Tufting machine and tufting method

Abstract

This is a tufting machine for selectively forming tufts of yarn, including different colors or types of yarn, to create patterned tufted products such as carpets. A series of needles enter and exit a base fabric material supplied through the tufting machine and engage with a series of gauge components to capture loops of yarn from the needles. The gauge components are selectively controlled by actuators to extend or retract them to a position or height sufficient to capture or not capture loops of yarn from the needles. The yarn supply is further controlled to backlob yarn that is not captured by the gauge components. Meanwhile, the supply of the base fabric material is controlled to allow tuft formation at a speed exceeding the pattern stitch rate of the pattern of the tufted product being formed.

Description

Technical Field

[0001] (Cross - References to Related Applications) This patent application is a continuation - in - part of co - pending U.S. patent application Ser. No. 18 / 168,928, filed on Feb. 14, 2023, which claims the priority of U.S. Provisional Patent Application Ser. No. 63 / 149,957, filed on Feb. 16, 2021, and is a continuation of U.S. patent application Ser. No. 17 / 353,995, filed on Jun. 22, 2021, which issued as U.S. Patent No. 11,585,029 on Feb. 21, 2023. This patent application is further a continuation of U.S. Design Patent Application Ser. No. 29 / 888,841, filed on Apr. 5, 2023, and claims the priority of U.S. Provisional Patent Application Ser. No. 63 / 463,758, filed on May 3, 2023.

[0002] (Incorporation by Reference) U.S. patent application Ser. No. 18 / 168,928, filed on Feb. 14, 2023, U.S. patent application Ser. No. 17 / 353,995, filed on Jun. 22, 2021, which issued as U.S. Patent No. 11,585,029 on Feb. 21, 2023, U.S. Provisional Patent Application Ser. No. 63 / 149,957, filed on Feb. 16, 2021, U.S. Design Patent Application Ser. No. 29 / 888,841, filed on Apr. 5, 2023, and U.S. Provisional Patent Application Ser. No. 63 / 463,758, filed on May 3, 2023 are hereby specifically incorporated by reference in their entirety.

[0003] (Field of the Disclosure) This disclosure generally relates to tufting machines and methods of forming tufted fabrics. In particular, this disclosure relates to tufting machines that include selectively controllable gauge parts and modules or gauge blocks that hold such gauge parts, and methods of forming patterned tufted fabrics.

Background Art

[0004] In the tufting field, particularly with regard to commercial and hospitality carpets, there is a growing demand for the production of carpets and rugs with new visual patterns using multiple different colors, in order to respond to changing consumer preferences and intensifying market competition. Therefore, carpet designers and manufacturers are focusing on creating new, diverse, and more eye-catching patterns for carpets, rugs, and other tufted fabrics, including patterns that selectively place and display specific colors or types of yarn within the pattern field. The resulting tufted fabric is formed with a substantially accurate pattern density of visible tufts in the pattern. In particular, there is a desire to reproduce the look and feel of patterned carpets, rugs, or other fabrics as faithfully as possible, which can be created and formed using a broadloom tufting machine, improving the production efficiency of such patterned tufted carpets, rugs, and / or other fabrics.

[0005] Furthermore, it is generally desirable to increase the operating speed of tufting machines and thereby increase their output. This means that gauge components such as loopers and hooks, and other components such as needles, are subjected to increased machine cycles. As a result, these gauge components and the modules or blocks that hold them are subjected to faster wear and require replacement.

[0006] Therefore, it is clear that there is a need for systems and methods for forming tufted fabrics such as carpets and rugs to address these and related or unrelated issues. [Overview of the Initiative]

[0007] In short, this disclosure relates to a tufting machine and a method for forming patterned tufted products, which allows for selective control of the arrangement and pile height of the tufts of threads or stitches formed on a base fabric, enabling the formation of patterned tufted products with various pattern effects, such as carpets, including the formation of tufted products with freely flowing multi-color and / or multi-pile height patterns.

[0008] In one embodiment, a tufting machine typically includes a control system that controls the operating elements of the tufting machine to form or create a tufted product according to a desired or designed pattern. The resulting tufted product may include a variety of pattern effects, such as multiple diverse or different pile heights, the use of different types of tufts within the same tuft row and / or changing tuft rows, and other texture effects. In addition, it is also possible to visibly arrange various colors and / or types of yarn at selected positions and pile heights across the entire base fabric. Furthermore, in at least some embodiments, the resulting tufted product is configured such that the density of colored yarns or stitches held and / or visible per inch substantially matches a desired or specified pattern density or number of stitches for the pattern being formed (tufted).

[0009] In embodiments, a tufting machine includes one or more needle bars, each fitted with a series of needles. The needles can be arranged in a straight line, a staggered pattern, or other arrangements. As the base fabric material is fed through the tufting zone of the tufting machine, thread is introduced therein as the needles move in and out of the base fabric material. Furthermore, a shift mechanism can be provided to move the needle bar laterally across the tufting zone, and multiple shift mechanisms may be utilized as needed. The shift mechanism is generally operable in response to instructions or communications from a control system and, according to programmed and / or designed pattern shift steps, steps or shifts the needle bar laterally across the base fabric, presenting the thread carried therein along / across the base fabric to the tuft or stitch position.

[0010] A tufting machine generally includes at least one yarn feeding mechanism or attachment for controlling the supply of yarn to each needle. Such a yarn feeding mechanism or pattern attachment can include, without limitation, various roll, scroll, servo scroll, single-ended, double, or multi-ended yarn feeding attachments, and may include, for example, Yarntronics® or Infinity® / Infinity IIE® yarn feeding attachments manufactured by Cardo Monroe Corporation. Other types of yarn feeding control mechanisms may also be used. At least one yarn feeding mechanism or pattern attachment can be operated to selectively control the supply of yarn to those needles in order to form a yarn tuft. This may include forming a tuft with a selected pile height to create a desired pattern appearance, and / or not forming a tuft.

[0011] In some embodiments, the control system may further include a stitch distribution control system such as that disclosed in U.S. Patent No. 8,359,989 (the disclosure of which is incorporated by reference as fully described herein), and may coordinate control of the base fabric supply and control of the operation of a shift mechanism for shifting at least some needles with control of at least one thread supply mechanism, so that various threads can be presented to various stitch positions or pixels, and the threads that are visible on or on the surface of the tufted product can be supplied in sufficient quantities to form a tuft of the desired height, and the invisible threads that are not visible in the tufting field can be pulled down sufficiently low or pulled out from the base fabric. For each pixel or stitch position of the pattern, a set of threads can be presented, and threads that are not selected to be visible or visible at such stitch positions can be pulled down sufficiently low and hidden so as not to interfere with the threads that are selected to be visible. In some embodiments, this includes pulling out the invisible or unselected threads from the base fabric, or leaving a sufficient portion of the invisible threads in the base fabric to retain or tack the unselected or invisible threads to the base fabric, substantially minimizing interference with the surface of the pattern or with the tuft of the retained visible threads. Therefore, in the embodiment, only the desired or selected thread / color to be placed at a specific stitch position can be retained at that stitch position, and the remaining thread / color can be hidden so as not to be visible in the pattern field being sewn at that time. The control system can further control and adjust the operation of the gauge component assembly to control the selective formation of loops and / or thread tufts, and their length or pile height, along with at least the thread supply, according to the instructions of the pattern being formed.

[0012] Furthermore, in embodiments, the gauge component assembly generally includes a series of gauge components provided below the tufting zone, including, but not limited to, loopers, hooks, level-cut loop loopers, cut / loop clips, etc. The gauge component assembly is movable in a first direction to engage with the needle when piercing the base fabric material and capturing loops of yarn therefrom. In some embodiments, the gauge components are further selectively movable in a direction substantially perpendicular to the direction of their reciprocating motion, for example, moving substantially perpendicular, i.e., up and down, with respect to the stroke or reciprocating motion of the needle against the base fabric, and moving reciprocally toward and away from the needle to selectively capture and form loops of yarn in the base fabric material. Furthermore, the vertical movement of the gauge components can be controlled to form loops of yarn of varying pile heights in the base fabric material, including the formation of loops of different pile heights or not forming loops of yarn in the base fabric at all. In yet other embodiments, loop-pile loopers, cut-pile hooks, cut / loop hooks, level-cut loopers or hooks, and / or other configurations and / or combinations of gauge components can also be used.

[0013] For example, in some embodiments, a gauge component may include a looper or hook, each having a body slidably mounted within a gauge module or gauge block and comprising a first and second part which may include an elongated throat ending at a pointed proximal or apices (bill). The first part of the body may extend through the gauge block or module and may be connected at its distal end to an actuator. In some embodiments, each gauge module may include a module or block body having a first rear section adapted to be coupled or mounted along a gauge bar, and a second or front section formed with at least one channel or passage through which a gauge component is received. The module may further include interchangeable inserts which can be received within passages or channels formed within the module body. The interchangeable inserts may further include slots or recesses adapted to receive and guide the gauge component as it moves through / along the passage of the module block. Alternatively, the inserts can be integrated with the modules, for example, by being glued or otherwise attached substantially permanently, or fixed to the bodies of those modules or gauge blocks, and in some embodiments, substantially fixed while allowing at least serviceable removal as needed.

[0014] In embodiments, replaceable inserts are formed from a hardened material which may include, but is not limited to, a variety of metal carbides, metals, ceramics and / or composite materials, while the module body may be manufactured from lightweight materials such as aluminum and / or other metals, as well as a variety of composite or composite materials. The insert may further include openings or slots configured to receive guide pins or other positioning devices and may include one or more fasteners for securing the insert within the gauge module. The openings are further generally configured to allow the insert to be adjusted in at least one direction, e.g., longitudinal, and / or multiple directions, e.g., longitudinal and / or transverse, to adjust the position of the insert, thereby adjusting the arrangement or positioning of gauge components throughout and / or along those gauge modules. The insert is further replaceable, allowing for easy removal of the insert, and thus allowing for the replacement of one or more gauge components received therein, for example, to replace a worn or damaged gauge component or to change the spacing between gauge components.

[0015] Alternatively, in some embodiments, the module or gauge block itself can be removed and configured to be interchangeable with other gauge blocks or modules. Each module has a set of gauge components mounted inside, which allows for changes in the gauge spacing between gauge components, changes in the type or size of gauge components used, or the replacement of substantially all, or at least most, worn or damaged gauge components as a unit. In addition, guide slots or recesses formed in the insert are generally configured to accommodate the body of the gauge component with sufficient clearance (gap) so that the gauge component can slide substantially freely through them. However, the configuration is such that improper displacement or twisting does not occur so that the bill or throat of the gauge component does not become misaligned with the corresponding needle. Furthermore, the rear end or rear end of the slot or recess of the insert can be configured or adapted to provide a base or engagement area to which the edge of the gauge component body can abut (seat) and / or slide along it. This helps maintain the desired alignment of the gauge component as it reciprocates or moves within the module.

[0016] Gauge components can be further positioned to engage with the needles and can be positioned in inline, offset, or staggered arrangements, and / or inline, staggered, and / or dual needle bar arrangements as needed. In embodiments, each gauge component can be positioned at an angle to the needle as the needle penetrates the base fabric. For example, in some embodiments, the gauge components are positioned at an angle of about 1° to about 10° from perpendicular to the needle and / or its stroke or vertical movement, and / or are expandable / retractable. In other arrangements, no offset, i.e., an angle of 0°, can be provided. The offset of the gauge components with respect to the needles is further modifiable, and the gauge components can be expanded and retractable along a travel path that is angled or offset relative to the needles to minimize potential engagement with the needles as the gauge components move, depending on the spacing and / or arrangement of the needles.

