System and method for forming patterned tufted products (cross-reference) This application claims the interests of U.S. Provisional Application No. 63 / 533,171 filed on 17 August 2023, U.S. Provisional Application No. 63 / 555,590 filed on 20 February 2024, and U.S. Provisional Application No. 63 / 683,097 filed on 14 August 2024.

Abstract

Systems, apparatus, and methods for forming tufted products may include tufting machines for forming patterned tufted products such as carpets, rugs, and artificial turf or turf products with integrated logos or other designs of multiple colored yarns. The tufting machine may include a series of hollow needles arranged at gauge intervals along a needle bar and capable of receiving a series of different colored and / or typed yarns from a yarn supply system. A yarn selection system may be controlled to selectively hold or pull back yarns from the needles. The needles reciprocate against the backing material to deliver a series of yarns to the backing material and engage with corresponding knives to form yarn tufts.

Description

Technical Field

[0001] (Incorporation by Reference) The disclosures of U.S. Provisional Application No. 63 / 533,171, filed on August 17, 2023, U.S. Provisional Application No. 63 / 555,590, filed on February 20, 2024, and U.S. Provisional Application No. 63 / 683,097, filed on August 14, 2024, are hereby incorporated by reference in their entirety for all purposes as if fully set forth herein.

[0002] The present disclosure generally relates to tufted fabrics or products, and particularly to systems and methods for forming tufted fabrics or products having a patterned design, including the formation of patterned artificial / synthetic sports turf or turf fabrics or products.

Background Art

[0003] Tufted products such as carpets, rugs, and turf featuring corporate branding, including logos, script designs, and other patterned graphics, are becoming increasingly popular. Furthermore, as the installation of artificial or synthetic turf or turf products expands to both indoor and outdoor applications, there is a growing demand for the formation of such turf products with a wider variety of colors and / or patterns, including team or sponsor logos or various graphic patterns. Traditionally, creating large tufted product fields, such as turf or artificial turf fields, with graphic patterns or designs such as logos, numbers, or other features required either installing a section of plain turf or artificial turf on site and painting the desired design or logo onto the turf or artificial turf, or cutting and removing a portion of the installed turf or artificial turf and inserting and fixing (e.g., gluing) pre-cut logos, numbers, or other design features in the desired colors. Such processes are often highly labor-intensive, time-consuming, expensive, and can lead to increased material waste, and in some cases, can result in inaccuracies in terms of alignment of such later-applied logos or other complex designs. Furthermore, as players become larger and stronger, greater forces may be applied to the turf or artificial turf field during play, which could increase the likelihood of turf separation and separation along seams where logos or other designs are applied.

[0004] Therefore, it is clear that there is a need for systems and methods for forming patterned tufted products, including artificial / synthetic turf or sports turf products, to address the aforementioned and other related and unrelated technical issues. [Overview of the project]

[0005] (Summary of Disclosure) In short, this disclosure relates to a system and method for forming patterned tufted products, including, but not limited to, commercial and residential carpets, carpet tiles, rugs, artificial turf or turf, sports carpets, landscape applications, and / or other tufted products. In embodiments, the tufted product may include a patterned design with multiple different colors, varying pile heights, and / or loop pile and / or cut pile tufts. In one exemplary embodiment, a patterned tufted product formed using the system and method of this disclosure may be formed from various colors and / or types of yarn, including synthetic turf or turf-type filaments or yarns, and / or other yarns, which can be inserted into a backing material to form patterned artificial / synthetic turf or turf products, as well as tufted products, including carpets and rugs.

[0006] In embodiments, the yarn may include one or more yarns for forming carpets and rugs (e.g., shag carpets) or sports carpets or turf products, which may include combinations of one or more filament and / or ribbon yarns for forming sports fields and landscape applications. In embodiments, the systems and methods of the present disclosure may be included in and / or adapted to be used in a tufting machine which generally includes at least one row of needles that can be reciprocated with respect to a backing material passing beneath the needles, thereby inserting a plurality of yarns into the backing material to form a tuft of such yarns therein. In embodiments, the tufting machine may comprise a hollow needle tufting machine having a plurality of hollow needles mounted in a series and spaced apart along a needle bar. In some embodiments, the tufting machine may include two or more needle bars with a plurality of needles spaced apart therewith (e.g., a pair of needle bars may be provided, each carrying a plurality of needles).

[0007] Furthermore, in embodiments, the tufting machine may include a needle stroke support assembly configured to guide a push rod that drives the reciprocating motion of a needle bar. In embodiments, each needle stroke assembly may include a set of support plates, including an upper support plate that receives the push rod and a lower support plate that can function as a brace or strut along which a first guide may be mounted. The push rod extends through the support plates and connects to a push foot coupled to the needle bar. The push rod foot may have a second guide that interacts with the first guide on the lower support plate to help guide the linear motion of the push rod and needle bar during each needle stroke, which can reduce the pressure on the push rod during the stroke in which the needle moves in and out of the lining and help suppress excessive vibration and / or lateral movement of the push rod.

