of yarns to be fed to the hollow needle and feeding selected lengths of the one or more yarns to the hollow needle; controlling the feeding of unselected yarns to the hollow needles, moving one or more of the jerkers from an extended position to a retracted position to retract unselected yarns or inhibit the feeding of the unselected yarns to the hollow needles; reciprocating the hollow needle in and out of the substrate to deposit tufts of the one or more yarns into the substrate according to a pattern being formed; A method comprising:

26. 26. The method of claim 25, further comprising shifting the substrate laterally relative to its path of travel.

27. 26. The method of claim 25, further comprising advancing the feeding of the selected yarns by the yarn feeding system and the movement of the jerkers between their extended and retracted positions earlier than the next stitch placement step in the pattern being formed based on rotation of a main drive shaft of the tufting machine.

28. 26. The method of claim 25, further comprising cutting the one or more yarns carried into the substrate with the hollow needle to form the tufts.

29. A tufting machine, comprising: A plurality of hollow needles; a yarn feeding system configured to control the feeding of selected yarns from a plurality of yarns supplied to the hollow needles according to a pattern; an air supply source for supplying pressurized air; a yarn selection system configured to retract unselected yarns or inhibit unselected yarns from being fed to the hollow needles; Equipped with The yarn selection system comprises: a series of injectors configured to inject the selected yarns into the needles of the hollow needles; a series of jerker modules disposed along a path of travel of the yarn from the yarn feed system to the hollow needles, each of the jerker modules communicating with the air supply and including a plurality of holes with pistons received therein; a plurality of jerkers coupled to the piston; Equipped with each of the plurality of jerkers comprises a body having a proximal end and a distal end, the distal end configured to engage at least one of the yarns supplied by the yarn delivery system; The tufting machine, wherein the jerkers are individually movable between an extended position and a retracted position to retract unselected yarns or prevent the unselected yarns from being fed into the hollow needles by selective control of pressurized air to holes in the jerker modules according to a pattern being formed.

30. 30. The tufting machine of claim 29, further comprising a substrate support along which the substrate is moved, and a cutting assembly disposed below the substrate support and including one or more knives configured to cut selected yarns as the selected yarns are carried into the substrate by the reciprocating movement of the needles into and out of the substrate.

31. 30. The tufting machine of claim 29, further comprising a control system configured to control operation of the yarn feed system and operation of the jerker to feed the selected yarn to the needles, the control system including programming configured to dynamically advance operation of the yarn feed system and the jerker ahead of a next stitch placement step in a pattern being formed.

32. 32. The tufting machine of claim 31, wherein the control system further includes programming configured to feed the selected yarns and selectively move the jerkers between their extended and retracted positions based on rotation of a main drive shaft of the tufting machine.

33. 30. The tufting machine of claim 29, wherein the jerker modules comprise double-acting cylinders having reduced profiles, and the jerker modules are mounted in one or more groups of eight jerker modules spaced within about two inches of each other.

34. 30. The tufting machine of claim 29, wherein the proximal end of each of the jerkers includes an anti-rotation mechanism configured to resist rotation of the jerkers when the jerkers are moved between their extended and retracted positions.

35. 30. The tufting machine of claim 29, further comprising a plurality of funnels disposed between the yarn selection system and the hollow needles, each of the funnels including an upper end defining an entrance portion and a lower end defining an exit in communication with an associated one of the needles, the entrance portion comprising a multi-angled orifice including a first portion having a first diameter and a second portion having a second diameter different from the first diameter.

36. 30. The tufting machine of claim 29, further comprising one or more regulators positioned between the air supply and the jerker module, the regulators including programming configured to control the pressurized air to the jerker module according to the pattern being tufted.

37. 30. The tufting machine of claim 29, further comprising a substrate support over which a substrate is moved for insertion of tufts of yarn by the hollow needles, and a rack and pinion shift mechanism connected to the substrate support and configured to move the substrate support transversely relative to a path of travel of the substrate.

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