[0017] In various embodiments, the actuator driving the movement of the gauge component may include a hydraulic, electric, pneumatic or air-pressure cylinder, motor, or other similar actuator. The actuator for each gauge component is selectively controlled according to pattern instructions to move the gauge component to a desired vertical position relative to the associated needle in order to capture a loop of yarn from the needle, capturing the loop of yarn at different points in the needle stroke to form loops / tufts of different pile heights, and being pulled to a “non-sewn” position where the loop of yarn is not captured. In yet another embodiment, the actuator is controlled / triggered to move the gauge component with a loop of yarn captured, stretching or pulling the captured loop to provide other pile heights and / or other effects, such as tip shear or other pattern or texture effects.

[0018] In various aspects, gauge components can be further coupled to their respective actuators by connectors or gates configured to extend between the actuator shaft or rod and the distal end of the associated or corresponding gauge component. In some embodiments, the connectors or gates may include arms or links. The arms or links include a first end configured to engage with or connect to the drive rod of the actuator, an intermediate portion projecting from the first end, and a second end configured to engage substantially with the distal end of the associated gauge component. When each actuator is actuated or stopped, each actuator extends or retracts the actuator shaft, moving the associated gauge component in the desired direction relative to the needle.

[0019] For example, in some embodiments, the actuator can drive the gauge component substantially perpendicular to the reciprocating motion of the needle in the direction in which the needle moves in and out of the base fabric, and is used to adjust the height of the gauge component relative to the needle as the gauge component reciprocates toward and away from the needle. In other embodiments, the operation of the actuator and the movement of the connector assist in controlling the movement of the gauge component toward and away from the needle, and are performed substantially along the direction in which the gauge component reciprocates toward and away from the needle.

[0020] Furthermore, in some embodiments, the connector or gate link or arm may be housed within a housing or support structure. In one exemplary embodiment, such a housing or support structure may include a body formed from a durable, lightweight material, such as carbon-filled nylon or other similar composite or plastic material, allowing for weight reduction while ensuring durability and support for the link or arm. Other materials, including various metals, synthetics, and / or composite materials, may be used. The configuration of the support structure or housing can be modified as needed to accommodate links of various configurations and / or sizes. In various embodiments, further weight reduction can be achieved by further reducing the thickness or structure of the connector link or arm. In some embodiments, a skeletonized structure may be included. The connector link or arm is housed within a channel or passage formed in the connector housing and moves when the actuator is engaged and disengaged, transmitting this movement to the associated or corresponding gauge component.

[0021] In some aspects of this disclosure, a tufting machine is provided. This tufting machine comprises at least one needle bar on which needles are mounted, and a base fabric feed roll for supplying base fabric material. The insert has a series of slots in which one of the gauge components is slidably housed. The tufting machine further includes at least one thread supply mechanism for supplying thread to the needles, and a gauge component assembly positioned beneath the base fabric material.

[0022] In some embodiments, a gauge component assembly may include at least one module that carries a series of gauge components that reciprocate toward and away from engagement with a needle as the needle reciprocates across a base fabric material. The at least one module includes a module body formed by casting, molding or otherwise from a metal, polymer, composite or synthetic material, or a combination thereof, and having a first hardness. The module body is adapted to be mounted along a gauge bar and is configured to have a passage through which it passes. Inserts are mounted on the module body on the opposite side of the passage, and each insert has a series of spaced slots, each of which is configured to slidably accommodate at least a portion of a gauge component. In some embodiments, the inserts are cast, molding or otherwise formed from a metal or metal carbide or powder metal material having a hardness higher than that of the module body, and the slots are formed or defined. In embodiments, each gauge component may include a body that is at least partially housed in the opposing slot of the insert and is movable through the passage of the module body in additional directions relative to the stroke of the needle. The body of each gauge component has a first portion extending through a passage of at least one module and a second portion having a throat configured to capture the loop of thread from the needle.

[0023] In the embodiment, the tufting machine includes a series of actuators coupled to a gauge component to control the movement of the gauge component through a module body, and a control system including a program for controlling at least one thread supply mechanism. The program, in conjunction with controlling the operation of the actuators, controls the supply of thread to the needle, stretches and contracts the selected gauge component, and moves the throat of the selected gauge component between a no-sew position and an engaging position relative to the needle's stroke through the base material in order to selectively form a thread tuft in the base material according to the pattern to be formed.

[0024] In various embodiments of the tufting machine, the gauge parts may include a level cut loop looper, a loop pile looper, a cut pile hook, or a cut / loop clip, and / or combinations thereof. In yet another embodiment of the tufting machine, the actuator may include a hydraulic or pneumatic cylinder, a servo motor, or other types of actuators.

[0025] In yet another embodiment of the tufting machine, the gauge part assembly may further include a series of connectors extending between each gauge part and the associated actuator. Each connector is housed within a housing and includes a movable link.

[0026] In some embodiments, the housing of each connector may be formed from a polymer, composite material or synthetic material or combinations thereof, and includes a body having a channel therethrough, and each link includes a metal or composite material or combinations thereof.

[0027] In other embodiments, the body of each housing may include a composite material including a polymer or plastic and a fiber-filled material, having a defined channel therein, the link being movable, and the link of each connector includes a hardened metal body coupled to the body of the housing, having a proximal end configured to engage a first portion of one of the gauge parts and a distal end configured to be engaged by an actuator associated with the gauge part to transmit movement to the gauge part by the actuator.

[0028] In yet another embodiment, the insert of at least one module includes a first insert and a second insert, each including a tab or flange portion that is overlapped and / or attached to the first or lower or second surface of the upper or module body. In other embodiments, the body of each insert can have an upper or proximal portion, a lower or distal portion, and an intermediate portion extending therebetween and along a passage defined through the module body, and the slots of the first or left insert face and are substantially aligned with the corresponding slots of the second or right insert with a spacing therebetween.

[0029] Further, in an embodiment, each tab or flange portion of the first and second inserts is configured to overlap the upper surface of the module body, includes a slotted opening, is adapted to receive a fastener therethrough, and is used to adjustably attach each of the first and second inserts to the module body, the inserts being arranged at a selected spacing from each other and at a selected position with respect to a passage defined through the module body. Further, the inserts may be substantially integrated within the module body by molding, casing, encapsulating, or other means. The insert can also include a tab or flange portion that can engage the opposite side surface of the module body, and a plate or intermediate portion may be provided there. The intermediate portion can connect the tabs or flanges of the insert, and the slots of the insert are at least partially formed therein and extend therealong. Alternatively, a bearing plate for support may be received between the tabs or flanges of the insert and along the first and second side surfaces of the passage.

[0030] Accordingly, in some aspects of this disclosure, a gauge component assembly for a tufting machine is disclosed. The assembly comprises at least one module, the module body having a defined passage. The assembly further comprises a series of gauge components that are received within the passage of the module body. Each gauge component has a body comprising a first portion and a second portion having a throat. The gauge component is carried in a first direction with the module and moves to engage with the associated needle of the tufting machine, capturing the loop of thread from the needle along the throat of the gauge component. The gauge component is selectively movable in a second direction along the passage of the module body. First and second inserts located on the opposite side of the passage of the module body are formed from a material having a hardness higher than the hardness of the metal or composite material of the module body and have a series of spaced slots configured to receive a portion of at least one gauge component. The slots of the first and second inserts are substantially aligned across the passage. Multiple actuators are configured such that each actuator is coupled to a first portion of a related gauge component in a series of gauge components, and moves the related gauge component in a second direction through a passage in at least one module, thereby extending or retracting the gauge component through the module body, moving the throat of the gauge component between an extended position for capturing the loop of thread from the needle and a retracted position that substantially avoids capturing the loop of thread from the needle.

[0031] In some embodiments, the gauge component assembly may further include connectors extending between each actuator and its associated gauge component, each connector having a housing formed from a polymer material with a link enclosed inside. In some embodiments, the module body of at least one module is molded or cast from a metal or composite material.

[0032] In yet another embodiment, the gauge component assembly may include first and second inserts comprising bodies formed or cast from metal, carbide, or powder metal material, and including slotted tab or flange portions. Furthermore, each body of the first and second inserts further includes upper and lower tab or flange portions that engage with the upper and lower surfaces of the module body, with slots extending through the upper and lower tab or flange portions.

[0033] In additional embodiments, the gauge component assembly may include first and second inserts. Each of the first and second inserts is molded or cast from a metal, carbide, or powder metal material and has a body including a slotted tab or flange portion. The module body of at least one module includes a metal or composite material molded or cast to form a module body substantially integrated with the first and second inserts.

[0034] In several aspects of this disclosure, a method for operating a tufting machine is disclosed. According to an example embodiment of this disclosure, as the needle of the tufting machine moves in and out of the base fabric, an actuator of a gauge component is selectively engaged or disengaged, and the gauge component moves between a fully retracted position or a non-sewing position in which it does not engage with the relevant or corresponding needle, and therefore no loop of yarn is formed, and between a fully extended position, and between a range of extended or raised positions, including a fully extended position. In the raised or extended positions, the gauge component engages with the needle at the take-off portions of the needle as the needle moves in and out of the base fabric material, and captures a loop of yarn from the needle. The loop of yarn captured from the needle can have a range of pile heights or lengths depending on the position and / or movement of the gauge component relative to the relevant or corresponding needle. For example, in the fully raised position, a smaller or shorter loop of yarn may be formed, creating a lower pile height, or the loop of yarn may be substantially hidden in the base fabric, and such loops may be substantially removed by control of the yarn supply. When the looper is moved to a lower position, it captures and forms longer thread loops, and pulls the thread loops as needed to create thread tufts with higher or greater pile heights in the base fabric. Furthermore, the actuator can be controlled to selectively lower or retract the corresponding gauge component, forming even longer thread loops along with the thread loops captured therein, allowing for additional pattern effects such as tip shearing.

[0035] The needle is further shifted laterally relative to the longitudinal movement of the base fabric through the tufting zone, presenting a different color or type of thread at each stitch position of the pattern formed in the base fabric material. For example, one or more needle bars can pass thread in a series of desired colors in various thread-up sequences. Furthermore, the base fabric material can be run at an actual or effective stitch rate that is substantially higher than the pattern stitch rate specified or desired for the pattern being formed. As a result, as the needle is shifted, a desired number of different colors or types of thread can be presented at each stitch position. By controlling the positioning and / or movement of the gauge component, loops of thread are selectively formed in the base fabric material, and the formation of such loops of thread is, in some embodiments, further controllable to form a variety of pile heights of the resulting threads. For example, in various aspects, as the needle bar is shifted, a series of different colors or types of thread are presented at each stitch position, and if a tuft of a particular color or type of thread is not selected to be sewn at that stitch position, the corresponding gauge component is held in a retracted or lowered position, and loops of such unselected threads are generally not formed.

[0036] Furthermore, as the needle moves back and forth from the base fabric, the thread supply is also controlled, and any unselected threads are pulled back from the base fabric material with the needle in a manner such as deform, backlob, or otherwise, causing some thread loops to deform, backlob, or pull back to a degree sufficient to ensure that no such threads are visible at their stitch location in the finished pattern product. Higher operational, effective, or actual control of the base fabric material at a higher stitch rate substantially increases the number of stitches in the presentation of threads to the base fabric material, substantially avoiding the creation, display, or otherwise manifestation of missing color or type of thread or gaps in the pattern field of the patterned tufted product. Thus, the finished patterned tufted product can provide a thread density per inch that substantially matches the desired or specified pattern stitch rate, i.e., a pattern designed with a pattern stitch rate of 8, 10, or 12, or other stitch counts per inch, and the resulting finished patterned tufted product can form a visible and / or retained surface thread or thread density per inch that closely matches the pattern stitch rate.