[0008] In some embodiments, yarn of a specific color can be assigned to or associated with each needle. For example, the needles may have thread-ups of selected colors such as ABC, ABCD, ABCDE, ABCDEF, and the yarn of the selected color can be directly supplied to one needle. In some embodiments, two or more yarns can be directly supplied to each needle. In some embodiments, the yarns can be directly supplied to the needles associated with them using air from at least one injector. In some embodiments, two injectors can be provided, one on each side of the needle. Thus, one or more yarns of a selected color can be directly supplied to the associated needle without supplying multiple colors of yarn to a funnel for each hollow needle and then selectively supplying one of those colors of yarn to the hollow needle.

[0009] Furthermore, in some embodiments, yarn tubes can be mounted along a needle bar and communicate with each needle to help retain yarn within the needles. In embodiments, the yarn tubes can extend at an angle into and through the openings of the needle bar to guide the yarn to the corresponding needles. In some embodiments, the yarn tubes can be positioned adjacent to the needle bar and communicate with and supply through a passage extending through the needle bar, supplying yarn to a defined passage through the associated needle. In other embodiments, the yarn is supplied directly to a passage formed along the needle bar and supplied to a hollow needle.

[0010] In some embodiments, the needle bar can be coupled to a shift mechanism, such as a servomotor-driven shift mechanism, a rack-and-pinion shift mechanism, or other shift mechanism, to shift the needles laterally relative to the lining material. In some embodiments, a lining support or shuttle that supports the lining material during the tufting operation can be coupled to the shift mechanism and can be shifted in conjunction with the needle shift, or, in some embodiments, independently of the needle shift. In any embodiment, the lining can be shifted, or the needle bar can be shifted laterally, or both the lining and the needle bar can be shifted laterally. In yet another embodiment, only the shuttle supporting the lining can be connected to the shift mechanism so that the lining can be shifted such that the lateral position of the needles remains substantially consistent as the lining moves laterally relative to the needles, or the needles can be shifted in different increments and / or in different directions.

[0011] In some embodiments, the system of the present disclosure may further comprise a tufting machine having a plurality of hollow needles, a yarn feeding system, a yarn selection system, a yarn cutting system, and a control system. In embodiments, the yarn feeding system may include a yarn feeding mechanism or pattern attachment having a plurality of yarn feeding devices, each configured to feed one or more yarns to the hollow needles. For example, in embodiments, the yarn feeding mechanism may include a single-ended or double-ended yarn feeding mechanism having a plurality of individual yarn feeding devices that can be selectively controlled to feed one or two yarns, or in some embodiments, more than two yarns, to one or more associated needles. Furthermore, in some embodiments, the yarn feeding devices of the yarn feeding system may include a yarn feeding roll driven by a servo motor, which can be sized or otherwise configured to control the supply of a selected length of yarn per revolution of the yarn feeding roll to form individual stitches or tufts and / or tufts of a selected pile height. For example, in some embodiments, a yarn supply device may include one or more supply rollers, which may be configured with a larger diameter, to supply a specified amount of yarn per revolution and assist in supplying yarn such as polymer yarn or filament commonly used in artificial turf or turf, and a drive roll having a smaller diameter than the supply rollers to compensate for the potential decrease in torque for yarn supply due to the increasing size of the supply rollers.

[0012] In embodiments, the yarn selection system may be positioned along a yarn travel path or route from the yarn supply system to the needle. In embodiments, the yarn selection system may include a series of yarn jerkers, each coupled to an actuator and positioned along the yarn travel path from the yarn supply system to the needle to selectively engage the yarn being supplied to the needle. The yarn jerkers can be selectively controlled to extend and retract along a selected length or travel distance, which in embodiments can be set or adjusted to a selected distance. The yarn jerkers can be moved between an extended position and a retracted position to allow the selected yarn to be supplied to the needle, or to retract or hold unselected yarn from being supplied through the needle according to a forming pattern.

[0013] Furthermore, in embodiments, the yarn jerker may be coupled to or incorporated into a jerker module which may include or have an actuator for controlling the movement of the yarn jerker between an extended and retracted position. For example, in embodiments, the jerker module may include a plurality of bores, each receiving a piston rod, but other types of actuators may also be provided. In some exemplary embodiments, the jerker module (and / or its actuator) may comprise a double-acting air cylinder configured without mechanical spring return, which in embodiments may use air supplied to different portions of the bore of the jerker module (and / or its actuator) to cause selective movement of the piston along the bore to control the extension and retraction of the yarn jerker.

[0014] In some embodiments, the cutting system is positioned beneath a lining support and can be selectively operated to cut the yarn carried by the needle to form a yarn tuft within the lining material. In some embodiments, the cutting system may include a series of knives or one or more cutting blades. In some embodiments, the knives or one or more cutting blades may be mounted individually along a knife bar or received in a module that can be mounted along a knife bar.