[0037] The aforementioned advantages and other aspects of the embodiments of this disclosure will become apparent and more readily understood when considered in conjunction with the following detailed description and claims and the accompanying drawings. Furthermore, it should be understood that the summary of the foregoing disclosure and the following detailed description are illustrative and intended to provide further explanation without limiting the scope of this disclosure. [Brief explanation of the drawing]

[0038] The accompanying drawings are included to provide a further understanding of the embodiments of the Disclosure, are incorporated into this Specification, constitute part thereof, illustrate the embodiments of the Disclosure, and, together with the detailed descriptions, serve to illustrate the principles of the embodiments discussed herein. No attempt has been made to show structural details of the Disclosure beyond what is necessary for a basic understanding of the exemplary embodiments discussed herein and the various ways in which they are carried out. Furthermore, those skilled in the art will understand and appreciate that, in accordance with common practice, various features of the drawings discussed below are not necessarily drawn to scale, and that the dimensions of various features and elements of the drawings may be enlarged or reduced to more clearly illustrate the embodiments of the Disclosure described herein. [Figure 1] Figure 1 is a side view of an example embodiment of a tufting machine equipped with a selectively controllable looper assembly according to the principles of this disclosure. [Figure 2] Figure 2 is a side view of the tufting zone of the tufting machine shown in Figure 1. [Figure 3] Figure 3 is a perspective view of the tufting machine shown in Figures 1 and 2. [Figure 4] Figure 4 is a perspective view of an example embodiment of a gauge module or gauge block and gauge component according to the principles of this disclosure. [Figure 5] Figure 5 is a cross-sectional view of the gauge module or gauge block and gauge components shown in Figure 4. [Figure 6] Figures 6A to 6B are plan views of the gauge modules or gauge blocks shown in Figures 4 and 5. [Figure 7] Figures 7A–7E show another embodiment of a gauge module or gauge block in accordance with the principles of this disclosure. [Figure 8] Figures 8A and 8B show embodiments of a connector for connecting a gauge component to its actuator in accordance with the principles of this disclosure. [Figure 9] Figures 9A-9B show another embodiment of a connector for connecting a gauge component to its actuator in accordance with the principles of this disclosure. [Figure 10] Figures 10A-10B show yet another embodiment of a connector for connecting a gauge component to its actuator in accordance with the principles of this disclosure. [Figure 11] Figures 11A-11B are perspective views of a series of needles and parts of their respective gauge components in an example embodiment according to the principles of this disclosure. [Figure 12] Figures 12A to 12C are side views illustrating embodiments of the operation of a selectively operable gauge component in accordance with the principles of this disclosure. [Modes for carrying out the invention]

[0039] In the following drawings, similar numbers indicate similar parts throughout several drawings. Figures 1-11C generally illustrate embodiments of a tufting machine 10 and a method for forming patterned tufted products according to the principles of this disclosure, where the stitching of yarn Y or the placement of yarn 5 can be controlled to desired positions on the base fabric material B. Such yarns or stitches are formed with a sculpted, multi-pile height tufted appearance and can be further arranged with enhanced selectivity and / or control for further variation or free-flowing pattern effects. For example, a tufted fabric can be formed with tufts of yarns formed at various pile heights, providing a sculpted appearance and can be formed with different colors or types of yarn for the formation of multi-color patterns of various geometric and / or free-flowing designs. Furthermore, it should be understood that various numbers of different types and / or colors of yarn (i.e., 2 colors, 3 colors, 5 colors, 6 colors, etc.) can be used to form multi-pile height patterned tufted products according to the principles of this disclosure.

[0040] As schematically shown in Figure 1, in one embodiment, the tufting machine 10 includes a frame 11 that houses a needle bar drive 13 and includes a head or upper part 12 that defines the tufting zone T. The needle bar drive mechanism 13 (Figures 1 and 2) typically includes a series of push rods 14, which may be connected by connector rods 17 to a needle bar drive 16 or similar mechanism, such as a gearbox / assembly shown in Figure 1. The needle bar drive 16 is further connected to the main drive shaft 18 of the tufting machine and driven, for example, by one or more drive belts or drive chains 19, and the main drive shaft 18 itself is driven by a motor such as a servo motor. Alternatively, the push rods 14 of the needle bar drive mechanism 13 may be connected to the main drive shaft 18 via connector rods 17 and driven directly from the main drive shaft, or driven by an independent drive system (not shown).

[0041] Furthermore, an encoder or similar sensor may be provided in the control system 25 (Figure 1), which monitors the rotation of the main drive shaft and controls the operation of the tufting machine 10, to report the position of the main drive shaft. The control system 25 generally constitutes tufting machine control, including a computer / processor or system controller 26, and includes an operator interface 26A such as a touchscreen, keyboard, or mouse, which allows the operator to input and adjust patterns. In some embodiments, the control system 25 may include a stitch distribution control system, such as that disclosed in U.S. Patent No. 8,359,989, which is incorporated by reference as fully described herein, and the controller 26 further includes programming of a control methodology for forming tufting patterns, including carved patterns, which include tufts formed with multiple pile heights, and various color / stitch placement control patterns, such as those disclosed in U.S. Patent No. 8,359,989.

[0042] The control system 25 generally includes programming for monitoring and controlling the operating elements of the tufting machine 10, controlling the needle bar drive mechanism 13, yarn supply attachment 27, base fabric feed roll 28, main drive shaft 18, needle bar shift mechanism 40 (Figure 3), and gauge component assembly 30 mounted below the tufting zone T, according to calculated / determined pattern instructions. The control system 25 (Figure 1) can also receive, execute, or save pattern information in the memory storage of the system controller 26. In accordance with the developed / programmed pattern instructions, the control system 25 controls the operating elements of the tufting machine 10 to form a desired tufting pattern on the base fabric material B as the base fabric feed roll 28 passes the base fabric material through the tufting zone T in the direction of arrow 33, as shown in Figure 1-3.

[0043] In some embodiments, the system controller 26 of the control system 25 can program instructions for forming one or more desired patterns for one or more tufting products. This includes a series of pattern steps, which can be manually created or calculated using a design center or design software as understood by those skilled in the art, and such patterns can be received from input from disk, USB, other external drives, or via a network connection. Alternatively, the controller 26 may include image recognition software that enables spun and / or designed pattern images. For example, designed patterns, including the arrangement of loop pile and cut pile tufts in the pattern indicated by different colors or similar markers or indicators, pile height and other characteristics, photographs, drawings and other images can be input, programmed, recognized and processed, and input can be received from a design center, via various design software systems, or via a scanner or other imaging device 31 (Figure 1). The control system can recognize and identify various pattern characteristics, including differences in color and / or texture, that show texture effects such as the arrangement and position of loop and / or cut pile tufts, and assign selected yarns to them.

[0044] Furthermore, the control system 25 operates in conjunction with a stitch distribution control system, as disclosed in U.S. Patent No. 8,359,989, or is incorporated by reference as fully described herein (in the embodiment). For example, but not limited to these, the control system may incorporate programming to provide the functionality of such a stitch distribution control system, or may link to another stitch distribution control. The control system may also provide software / programming to read and recognize the colors of an input skewing pattern, assign the supply positions of the yarns supplied from the supply clair to different needles based on the thread-up sequence of the needles of the needle bar, optimize the supply of different colored yarns in the clair to make the best use of it, and form a recognized pattern field from the pattern image. The control system may further include programming that enables the creation of a pattern field or pattern mapping, including a mapping of a series of pattern pixels or tuft / stitch placement positions that identify spaces or positions for different colored yarns and / or cut / loop pile tufts to be selectively placed to form an imaged pattern. The desired pattern density, i.e., the desired number of stitches per inch that will appear on the surface of the finished pattern-tufted product, can also be selected, and the actual effective or operational process stitch rate of the pattern can be calculated to achieve the desired fabric stitch rate appearance of the pattern.

[0045] The control system 25 of the present disclosure may further include programming for receiving, determining, and / or executing various shift or cam profiles, and may calculate proposed shift profiles based on tufted, input, or other designed pattern images or pattern files. For example, in a non-limiting embodiment, a designed pattern file image, photograph, drawing, etc., may be loaded, tufted, or otherwise input by the tufting machine, or input by a network connection. The control system may read, recognize, and calculate pattern steps / parameters including control of yarn supply, control of base fabric movement and / or needle reciprocating motion, form tufts on the base fabric at an effective stitch rate to achieve a desired pattern density, arrange yarns to match the tufted and / or designed pattern image, and then control the operation of the tufting machine to form this selected pattern. The operator can further select or modify the stitch rate, thread supply, selected cam profile or calculated shift profile, for example whether the pattern has 2, 3, 4, 5, or 6 or more colors, or the desired number of pattern repetitions, or manually calculate, input and / or adjust or modify the clair assignment, shift profile and / or color mapping created by the control system via manual override control / programming as needed.

[0046] As shown in Figure 1-3, the tufting machine 10 further includes one or more needle bars 35 mounted and driven by a push rod 14. The needle bars 35 move a series of needles 36 in and out of the base fabric material B in a reciprocating motion (indicated by arrows 37 / 37') to carry or insert the yarn Y into the base fabric. In some embodiments, the needles can be arranged in a single inline row along one or two needle bars. In other embodiments, the needles 36 are stepped along a single needle bar or a pair of needle bars, with offset rows of needles spaced laterally along the length of each needle bar stepped across the tufting zone of the tufting machine. The needle bars 35 are further shiftable laterally across the width of the base fabric material, allowing the needles 36 to be shifted or stepped laterally or substantially perpendicular to the longitudinal path of movement of the base fabric material as it passes through the tufting machine. Therefore, while an example embodiment including a single needle bar 35 may be shown, with an inline row of needles 36 arranged along it, as shown in the figures, the disclosure is not limited to a single needle bar or a specific arrangement of needles. Instead, additional configurations of double needle bars and single needle bars with spaced rows of needles 36 that can be arranged inline, stepped, or offset will be understood by those skilled in the art. Furthermore, it will be understood by those skilled in the art that both are shiftable and can be utilized in a tufting machine 10 incorporating a system according to the disclosure.

[0047] Each needle generally includes a thread loop or body 38 ending with a pointed end 38A and includes a take-off point or region 39 where a gauge component 32 can take in thread Y from the needle, as shown in Figures 10A-11A. As the needle reciprocates in a motion substantially perpendicular to the direction of arrows 37 and 37' (Figure 2), it moves in and out of the base fabric material B along the stroke to a desired or predetermined penetration depth, carrying thread Y, which is selectively taken in by the gauge component 32 of the gauge component assembly 30 to take in a loop L of thread from the needle, as shown in Figures 11A-11C. Furthermore, as shown in Figure 3, a shift mechanism 40 can be linked to a needle bar 35 (or needle bar) if used to shift the needle bar across the tufting zone in the direction of arrows 41 and 41' according to calculated or calculated pattern instructions. The shift mechanism 40 may include a Smart Step® type shifter manufactured by Card-Monroe Corporation, or alternatively, it may include various other types of shift mechanisms, including servo-motor or hydraulically controlled shifters, and / or conventionally used pattern cam shifters. Additional shift mechanisms, including a base fabric or jute shifter, may be operated separately or in conjunction with the needle bar shifter to shift the base fabric laterally relative to the needle.

[0048] Furthermore, as shown in Figure 1, one or more thread supply mechanisms or attachments 27 can be mounted on the frame 11 of the tufting machine 10 to control the supply of thread Y to each needle 36 during operation of the tufting machine 10. For example, as shown in Figure 3, a series of different types or colors of thread (Y1-Y4) are supplied to each needle in a selected thread-up sequence or series (e.g., A, B, C, D), and the thread-up sequence is determined or selected based on a pattern that is generally performed. In addition, although one thread supply unit 27 is shown along one side of the tufting machine 10 (for illustrative purposes), in other embodiments, multiple thread supply units can be mounted on one or both sides of the tufting machine to supply thread to the needles 36 of one or more needle bars 35.

[0049] There are various yarn supply attachments available for use with the stitch distribution control system of the present disclosure to control the supply of different yarns Y to various needles 36. The pattern yarn supply attachment or mechanism 27 (Figure 1) may include conventional yarn supply / drive mechanisms such as roll or scroll pattern attachments, which extend at least partially along the tufting machine and are driven by motors under the direction of the control system 25 to supply yarn throughout the tufting machine and control the formation of pattern repetitions, multiple pile heights, or other texture effects across the width of the base material. Such yarn supply mechanisms or attachments may include Quick Thread®, Enhanced Graphics®, and / or Multi Pile Height Scroll yarn supply controls / attachments manufactured by Card-Monroe Corporation.

[0050] In some embodiments, as shown in Figure 1, a pattern yarn feeding attachment having multiple yarn feeding drives 45 can be used, each drive comprising a motor 46 and a feeding roll 47, which controls the feeding of a specific repeating set of yarn to a selected needle. This includes the use of individual yarn feeding rolls or drives 45 for feeding a single yarn (or end) or multiple yarn ends (i.e., two to four or more yarns) to a needle 36, and includes single and multi-end / servo scroll attachments, including the Infinity® and Infinity IIE® systems manufactured by Card-Monroe Corporation. Thus, although Figure 1 shows a single or multi-end type yarn feeding mechanism 27, it will be understood by those skilled in the art that the pattern yarn feeding mechanism used to control yarn feeding can include single or double-end yarn feeding controls, scrolls, rolls, and / or similar attachments, or various combinations thereof, and can be mounted on one or both sides of the tufting machine. Furthermore, in some embodiments, the control system 25 may perform yarn supply compensation and / or yarn supply modeling to help control, reduce or minimize the amount of yarn supplied that is not retained / not appearing in order to avoid oversupply of yarn and minimize waste during the tufting operation.

[0051] The yarn supply attachment can work in cooperation with other operating systems of the tufting machine, namely the base fabric supply, needle bar movement, and operation of the gauge component assembly 30, to control the selective supply of yarn to each needle, thereby presenting various colors or types of yarn to the packing, and selectively picking up and holding loops of selected or desired yarns from among the presented yarns to form tufts of such yarns at a selected or desired pile height. Furthermore, the amount of yarn or tuft that appears on or on the surface of the tufted product can be controlled to be supplied in sufficient quantity to form tufts of selected colors or types of yarn at a desired or specified pile height, while non-appearing yarns that should be hidden in a particular color and / or texture field can be pulled back or pulled out significantly lower or outward from the base fabric material to the extent that they do not interfere with the surface yarns or held tufts that should be visible in the pattern field, so as not to create undesirable spaces or gaps between the held tufts or surface yarns.

[0052] In one embodiment, each color or type of yarn that can be placed / tufted at each pixel or stitch position is generally supplied for tufting at such pixel or stitch position, and only the selected yarn to be displayed or appear at the pixel or stitch position is retained and formed at the desired pile height. Thus, for example, in the case of a four-color pattern, each of the four colored yarns A, B, C, and D that can be tufted at a particular pixel or position is presented at such pixel, and only the selected yarn of the pattern, e.g., yarn "A", is retained, while the remaining unselected yarns, B, BC, BD, and / or other combinations, can be presented at such pixel or stitch position, pulled back, or removed from the base fabric material. Thus, when yarn is supplied to a pixel or stitch position, if the yarn is retained or appears at the pixel or stitch position, the yarn supply 27 can be controlled to supply an amount of yarn to form a tuft of yarn at the pixel or stitch position. If the supplied yarn is not retained or appears at the pixel or stitch position, it can be controlled so that no loop or tuft is formed, or it can be pulled back, or removed. If no thread has been selected to insert into a specific pixel or stitch position, the gauge component can also control whether or not to selectively pick up loops of thread supplied to a particular pixel.

[0053] Furthermore, as shown in Figure 1-3, the gauge component assembly 30 is typically mounted under the bed 34 and tufting zone T of the tufting machine 10. When needles penetrate the base fabric material, they are engaged by a series of gauge components 32 of the gauge component assembly 30 to form loops L (Figure 23) of yarn Y for forming a tuft 5 of yarn of a selected color or type, formed to a selected length or pile height. In various embodiments, the gauge components 32 of the gauge component assembly 30 may include a series of loopers or hooks 50, each slidably mounted within a gauge module, gauge block or other holder, and may be mounted along a gauge bar 52 or similar mount or attachment, coupling the gauge components to a drive mechanism 53 to drive the reciprocating motion of the gauge components toward and away from the needles 36, as shown in Figure 1-3. Furthermore, it will be understood by those skilled in the art that various types of gauge components, including cut pile hooks, loop pile loopers, level-out loop loopers, cut / loop clips or other gauge components, may also be used.

[0054] As shown in Figure 4-5, in one embodiment, the gauge component 32 may include a looper or a hook 50. Each looper or hook 50 has an elongated body 55 which is slidably mounted and movable within the gauge module 51. The body 55 of each looper or hook 50 includes a first portion 60, and the second portion 61 includes an elongated throat 62, which, as shown in Figure 4-5, in one embodiment may extend at an angle to a middle portion 56 of the body 55 and may terminate at a generally pointed proximal or bill 63. For example, the throat 62 and proximal bill 63 may be configured similarly to a loop pile looper. Gauge components of other configurations may also be used. Furthermore, as shown in Figure 4-5, the first portion 60 of the body of each looper or hook 50 generally protrudes through a gauge module or block 51, forming a slot or recess 64, which allows the looper or hook to engage and / or connect to an actuator 66, for example, by a gate or connector 67 (Figure 2).

[0055] Figure 4-5 shows one embodiment of a gauge module or gauge block 51. The gauge module or gauge block 51 includes a body 75 and may have a substantially rectangular or square configuration as shown, but other configurations may also be used to accommodate a series or set of gauge components 32, such as loopers or hooks 50. In some embodiments, the module body 75 of each gauge module 51 is formed from a metal or metal alloy material, but various composite materials, synthetic materials and / or other materials may also be used. For example, but not limited to, the body of the gauge module may be made from lightweight steel, such as mild steel or tool steel, or aluminum, or other similar lightweight yet substantially rigid and durable materials. In embodiments, the module body may be formed by casting, molding or other methods. The material from which the body of the gauge module is formed may be selected to reduce the weight of the gauge module, while at the same time providing sufficient durability and rigidity to hold and / or substantially maintain the alignment or position for engaging the take-off portion of the needle when the gauge components engage and disengage during operation of the tufting machine.

[0056] As generally shown in Figures 4-6B, the module body 75 of each gauge module 51 includes a first front or front section 76 and a second rear or rear section 77. The rear section 77 of the body 75 of each gauge module 51 is more generally configured to engage and attach to a gauge bar, as shown in Figure 3. For example, the rear section of the body may include a tab or other positioning device 77A (Figure 5) for aligning the gauge module along the gauge bar, and further include at least one fastener opening, as shown in Figures 6A-6B. A removable fastener, such as a socket, hex screw, or other similar removable fastener or attachment device, is inserted through the fastener opening 78 and into the corresponding opening 79 (Figure 6B) on the gauge bar, thereby removably attaching the gauge module 51 to the gauge bar. As a result, in some embodiments, the gauge module can be removed and replaced as a unit, along with the gauge components contained therein. It is not always necessary to replace individual gauge components. For example, this could be used to quickly replace damaged or broken gauge components, or to change the spacing or arrangement of gauge components in a tufting machine.

[0057] As shown in Figure 4-6B, a passage 80 is generally formed in the body 75 of each gauge module 51, and the passage 80 is generally located along an intermediate portion 81 between the first and second sections 76 / 77 of the body. The passage 80 is sized and / or configured to accommodate multiple gauge components such as loopers or hooks 50. In embodiments such as those shown in Figure 4-5, each body 55 of the looper or hook 50 extends to generally fit within and pass through the passage 80. The first portion 60 of the looper or hook generally protrudes downward beyond the lower or bottom surface 82 of the module body 75, and the second portion 61 of the looper or hook may extend / protrude upward from the upper or top surface 83 of the module body 75.

[0058] Furthermore, as shown in Figure 4-5, one or more inserts 85 can be mounted on opposite surfaces of each module body, for example, the top and bottom surfaces, and can be mounted in positions or locations aligned along the defined passage 80 throughout each gauge module. The inserts are configured to engage and guide the gauge components as they move through the passage of the gauge module body. For example, in some embodiments, such as shown in Figure 4-6A, there may be a pair or set of inserts 85A and 85B. One of the inserts (e.g., first insert 85A) is mounted on the first, left or front side 80A of the passage 80, and the insert (e.g., second insert 85B) is mounted on the second, right or rear side 80B of the passage 80. The inserts 85A and 85B are generally positioned opposite each other, on opposite sides, and in a parallel relationship, with the gauge component 32 engaging and moving between them. Furthermore, in the embodiment shown in Figure 4-5, the first pair of inserts can be mounted on the top and bottom surfaces of the module body along the first or left side of the passage, and the second pair of inserts 85B can be mounted on the top and bottom surfaces of the module body along the second or right side of the passage.

[0059] Each insert 85 is generally formed from a hardened metal or metal alloy material, a metal carbide, a ceramic, and / or a powder metal material containing metal powders including tungsten, titanium, or other material having a hardness higher than the hardness of the material of the gauge module body. For example, in some embodiments, the insert can be formed from a metal carbide material with a hardness of about 74+RC or higher, and the module body can be formed from mild steel. In other embodiments, the insert may be formed from a ceramic, a powder metal material containing tungsten, titanium, or similar hard metal components, a metal carbide, or other material with a hardness of about 74+RC to about 85+RC or higher.

[0060] Each insert 85 may further include an insert body 86 having a tab or flange portion 87 extending forward or backward from the passage of the gauge module body, as shown in Figure 5, and generally seating and engaging with the upper and lower surfaces 83 / 82 of the module body. Furthermore, as shown in Figures 4 and 6A-6B, each insert 85 includes at least one opening or slot 89 formed along the tab or flange portion, through which a fastener such as a set screw 90 or other similar removable fastener can be received. The slot or opening 89 formed in the tab or flange portion can generally be aligned with a corresponding slot or positioning opening 91 formed along the upper and / or lower surfaces 83 / 82 of the module body, helping to position and mount each insert to the body of its module and align it along the passage of the gauge module. As shown in Figure 6B, the inserts are movable laterally across the module body, movable substantially parallel to the passage 80, and further adjustable toward or away from each other across the passage of the gauge module body, after which a fastener can be inserted and tightened to secure the insert 85 to its module body. The additional positioning guide pins 92 can further be received into slots in positioning openings 93 formed along the flange or tab portion 87 of each insert, further assisting in positioning the inserts along and across the passages of the module body as needed.

[0061] In additional embodiments, the insert 85 may be substantially integrated with its module. The insert may be fixed to the module body by bonding, molding, encapsulation, and / or other means, and the insert may be substantially integrated with the module body to form a substantially one-piece structure of the module body, and the insert may form or define part of its passages. For example, in some embodiments, the insert may be positioned or received within the passages of the module body and be substantially permanently installed, while in other embodiments, the insert may be molded or cast as part of the module body itself, defining passages and slots for loopers or hooks, and may be coated or treated with a hard metal coating such as carbide or other substantially wear-resistant coating. In such cases, the gauge component is supplied as a set with its gauge module and can be replaced as a set by removing and replacing or substituting the gauge module and gauge component as a unit. In other embodiments, the insert may be substantially engaged or locked to its module, and the ability to remove or take out one or more inserts may be limited for serviceability as needed.

[0062] Furthermore, as shown in Figures 4 and 6A-6B, the insert further includes a series of slots or slits 95 arranged along the rear portion 88 along the body 86 of each insert. Each slot 95 is generally sized or configured to receive a gauge component 32, such as a hook or looper 50, as shown in Figures 4 and 5. The slots 95 of the insert are generally arranged at selected intervals, such as gauge spacing for the gauge components, and as shown in Figure 6A, each slot 95 of the first insert 85A is roughly aligned with the corresponding or related slot 95 of the second insert 85B. The aligned, corresponding or related slots of each insert receive at least a portion of the body of each gauge component to be received therein, for example, the front edge 55A and rear edge 55B portions of the body 55 of each looper or hook 50. The insert defines a contact area 98 that reduces or minimizes the area or profile between the gauge module and the looper or hook.

[0063] Furthermore, as shown in Figure 6A, for example, the ends 96 of the slot 95 can be formed into a substantially flat, slightly curved, or arc-shaped form. This defines a seat 97 into which the first and second edges of each looper or hook housed in each slot can be positioned and abutted. This is for mounting the looper or hook within the insert and then securing the insert with the looper or hook housed in each gauge module. The slots in the insert guide the looper or hook as it extends, retracts, or otherwise moves through the passage of its gauge module, helping to maintain the alignment of the looper or hook, and thus helping to maintain the throat and bill of the needle relative to the support material so that the needle moves in and out and engages with the looper or hook.

[0064] In another embodiment, each insert 85 may include an insert body 86 having a first top or upper portion and a second lower or bottom portion. An intermediate portion extends between them, connecting the first and second portions of the body of each insert. At least one of the upper and / or lower portions of the body of each insert may further be formed as a tab or flange, extending forward or backward from the intermediate portion and the passage of the gauge module body, generally overlapping and engaging with the upper and lower surfaces 83 / 82 of the module body, helping to position and secure each insert within the passage of its gauge module. Thus, the first and second inserts 85A / 85B may have a substantially integrated structure, including upper and lower portions, with slots extending through its upper and lower portions and along the intermediate body portion, allowing for further engagement and guidance of at least some of the first and second edges of the looper or hook. In embodiments, inserts of such a structure can be molded or cast to have a substantially one-piece body, allowing for a reduction in parts and reducing the need for separate inserts along the top and bottom surfaces of the module body and the opposite side of its passage, increasing the contact points / area between the insert and the looper or hook, and enhancing the consistency and / or control of motion.

[0065] Alternatively, the first, second, and intermediate body portions of each insert may be formed as separate parts and mounted together along the passage of the module body. For example, in yet another embodiment, an intermediate guide or bearing plate may also be used to help guide the movement of the looper or hook, with the guide or bearing plate extending along the passage between the inserts positioned along the top and bottom surfaces of the module body. Such a guide or bearing plate may provide a body or surface on which the first and second or front and rear edges of the looper or hook can ride / slide as they move along the passage of the module body. The guide or bearing plate may also function as a connecting member or portion between the inserts or between inserts 85A and / or 85B of each pair or set. Such a guide or bearing plate may be formed from a similar high-hardness material (e.g., hardened metal or carbide or powdered metal or other high-hardness material) and may provide a hardened surface on which one or both edges of the looper or hook can slide. Alternatively, in some cases, it may function as a sacrificial plate that is easily replaceable and protects the module body along the sides of the passage.

[0066] During operation of a tufting machine as disclosed in embodiments of this disclosure, loopers, hooks, or other gauge components are moved in multiple directions, including in and out of engagement with the needle, and also moved in a second direction through a gauge module or gauge block. For example, they are moved vertically between an up and down position to engage with the needle, and moved to a non-sewing position, and in some operations, they are moved after the loop of thread has been taken from the needle to form an extended or long loop. Thus, this tufting machine enables the formation of highly detailed tufted patterns, which can include different pile heights and other sculpted or multicolor pattern effects. However, the repeated periodic movement of such gauge components causes significantly rapid wear of the gauge components, particularly their gauge modules, as the loopers, hooks, or other gauge components slip and their edges frictionally engage with the body of their module. As these components wear down, their ability to engage with the needle and form loops of thread to create tufted patterns with substantially high precision may be reduced. For example, the gauge components may become misaligned and fail to engage with the needle properly or with the desired precision, requiring more frequent replacement of the gauge components / gauge modules.

[0067] By using powder metals including metals (such as high-hardness heat-treated steel), metal carbides, ceramics, and / or other hardened metallic materials, tungsten, titanium, or other similar high-hardness materials, the insert is provided with a hardness of at least 75+RC or higher, substantially improving the wear resistance of the gauge module and looper or hook by defining the contact area 98 between the looper or hook and the gauge module with a minimized area or profile. The high hardness of the insert is configured to protect the gauge module from direct contact and rapid wear as the looper or hook circulates therethrough, and to reduce frictional engagement between the insert and the looper or hook by reducing the size of the contact area 98 defined by the insert, thereby substantially consistently guiding and maintaining the alignment of the looper or hook during such movement. The looper or hook is also generally pre-hardened or heat-treated to harden its body. In some embodiments, a low-friction material can also be coated, treated, or bonded to the surface of the looper or hook body. This helps reduce friction between the edges 55A / 55B that engage and slide along the slots of the insert, thereby helping to extend their wear life. For example, in some applications, the wear life of a looper or hook has been found to reach 50 million to over 100 million machine cycles, and in some embodiments, it reaches at least about 100 million to 500 million cycles or more.

[0068] Increasing the insert's hardness protects the gauge module and allows it to be formed from substantially lightweight, low-hardness materials such as mild steel, aluminum, or their alloys. For example, instead of needing to form the gauge module from a substantially high-hardness material like tungsten, or substantially heat-treating it to significantly increase its hardness, the gauge module may be cast, molded, or otherwise formed from a lightweight metal, composite, or other similar material with substantially lower hardness than the insert (for example, the body of the gauge module can be formed from mild steel or an aluminum alloy with a hardness of less than approximately 60RC). This can be achieved while reducing the weight and cost of the overall gauge component assembly without degrading operational cycle performance. Reducing the weight of the gauge module or block can enhance control of the looper's movement as it passes through the gauge module and improve the reciprocating motion of the looper or hook toward and away from the needle. This is achieved, for example, by reducing the inertia that must be overcome during the reciprocating motion of the looper or hook toward and away from the needle.

[0069] Figures 7A–7E show embodiments of a gauge module or gauge block 151, including a body 152 adapted to be mounted along a gauge bar. As shown in Figures 7A, 7C, and 7E, in some embodiments the body 152 of the gauge module 151 may be reduced in size and may have substantially H-shaped or Y-shaped configurations in embodiments, although other configurations that are not generally square or rectangular may also be used. The body 152 of each gauge module 151 is further configured to receive a set of gauge components 32, such as loopers or hooks 50.

[0070] In some embodiments, the body 152 of each gauge module 51 is formed from a metal or metal alloy material, but various composite materials, synthetic materials and / or other materials can also be used. For example, but not limited to, the body of the gauge module can be made from a lightweight steel such as mild steel or tool steel, or aluminum, or other similar lightweight yet substantially rigid and durable material. In embodiments, the module body can be formed by casting, molding or other methods.

[0071] Furthermore, in embodiments, the gauge module may have a reduced profile or configuration adapted to help reduce the weight of the gauge module. In some embodiments, the gauge module may include a skeletal structure, and in some structures, the removed body portion, the reduced size portion (e.g., thickness, length, width, or a combination thereof), or the reduced weight portion, or a combination thereof. Furthermore, in embodiments, the material from which the body of the gauge module is formed may be selected to reduce the weight of the gauge module. At the same time, sufficient durability and rigidity can be provided to hold or substantially maintain the gauge component in its alignment or position to capture thread from the corresponding needle during the reciprocating motion of the gauge component toward and away from the needle during the operation of the tufting machine. For example, in embodiments, a stronger metal or metal alloy material can be used to form at least a portion of the body. This allows for the formation of portions in the body that are formed with a reduced profile or removed to offset weight.

[0072] In the example gauge module structures generally shown in Figures 7A-7C and 7E, the body 152 of the gauge module 151 is shown to have a generally H-shaped or Y-shaped configuration. In embodiments, the body 152 of each gauge module 151 may include a first front or front section 153 and a second rear or rear section 154. In embodiments such as that shown in Figure 7B, the rear section 154 may have a thickness or height less than that of the front section 153, thereby providing a reduced profile for the gauge module. The front section 153 may have a front surface 156A, a rear surface 156B, and a side surface 156C (Figures 7A and 7C-7D), and the rear section 154 extends rearward from the rear surface 156B and, in some embodiments, may be tapered toward a mounting portion 157. In this embodiment, the front surface 156A of the front section 153 of the main body 152 may include a first or upper portion 158A and a second or lower portion 158B (Figures 7A-7B), with an open-end recess or channel 155 defined between them.

[0073] In embodiments, the mounting portion 157 of each gauge module is substantially reduced in thickness and can be configured to engage and mount to a gauge bar, for example, as shown in Figures 7A-7C. For example, in embodiments, the rear section 154 of the body may be tapered downward from the rear surface 156B of the front section 153 toward the mounting portion 157. In embodiments, the mounting portion may have a lower surface 157A configured to sit on the gauge bar and be spaced above the lower surface 153A of the front section 153. This facilitates engagement alignment and positioning of the body 152 along the gauge bar. In embodiments, the mounting portion 157 may include tabs or other positioning devices 159 (Figure 7B) which are positioned along their lower surface 157A and configured to align the gauge module 151 along the gauge bar.

[0074] In some embodiments, as shown in Figures 7A-7B and 7E, the recess 155 may be configured to define an opening 160 that facilitates access to gauge components, such as loopers or hooks. These are received within a gauge module and are movable. For example, in some structures, the recess may have a generally C-shaped configuration, with its opening 160 defined along the front of the gauge module and further open along its side 161. This allows access to the gauge components for maintenance, such as cleaning dust, debris, or other materials that have accumulated around them. In some applications, such a structure can also provide a simple visual inspection of the gauge components within the gauge module. Other embodiments may also provide other configurations.

[0075] The gauge module may further include at least one fastener opening, which may be positioned along the rear section 154 of the main body (e.g., along the mounting section 157), as shown as 163 in Figures 7A-7C. A removable fastener, such as a set screw, socket, hex screw, or other similar removable fastener or mounting device, may be inserted through the fastener opening and into a corresponding opening along the gauge bar, thereby allowing the gauge module 151 to be detachably attached to the gauge bar. By removing the fastener, the gauge module, including the gauge components, can be made detachable. This allows the unit to be removed and replaced without necessarily having to replace individual gauge components. In other embodiments, the gauge module is removable / replaceable to change the spacing or arrangement of gauge components in the tufting machine. In other embodiments, the gauge module can be configured to allow selective removal of one or more gauge components.

[0076] Furthermore, as shown in Figures 7A and 7C, a passage 170 can be formed through the body 152 of each gauge module 151. In embodiments, the passage 170 can be positioned along the front section 153 of the body 152. The passage 170 may generally have a size and / or configuration to accommodate multiple gauge components, such as loopers or hooks 50, as shown in Figures 7B, 7D, and 7E. In embodiments, the body 55 of each looper or hook 50 can be received and passed through the passage 170, the first portion 60 of each looper or hook may generally protrude downward past the lower or bottom surface 171 of the body 152 of its gauge module 151, and the second portion 61 of each looper or hook may extend / protrude upward from the upper or top surface 172 of the body 152. The passage 170 may further be configured to allow the loopers or hooks to move over it.

[0077] As shown in Figures 7C and 7E, in some embodiments, the passage 170 may extend through a recess 159. For example, in some embodiments, a first portion 173A of the passage may be defined through the upper portion 158A of the body 152, and a second portion 173B of the passage may be defined in the lower portion 158B of the body 152. The second portion of the passage is aligned with a gap from the first portion of the passage. Furthermore, in some embodiments, the passage may extend at an angle, and in some embodiments, the front and rear surfaces of the passage and / or the front section may be angled so that the gauge components are inclined as needed, as described above.

[0078] Furthermore, in some structures, the first and second portions of the passage 173A and 173B may be divided, as shown in Figure 7C, and can be separated, for example, into section 174. For illustrative purposes only, in embodiments, the passage may be divided into multiple sections (e.g., 1 / 10 inch, 1 / 8 inch, 5 / 16 inch, or other intervals) to accommodate selected gauge intervals. In embodiments, the passage may include a wall or partition 176 positioned along the middle portion of the passage between the sides 156C of the front section 153 of the body 152. In embodiments, the partition 176 may be formed integrally with the body of the gauge module or otherwise integrated. In some embodiments, the partition or multiple partitions may be configured to be insertable and / or removable into the passage 170 as needed, and the passage may be divided into two or more sections 174.

[0079] In some embodiments, as shown in Figures 7A and 7C, multiple slots or grooves 177 can be formed along either or both of the upstream and downstream or front and rear edges 174A and 174B of the passage 170. However, in other embodiments, such slots or grooves 177 may not be used. Furthermore, the number of slots or grooves 177 formed in the gauge module can be changed to suit various selected applications and may also be configured to accept one or more partitions as described above. For example, the number of slots or grooves can match the gauge spacing of the gauge components or a multiple of such gauge spacing. In some embodiments, as shown in Figure 7E, the slots or grooves 177 may have depth and / or width configured to accept, for example, the front or rear edge portion of a looper or hook 50, thereby allowing the looper or hook to move along the slots in a direction substantially perpendicular to the direction of reciprocating motion of the looper or hook toward and away from the needle during a tufting operation.

[0080] Furthermore, the gauge module 151 may include one or more inserts 180. In embodiments, the inserts 180 may be positioned next to the passages defined through the body 152 of each gauge module, as generally shown in Figures 7C and 7E. The inserts are generally configured to provide a contact area between the gauge component and the body of the gauge module, so that the gauge component can engage as it passes through and moves along the passage 170. For example, in some embodiments, a series of inserts 180 may be received within the body of the gauge module 151 and positioned along the front and rear or upstream and downstream sides 170A / 170B of the passage 170, and may function as wear surfaces that protect the body of the gauge module from excessive wear as the gauge component passes through the passage.

[0081] In some embodiments, the inserts may be received within the body of the gauge module (for example, within a passage formed in the body) and be removable from there. On the other hand, in some embodiments, the inserts may be substantially integrated with the body of the gauge module. In embodiments such as those shown in Figures 7C and 7E, the inserts 180 may be arranged in a set, with one or more inserts substantially facing and parallel to the gauge components 32 received within the passage 170.

[0082] In embodiments, the insert 180 may include a pin, bar, or rod that is received in a passage or opening 183 within the body of the gauge module. Each insert 180 is further typically formed from a material different from the material of the body of the gauge module, for example, a harder material. As described above, in embodiments, the insert 180 may include hardened metal or metal alloy materials, metal carbides, ceramics, and / or powder metal materials including tungsten, titanium, or other materials that are harder than the material of the gauge module body. For example, in some embodiments, the insert may be formed from a metal carbide material with a hardness of about 74+ RC or higher, while the module body is formed from mild steel. In other embodiments, the insert may be formed from ceramics, powder metal materials including tungsten, titanium, or similar hard metal components, metal carbides, or other materials with a hardness of about 74+ RC to about 85+ RC or higher.

[0083] As shown in Figure 7E, in an embodiment, the gauge component 32 (e.g., a looper or hook 50) may be received within the passage 170 and extend through the recess 155 at the open end and the upper and lower portions of the front 153 of the body 152. The lower end of the gauge component may protrude and be located below the lower surface 153A of the front, and in an embodiment, may engage with a gate or connector 67 connected to an actuator 68 to control the movement of the gauge component through the gauge module. In an embodiment, at least a portion of the body of the gauge component is exposed and therefore accessible through the opening 160 defined by the recess 155, thereby facilitating cleaning, e.g., removal of dust and debris, and other maintenance, and also allowing for visual inspection of the gauge component.

[0084] Figures 8A-10B show various non-limiting embodiments of a gate or connector 67 that can be used with gauge components, including, for example, a looper or hook 50 (Figure 4) for connecting the gauge component to an associated actuator 68 (Figure 2-3). However, those skilled in the art will understand that the connector or gate shown in the embodiments of Figure 8A-10B is not limited to a particular type of tufting machine or a particular type of gauge component, and can be used with a variety of other types of gauge components, such as level-cut loop loopers or hooks and / or other gauge component arrangements, as well as with a variety of different types of gauge components, including loopers or hooks 50 as shown in Figures 4-6B and 11A-12C.

[0085] As generally shown in Figures 8A-10B, each connector or gate 67 generally includes a housing or support structure 101 that substantially contains, encloses, or accommodates a linkage or connector arm 102. The housing 101 of each connector or gate generally includes a first or proximal portion 103, an intermediate portion 104, and a second or distal portion 106. Furthermore, each connector body includes a passage or channel 107 into which the linkage or connector arm 102 is received and movable. The housing 101 of each connector 67 can generally be formed from a lightweight and durable material such as a composite material, plastic, or synthetic material, or a combination thereof. For example, a composite or polymer material such as nylon, polyamide, paramid nylon, or other similar polymer materials can be used and may be mixed with or include fibrous filler materials such as carbon fiber, glass fiber, or other support fibers that can provide additional reinforcement to the housing body material. The material of the housing body can be adapted or selected to not only reduce weight, but also to help reduce inertia during starting / stopping and movement, such as the expansion and / or contraction of gauge components by the associated actuator, and can also provide resilience and shock reduction or cushioning effects during such movement and starting / stopping operations.

[0086] As shown in Figures 8A-10B, in some embodiments, the housing 101 of each connector may be overmolded onto its linkage or connector arm 102, or formed in sections and applied around the linkage or connector arm, so that the linkage or connector arm is substantially surrounded or included. The linkage or connector 102 may further be made of a metal such as steel or other similar high-strength material, selected to provide sufficient strength and rigidity for each linkage or connector arm to withstand repeated impacts and increased motion cycles during operation of the tufting machine. For example, but not limited to, the linkage or connector arm 102 may include hardened steel material, and in some cases may be further heat-treated or annealed, for example, at its ends, in areas of contact and / or engagement with loopers or hooks, and between the connector arm or linkage and the associated actuator or drive shaft or rod of the actuator.

[0087] In some embodiments, the linkage or connector arm 102 may further include a skeletonized metal body configured to allow for a reduction in its weight. In such embodiments, each connector or housing 101 can provide additional support and rigidity to the linkage or connector arm 102, helping to guide and maintain consistent reciprocating motion or movement during operation. As a result, the connector or gate 67 can provide a more economical connector or gate design, allowing the use of a skeletonized or lightweight linkage or connector arm with a reduced profile, along with the additional support and shock resilience and cushioning effect provided by the housing 101.

[0088] As further shown in Figures 8A-10B, each connector or gate 67 can be formed in a variety of sizes and configurations. For example, the middle portion of each connector housing can have a short or long span depending on the gauge, distance, travel distance or the length of the linkage or connector arm, and thus may be modified to accommodate different tufting machines and / or tufting applications. As merely an example, as shown in Figures 8B, 9B and 10B, the connectors or gates can include various configurations for use with different gauge tufting machines, e.g., 1 / 8 gauge or 1 / 10 gauge machines, but it will be understood that they can also be used with other gauges (5 / 16, 1 / 16, 1 / 12, 1 / 14, etc.) and / or types of machines. The middle portion of the housing through each connector can further be angled, oriented at an angle that extends downward in some cases and at an angle that extends upward in other cases, so that adjacent connectors oriented at opposite angles or in configurations can minimize the space or footprint they occupy.

[0089] Each linkage or connector arm 102 of each connector or gate 67 (Figures 8A, 9A, 10A) may further be formed to various lengths as needed or desired. Each linkage generally has a first or proximal end 110, which can be adapted or configured to engage or connect to one or more actuator shafts or drive rods 69 of the associated actuator or actuator 68, and generally an angled body portion or portion 111 extends along a passage or channel in the housing, through the housing of the connector, and terminates at a distal flange or hook end 112. The body portion 111 of each linkage may further be located within or aligned and enclosed within the passage of its housing to help provide stability or to help guide the movement of the linkage along the channel of its connector housing.

[0090] For example, in some cases, pins or other inserts are used when forming a housing around or on a linkage to help align and support the linkage in position, after which the pins can be removed. Alternatively, several guide pins may be provided to help maintain and guide movement along one or more parts of the linkage or connector arm, and these may include or function as bearings. In yet another embodiment, slots may be provided along the body of each housing. By housing guide pins in these slots, they can assist in guiding the movement of the linkage and further enhance impact resilience.

[0091] In additional embodiments, a guide pin or fastener 114A passes through the housing and is inserted into the body of the linkage, engaging with a slot or guideway, or similar means for helping to guide, control, or maintain the movement of the linkage, so that it can move along the passage or channel 107 (Figures 8B, 9B, and 10B) of the connector housing without twisting, rotating, or otherwise becoming misaligned. In yet another embodiment, the guide pin 114A may function as a pivot point around which the linkage or connector arm moves or rotates, rather than the linkage or connector arm moves substantially linearly.

[0092] As further shown in Figures 8A, 9A, and 10B, the distal hook end 112 of each linkage or connector arm 102 is supported along at least one side by a second or distal portion 106 of its housing 101, which can help guide and support the hook end during the sliding motion of the linkage. The hook end of the linkage or connector arm engages with a corresponding hook portion, recess, or slot of the corresponding gauge component. For example, in one embodiment, it engages with a slot or recess 64 (Figure 5) formed in the first portion 60 or distal end of the corresponding or associated looper or hook 50. In another embodiment, the hook end of the linkage can engage with a clip of a level-cut looper, level-cut loop looper, or other movable gauge component. When each actuator is selectively actuated or activated / deactivated, the movement of its actuator shaft or drive rod is transmitted to the associated gauge component via the linkage or connector arm of the corresponding connector or gate. Therefore, the connector or gate can provide an economical, rigid, and high-strength connection between each actuator and its associated gauge component, and the gauge component can be removed or changed as needed, eliminating the need to replace the associated actuator.

[0093] In one embodiment, as commonly shown in Figures 2 and 12A-12C, the actuator may include a hydraulic, pneumatic, electric, or pneumatic cylinder 68, each cylinder generally including a cylinder rod or shaft 69 connected by a connector or gate 67 to one of the associated or corresponding loopers or hooks. In some embodiments, the actuator may further be used to control the operation of one or more loopers or hooks 50. Furthermore, other types of actuators, including solenoids, motors, or other similar operating mechanisms, may also be used, as will be understood by those skilled in the art.

[0094] Each actuator is generally linked to a control system 25, which selectively controls its operation to control the firing and / or movement of each looper relative to the needle. The actuator selectively extends and retracts the looper or hook, and controls the position of the throat / bill to change in a second direction with respect to the reciprocating motion of the needle entering and exiting the base material, and with respect to the movement of the loop looper or hook 50 in the direction of arrows 54 / 54'. For example, in an embodiment, the looper or hook moves approximately perpendicular to the needle (i.e., roughly up and down) as shown by arrows 71 and 71' in Figures 2, 4 and 12A-11C. The actuator can be selectively controlled to extend and / or retract the looper or hook between extended and / or non-sewing positions, as well as to extend the looper to a series of different positions or heights relative to the stroke or penetration depth of the needle. Therefore, the position or location of the looper or hook's throat can be controlled and modified relative to the needle, allowing it to capture and / or form loops of yarn at different pile heights or lengths from the selected needle, or to not capture the yarn at all.

[0095] For example, in the fully extended position, the selected looper or hook 50 can capture loops of yarn from the needle it engages with, and these loops are generally formed at the initially selected or desired pile height. A portion of the looper or hook is moved by the actuator to a fully lowered or retracted position and placed in a non-sewing position. In other operations, the actuator is selectively controlled or triggered to retract or lower each looper or hook after a loop of yarn has been captured, pulling the captured yarn loop downwards and creating a higher pile or increased yarn length to obtain additional pattern effects for tip shearing and / or other texturing effects.

[0096] As shown in Figures 11A-11B, each gauge component 32, such as a looper or hook 50, is generally arranged in a set or group contained within a module 51 / 151, the module being mounted in series along a gauge bar and providing multiple gauge components arranged at predetermined intervals (e.g., gauge intervals such as 1 / 10, 1 / 8, 5 / 16) across the entire tufting zone. The gauge components 32 are positioned to engage with the needles and are arranged in substantially linear, offset, staggered, and / or other configurations, depending on the configuration of the needle bar or the needles of the needle bar. Each of the loopers or hooks 50 is positioned at an angle or offset to the needles penetrating the base fabric material and is movable or extendable along an angled movement path 71 / 71' with respect to the needles and / or their raised position. Such offset movement of the loopers or hooks can be modified as necessary, depending on the spacing and / or arrangement of the needles, to minimize the possibility of the looper or hook engaging with the needles when the looper is retracted.

[0097] For example, in some embodiments, the looper or hook is positioned and / or moved along the movement path at an angle / offset indicated by θ in Figure 11B. θ is in the range of approximately 1° to approximately 10° or more relative to the vertical and / or the stroke of the needle as the looper or hook is retracted, and in one embodiment, it is an angle of approximately 4° to 6° relative to the path or direction of the needle's reciprocating motion as the needle completes its stroke or reciprocating motion in and out of the base fabric material. Thus, when the looper or hook is extended to a position / height sufficient to engage with the needle's rising region 39 (Figures 11A-12A), their throats / bills are generally well aligned or positioned to engage and capture the loop of thread from the corresponding needle. When the looper or hook is retracted, they move further along the generally offset movement path, positioning their throats / bills out of the needle's movement path, minimizing the possibility of miscapture of thread as the looper or hook is moved to the retracted non-sewing position.

[0098] According to some embodiments, tufted products can be formed during operation according to the systems and methods of the present disclosure, and these tufted products can be formed with a variety of patterns and pattern effects, including patterns formed using multiple different colors and / or types of yarn, and including sculptural or multiple pile height effects. For example, the systems and methods of the present disclosure can be implemented in combination with stitch distribution control systems or yarn color arrangement systems, such as those disclosed and illustrated in U.S. Patents 8,141,505, 8,359,989 and 8,776,703, and these disclosures are incorporated by reference as fully described herein.

[0099] In such embodiments, the stitches or thread tufts formed in the base fabric material may be further formed at an actual operation or effective process stitch rate compared to a desired or specified fabric or pattern stitch rate for the tuft pattern being formed. If the stitch rate or density of the pattern or fabric being formed requires that the tufted product have an appearance with a number of stitches formed therein, such as 8, 10, or 12, and / or presented on its surface, the actual operation or effective number of stitches formed during the operation of the tufting machine will be substantially greater than the desired or specified pattern or fabric stitch rate. Thus, the actual formation of the stitches or thread tufts in the base fabric material is achieved at an increased actual operation or effective process stitch rate. This effectively forms more stitches in the base fabric material than need to be displayed in the finished pattern, and stitches or face threads that are undesirable to be displayed or remain on the surface of the pattern field or area are pulled out from the back lobe or base fabric material or pulled low enough, while substantially avoiding the creation of undesirable or unwanted gaps or spaces between the held or face threads of the pattern, while allowing these threads to be held or tacked in the base fabric material.

[0100] For illustrative purposes, in one example embodiment, the effective process stitch rate can be based on or determined by roughly increasing the fabric or pattern stitch rate of the pattern to be formed by the number of colors selected or tufted into the pattern. For a pattern using 2-4 colors and having a desired fabric or pattern stitch rate of about 10-12 stitches / inch, the effective or operational process stitch rate (i.e., the rate at which stitches are actually formed in the base fabric material) can range from about 18-20 stitches / inch to about 40 or more stitches / inch. However, it will be further understood by those skilled in the art that additional variations or adjustments of such operational or effective process stitch rates can be made for a particular pattern depending on the type and / or size of the yarn and / or other factors. For example, if thicker, larger size or heavier yarn is used, the effective process stitch rate may be subject to additional variations as needed to account for the use of such larger yarns (for example, for a 4-color pattern, the effective process stitch rate may vary further, such as being performed at about 25-38 stitches / inch, but further variations can be used as needed). Therefore, if the selected or programmed pattern to be executed is designed or desired to have 10-12 stitches / inch as the desired pattern density or stitch rate, the system may actually operate to form 20-48 or more stitches / inch, and depending on the number of colors and / or the type of thread, visually, only roughly the desired / selected 10-12 stitches will be visible on the surface of the finished tufted product.

[0101] Furthermore, when a series of different colors are tufted, the needles 36 of the needle bar 35 can provide a generally desirable thread-up sequence, for example, in the case of a four-color pattern, thread-ups of A, B, C, and D can be used on the needles. Alternatively, when two needle bars are used, the needles of each needle bar can provide an alternating thread-up sequence, i.e., the front needle bar has thread-ups of A / C and the rear needle bar has thread-ups of B / D. Furthermore, the needles of such front and rear needle bars can be arranged in a staggered or offset configuration. More generally, one or more needle bars are shifted laterally relative to the base fabric by control of the needle bar shifter 40 (Figure 2) according to a shift profile for the pattern to be formed as the base fabric material is fed through the tufting zone, and in conjunction with the control of the base fabric material and the control of the yarn feed. This allows for the effective provision of threads of each color (i.e., 2, 3, 4, 5 colors, etc.), or each of different types of thread, to the looper or hook, which can be sewn at the selected pattern pixels or tuft / stitch locations.

[0102] For example, in the case of a four-color pattern, each of the 1 to 4 colors (i.e., one, two, three, four threads, or no thread) that can be sewn at the next pixel or stitch position is provided to the desired looper or hook at the selected pixel or stitch position. This is done as the base fabric material moves stepwise by approximately 1 / 8 to 1 / 40 inch (approximately 3.18 mm to 0.64 mm) with each shift operation or cam movement cycle. The looper or hook engages and forms a loop of thread, holding the desired thread or thread to form the selected tuft, while the remaining threads are generally pulled low or backlobbed by the control of the thread supply mechanism, pulling these unheld threads away from the base fabric material and floating along the base fabric material. Therefore, each looper or hook is given the ability to tuft any of the pattern colors, or potentially multiple colors (i.e., 2, 3, 4, 5, 6, etc.), or any of the presented colors, for each associated pattern pixel or tuft / stitch position during each shift sequence and the corresponding stepwise movement of the base fabric material. As noted, if a different type or color of thread is not tufted or placed at a particular tuft or stitch position or pixel, the thread supply can be controlled to limit or control the thread of the needle that may be presented at that stitch position or pixel, pulling back substantially all thread or preventing thread from being placed at that stitch position. Alternatively, the needle bar can be controlled to jump, bypass, or skip the presentation of the needle / thread to that stitch position or pixel.

[0103] The supply of the base fabric material B can also be further controlled. That is, it can be controlled in various ways by the stitch distribution control system. For example, the base fabric roll 28 of the tufting machine can be controlled to hold the base fabric material in place for a predetermined number of stitches or cycles of the needle bar. Alternatively, the base fabric material can be moved at a desired number of stitches per inch. That is, it can be moved by about 1 / 40 of an inch with each penetration, or, as a variation thereof, if four stitches are introduced into the base fabric in a four-color pattern and the effective stitch rate is 40 stitches per inch, it can be moved by about 1 / 10 of an inch. The movement of the base fabric material can be further varied or manipulated on a stitch-by-stitch or pixel-by-pixel basis so that the average movement of all stitches over the entire cycle substantially matches the calculated incremental movement of the manipulated or effective process stitch rate. For example, in a four-color cycle, the first stitch is executed at 1 / 80 inch, the next two at 1 / 40 inch, and the fourth at 1 / 20 inch, so that the average movement of the base fabric over the entire four-stitch cycle is 1 / 40 inch on average for each presented stitch, achieving the desired stitch / color placement as needed.

[0104] Therefore, each of the different threads / colors that can tuft at a particular stitch position or pixel can be presented at such stitch position or pixel as the pattern is formed on the base fabric material. To achieve the presentation of the thread at each pixel or stitch position, the needle bar can generally be shifted as needed / desired according to a calculated or selected cam profile or shift profile of the pattern being executed / formed. For example, a combination of single and / or double thread shifts or shifts can be used based on the number of colors executed in the pattern and the area of ​​the pattern field formed by each particular color. Such a combination of single and double shift threads or steps can be used to avoid over-tufting or interference with previously sewn tufts as the needle bar is shifted laterally and the base fabric material advances at its effective or operational stitch rate. The base fabric can also be shifted by the base fabric or jute shifter, etc., in conjunction with or separately from the needle bar shift mechanism.

[0105] As shown in Figures 1 and 2, when the needle penetrates the base fabric B, the looper or hook 50 of the gauge component assembly 30 reciprocates toward the needle in the direction of arrow 54, hooking and pulling out the loop of thread from the associated or corresponding needle. Furthermore, the actuator 66 of the looper or hook can be selectively controlled and actuated to extend or retract the selected looper or hook so that the tip (bille) 63 and throat 62 are positioned in a desired position relative to the needle when the needle 36 penetrates the base fabric and completes its stroke. As shown in Figures 11A-12C, the position or arrangement of the tip (bille) and / or throat of the looper or hook can be varied between a fully extended position or height and a lowered or retracted "non-sewing" position. In this position, it is possible to substantially prevent the yarn loops from being caught or formed by such loopers or hooks, providing selective pickup of yarn loops and allowing control over the length of yarn loops selectively caught from the yarn presented at each stitch position or pixel, according to the instructions of the pattern being formed, including ensuring that the yarn loops are not caught. As a result, it is possible to control the position at which selected or desired surface yarn loops appearing in the “finished” pattern are caught from the needle by the looper or hook, and the resulting tuft formation from the thus caught yarn loops remains in the base fabric, further controlled, so that it can be formed at a variety of different pile heights.

[0106] The type / color of each thread series presented at each pixel or stitch position held or displayed on the surface of the base fabric at a specific stitch position is generally determined according to pattern instructions or programming for forming the tuft pattern. By controlling the operation and / or position of the looper or hook 50 corresponding to or associated with the needle that carries such thread, the tufting machine can selectively capture and hold the loops of such thread at each stitch position where such thread should remain according to the pattern, thereby forming a tuft of such thread at a selected pile height. For example, if it is to prevent a supplied thread from being displayed or appearing (on the pattern surface), the loops of the thread can be prevented from being captured by retracting the corresponding looper or hook to a non-sewing position. Furthermore, by controlling the thread feed accordingly, such threads can be prevented from being held at the pixel or stitch position. For the held threads / colors, i.e., the threads displayed on the surface of the pattern tuft product, the position or height of the looper or hook and the thread supply mechanism that supplies these threads can be controlled in general coordination to enable the pickup and formation of enough thread loops to form a tuft of the desired type and pile height.

[0107] In accordance with the principles of this disclosure, further control of the base fabric feed, which increases the effective or operational process stitch rate (e.g., the actual rate at which stitches are formed in the base fabric), can provide a denser or more compressed field of stitches or tufts per inch, and can be pulsed low enough to avoid back-lobbed yarns being removed or undesirable spaces or gaps being created between retained surface yarns (those that appear on the surface of the tufted product according to the pattern), or to avoid interfering with or making visible such retained surface yarns formed in the base fabric material. Furthermore, the control system can perform yarn feed compensation and / or modeling to control and reduce the amount of unretained or unvisible yarn that may be “floating” on the back of the base fabric material, helping to further reduce / minimize excess yarn feed and / or waste.

[0108] Furthermore, the thread feeding mechanism, which controls the supply of each thread to each needle, can selectively control whether to substantially pull the thread held by the needle from the base material, or to "backlob" or "pull" the thread in accordance with the reciprocating motion of the needle. It is also possible to retract some thread loops to a sufficiently low position, or to "pull back / low" them. This largely prevents unselected thread ends (non-selected threads) from occupying selected stitch positions or interfering with the placement of "face threads" that should be displayed in specific color fields formed according to the pattern.

[0109] For example, in some embodiments, when a selected or specific looper or hook is retracted to a fully retracted or “non-sewn” position, the loop is not captured by the needle associated with such a fully retracted looper or hook, and the thread feed is controlled accordingly to allow the thread to enter and exit the base fabric material with the needle. Furthermore, in some cases in which a loop of thread is formed, such as when the looper or hook is in a fully extended position and forms a low loop, the resulting loop of thread can be further backlobbed or substantially lowered, or pulled out from the base fabric material, and the control of the thread feed can substantially remove such thread while leaving an amount of thread “tucked” into the base fabric, thereby largely avoiding the end of such unselected thread appearing on the surface at a particular stitch position or interfering with the placement of selected thread.

[0110] The placement of invisible threads, which are tucked or otherwise secured to the base fabric material, can also be controlled to prevent such long tails from getting caught later or causing other defects in the finished tufted product. For example, the control system can be programmed / set to tuck or form low stitches of such invisible threads at desired intervals, e.g., every 1 to 1.5 inches, although larger or smaller intervals can also be used. Yarn compensation is also commonly used to ensure that a sufficient amount of yarn is supplied as needed when tucking invisible threads to the base fabric. At the same time, it can prevent those threads from being visible or bubbling through gaps of other colors. That is, in situations where multiple threads are placed in the same position, those threads can be sewn into one of the stitch threads and held in place so that they pass through (reducing surface exposure). Furthermore, if long threads (tails) are formed for multiple invisible threads, the interval at which these different threads are tucked to the base fabric can be varied (e.g., some threads at 1-inch intervals, others at 1.5-inch intervals). This is to prevent the tucked threads from interfering with each other or with the threads of the resulting color field.

[0111] Furthermore, the actuators 66 are also controlled in conjunction with the yarn supply mechanism, and by operating the respective loopers or hooks to retract or lower them while capturing yarn loops, longer or extended yarn loops can be formed. Thus, the captured yarn loops can be further pulled or stretched, and the corresponding yarn supply can be controlled to supply such additional amounts of yarn. As a result, longer or larger yarn loops can be formed in the base fabric to create high pile tufts or other desired patterning effects such as tip shearing or other patterning functions. Selective control of the actuators 66 can be further used to selectively retract or extend the loopers or hooks 50, providing additional variations or transition steps within the pattern, or pile height. For example, they can be controlled as needed to provide gentler or more subtle differences or changes in pile height, or to provide more dramatic or distinct separations between the pile heights of the formed yarn tufts.

[0112] Therefore, across the entire width of the tufting machine, the control system controls the shifting and supply of threads for each color or desired pattern texture effect, ensuring that each color that can or could be sewn at a particular tuft position or pattern pixel is presented in its pattern pixel space or tuft position, while only the tufts of threads selected for a particular color or pattern texture effect remain in that tuft / stitch position or pattern pixel. Furthermore, it is possible to present additional or more colors to each looper or hook during the tufting process, forming mixed-color tufts or providing a desired tweed effect. This ensures that two or more stitches or threads are placed at the desired pattern pixel or tuft position. The result of the operation of the stitch distribution control system provides a multicolor visual effect of selectively placed pattern colors or texture effects to obtain the desired density and pattern appearance for the finished tufted product. This allows for the creation of a wider range of geometric, free-flowing, and other pattern effects by controlling the placement of tufts or threads at selected pattern pixels or tuft positions.

[0113] Therefore, the system and method for manufacturing engraved and multi-pile high-pattern tufted products of this disclosure enables the operator to develop and execute a wide variety of tuft patterns with diverse appearances and textures in a tufting machine without necessarily having to use a design center to draw and create patterns. Instead, according to this disclosure, in addition to or as an alternative to manual pattern preparation and the use of a design center, the operator can scan an image (photograph, drawing, JPEG, etc.) or upload a designed pattern file in the tufting machine. The stitch distribution control system then reads the image and creates program steps or parameters. This makes it possible to control the tufting machine to form the desired tuft pattern product with virtually no further input or control required from the operator.

[0114] The foregoing description illustrates and explains various embodiments of the present disclosure in general. However, those skilled in the art will understand that various modifications are possible. And, without departing from the spirit and scope of the present disclosure, various modifications and alterations can be made to the structures discussed above, and all matters included in the foregoing description or shown in the accompanying drawings are illustrative and not intended to be construed as limiting. Furthermore, the scope of the present disclosure should be interpreted to cover various modifications, combinations, additions, and alterations to the above and above-described embodiments, and these are considered to be within the scope of the present disclosure. Accordingly, the various features and characteristics of the present disclosure discussed herein can be selectively interchanged and applied to other illustrated and unillustrated embodiments of the present disclosure, and many more variations, modifications, and additions can be made without departing from the spirit and scope of the present disclosure as described in the accompanying claims.

Claims

1. It is a tufting machine, A needle bar comprising at least one needle bar, wherein multiple needles are attached along it, A base fabric feed roll that supplies the base fabric material, A thread supply mechanism that supplies thread to the plurality of needles, It comprises a gauge component assembly placed beneath the base fabric material, The aforementioned gauge component assembly is Multiple gauge components configured to capture thread from a needle, A body having a first hardness formed from a metal, polymer, composite material, or synthetic material, or a combination thereof, and at least one module having at least one passage defined through the body, The system comprises at least one insert arranged along the at least one passage, The at least one insert has a second hardness that is higher than the first hardness, The aforementioned gauge component is When the needle moves back and forth relative to the base fabric, the needle moves in a first direction. As the needle moves toward and away from engagement, the needle is movable along the passage of the body of the at least one module in a second direction relative to the needle. The aforementioned tufting machine further, A series of actuators coupled to the gauge component to control the movement of the gauge component in the second direction through the module body, A control system comprising: a program for controlling the operation of one or more actuators to move a selected gauge component in the second direction between a position where capture of the thread by the gauge component from the corresponding needle is substantially avoided and one or more positions for capturing the thread from the corresponding needle; and a program for controlling the at least one thread supply mechanism to control the supply of thread to the needle. Tufting machine.

2. It further includes a shifting mechanism for shifting at least one needle bar, a base fabric material, a shifter, or a combination thereof. The tufting machine according to claim 1, further comprising a program adapted to coordinate the shift of at least one needle bar or the shift of a base fabric material, or a combination thereof, with the control of an actuator and the control of at least one thread supply mechanism that supplies thread to the needle, enabling the presentation of one or more threads at selected stitch positions along the base fabric material.

3. The tufting machine according to claim 2, further comprising a program configured to control the supply of base material at an actual stitch rate greater than the pattern stitch rate of the pattern to be formed.

4. The tufting machine according to claim 1, further comprising a series of connectors extending between each gauge component and associated actuator, each connector comprising a link that is received and movable within a housing.

5. The tufting machine according to claim 1, wherein at least one insert includes a plurality of pins received in the body of at least one module adjacent to at least one passage.

6. The tufting machine according to claim 1, comprising at least two inserts arranged in a substantially aligned relationship between at least one insert and opposite sides of at least one aisle.

7. The tufting machine according to claim 1, wherein at least one passage includes a series of slots spaced apart along it, each slot configured to receive a portion of a gauge component.

8. The tufting machine according to claim 1, wherein the body of at least one module includes a first section through which at least one passage extends, and a second section having a thickness less than the thickness of the first section.

9. The tufting machine according to claim 1, wherein the body of at least one module includes a substantially H-shaped or Y-shaped configuration, including a recessed open end defined along the front surface.

10. The tufting machine according to claim 1, wherein at least one insert includes a plurality of pins positioned on opposite sides of at least one passage to determine a contact surface between the body of at least one module and a gauge component received in at least one passage.

11. A gauge component assembly for a tufting machine, Multiple gauge modules, each module containing a main body with a defined passage, Opposing inserts positioned on the opposite side of the passage, each insert comprising a metal, metal carbide, ceramic, or powdered metal material having a hardness greater than that of the module body, wherein the powdered metal material comprises metal powder including tungsten, titanium, or a combination thereof, and A series of gauge components slidably received in a passage, each having a first part and a second part, The insert is configured to define the contact area on which the gauge component slides. The gauge component is transported in a first direction with the module toward and away from the needle of the tufting machine, and is selectively movable in a second direction along the passage, selectively capturing the loop of thread from the needle, The gauge component assembly further comprises a plurality of actuators coupled to each gauge component, each actuator being selectively actuated, which moves the coupled gauge component in a second direction, such that the second portion of the gauge component moves between one or more extended positions for capturing a loop of thread from the needle and a retracted position for substantially avoiding capturing a loop of thread from the needle.

12. The gauge component assembly according to claim 11, further comprising a series of slots formed along at least one side of a passage, the series of slots configured to receive at least a portion of one of the gauge components therein.

13. The gauge component assembly according to claim 11, wherein the insert includes a plurality of pins positioned adjacent to a passage, and the ends of the gauge component contact the pins as the gauge component slides along the passage.

14. The gauge component assembly according to claim 11, wherein the insert has a hardness of at least 75+RC.

15. The gauge component assembly according to claim 11, wherein at least a portion of the module body includes a substantially H-shaped or Y-shaped configuration including a recessed open end defined along the front surface.

16. It's a tufting machine. A needle bar comprising at least one needle bar, wherein multiple needles are attached along it, A base fabric feed roll that supplies the base fabric material, A thread supply mechanism that supplies thread to the plurality of needles, The system comprises a gauge component assembly positioned beneath a base fabric material passing through the tufting machine, The aforementioned gauge component assembly is A module comprising a body having a first hardness formed from a metal, polymer, composite material, or synthetic material, or a combination thereof, with a defined passage within it, A plurality of gauge components slidably received within a passage, each gauge component including a first portion and a second portion configured to capture thread from a needle, The gauge component is transported in a first direction toward and away from the needle of the tufting machine together with at least one module, and is selectively movable in a second direction along the passage. The tufting machine further, One or more inserts accepted within at least one module, positioned along opposite sides of a passage, and positioned so that a portion of each gauge component contacts and slides when the gauge component selectively moves along the passage in a second direction, and comprising a material having a hardness greater than the hardness of the material of at least one module, and defining one or more contact surfaces along the passage, A series of actuators coupled to a gauge component and configured to control the movement of the gauge component in a second direction along a passage of at least one module, Equipped with a control system, The control system includes a program for controlling the supply of yarn to the needle, in conjunction with the control of one or more actuators in the second direction along the passage, such that, as the needle moves back and forth relative to the base fabric to selectively form yarn tufts in the base fabric according to the pattern to be formed, a second portion of a selected gauge component moves between a retracted position and one or more advanced positions relative to the needle. Tufting machine.

17. The tufting machine according to claim 16, wherein one or more inserts include a metal carbide, a ceramic, or a powdered metal material, and the powdered metal material includes a metal powder containing tungsten, titanium, or a combination thereof.

18. One or more inserts include a plurality of pins received within at least one module, the pins being at least partially positioned within a passage. The tufting machine according to claim 16.

19. The tufting machine according to claim 16, wherein at least one module has a body having a substantially H-shaped or Y-shaped configuration including a recessed open end defined along the front surface.

20. The tufting machine according to claim 16, wherein at least one module includes a body having a first section through which at least one passage extends, and a second section configured to be mounted along a gauge bar having a thickness less than the thickness of the first section.

21. The system further includes a shift mechanism for moving one or more needle bars laterally across the base fabric material. The tufting machine according to claim 16, wherein the control system further includes a program that adjusts the shift of one or more needle bars, controls the movement of a gauge component in a second direction, controls the supply of thread to the needle as the needle moves in and out of the base material, presents a series of threads at selected stitch positions along the base material, and pulls back any unselected threads if they are not caught by one of the gauge components.

22. The tufting machine according to claim 21, further comprising a program that controls the supply of base material so that it passes through the tufting zone at an actual stitch rate greater than the pattern stitch rate of the pattern to be formed.

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