[0015] In some embodiments, the knife or one or more cutting blades can be kept in a substantially stationary position, and the cutting edge of the knife or one or more cutting blades is positioned at a substantially fixed height or position relative to the lower part of the penetration depth or stroke of the needle as it penetrates the lining. In embodiments, the knife or one or more cutting blades can be moved up and down toward and away from the needle as the needle penetrates the lining, and the knife or one or more cutting blades can be moved separately or together between a retracted disengaged or non-cutting position and one or more extended cutting positions for engaging and cutting the yarn carried into the lining by the needle.

[0016] In some embodiments, the cutting system may comprise a plurality of individually controllable knife modules or blocks, each comprising a body to which a knife or at least one cutting blade is attached, and a multi-position actuator, for example, an air cylinder that can be selectively controlled or activated to move a corresponding or associated knife or at least one cutting blade between a non-cutting position and at least first and second cutting positions (e.g., a non-engaged position and one or more engaged positions) in relation to the stroke of a needle as the needle reciprocates within the lining.

[0017] In the embodiment, the knife may have a substantially flat cutting edge or surface suitable for cutting flat ribbon yarn or filament, such as that used for artificial turf or turf.

[0018] In other embodiments, the cutting system may comprise at least one elongated cutting blade or plate that can replace at least a portion of a series of knives. In embodiments, the at least one cutting blade may have an elongated, substantially flattened cutting edge. Furthermore, the at least one cutting blade or plate may be moved between an unengaged / non-cutting position and an engaged / cutting position to cut a series of yarns.

[0019] Furthermore, in embodiments, the cutting system may comprise one or more multi-position actuators. In embodiments, a controlled flow of pressurized air or other fluid may be supplied by a control system from an air source to the multi-position actuator to move a knife or at least one cutting blade between various selected cutting positions to form a cut pile tuft of a selected pile height, and to move it to an unengaged or non-cutting position to form a loop pile tuft. For example, in embodiments, the multi-position actuator may comprise a three-position actuator (such as a three-position pneumatic or hydraulic cylinder), a servo motor or a stepper motor, or other actuators. In embodiments, the multi-position actuator may comprise a four-way fluid valve for selectively controlling the supply of fluid (e.g., air) to the multi-position actuator. In embodiments, at least two positions may be provided for each of the knife or at least one cutting blade, for example, a high cutting position, a low cutting position, and a non-cutting or loop position.

[0020] In some embodiments, in addition to the knife or at least one cutting blade of the cutting system, other gauge components (e.g., loopers, hooks, level-cut looper loopers, clips, etc.) may also be provided.

[0021] In embodiments, the control system may be connected to the yarn feeding system, the yarn selection system, the cutting system, and other operating components of the tufting machine (e.g., the main shaft and / or one or more drive motors for it). The control system may be connected to one or more drive motors of the lining feeding system and an air supply source (which may comprise a compressor, blower, or tank in some exemplary embodiments) for controlling the flow of pressurized air to the jerker module of the yarn selection system and / or the actuator of the cutting system. In embodiments, the control system may comprise one or more processors and programming configured to coordinately control the supply of yarn to the hollow needle by the yarn feeding system, control the engagement of one or more yarn jerkers of the yarn selection system for pulling back unselected yarn, and / or control the movement of one or more knives or one or more cutting blades of the yarn cutting system for forming a selected pattern.

[0022] In embodiments, the control system may include instructions or programming that can be executed to coordinately control various operating systems or components of the tufting machine in order to form a pattern using an increased number of colors or types of yarn that can be formed without increasing the gauge spacing between needles. For example, in embodiments, without limitation, a patterned article containing 4, 8, 16, and possibly more colors of yarn can be formed with the hollow needles of the tufting machine positioned at a selected gauge spacing. For example, with a gauge spacing of about 1 inch, accompanied by a substantially constant supply of yarn to each needle. Other needle spacings may also be provided.

[0023] In some embodiments, the needles may be arranged at intervals that can be selected based on the tufting gauge of the tufted product. For example, in embodiments, the needles may be arranged at gauge intervals of approximately 1 / 4 inch to 1 inch, and in some embodiments, gauge intervals of approximately 1 / 4 inch, 3 / 8 inch, 1 / 2 inch, 5 / 8 inch, 3 / 4 inch, 7 / 8 inch, 1 inch, 1 1 / 4 inch, 1 3 / 8 inch, 1 1 / 2 inch, 1 5 / 8 inch, 1 3 / 4 inch, 1 7 / 8 inch, and / or 2 inch may be used. Thus, in embodiments, the needle bar may be configured such that the needles are arranged at true gauge intervals that generally match the gauge of the tufting machine, which may further match the desired or selected gauge of a commonly manufactured tufted product.

[0024] Furthermore, in some embodiments, by shifting the lining, shifting the needles, or both, it is intended to create other desired gauge fabrics based on multiples or fractions of the needle gauge spacing, enabling the presentation and tufting of various different colors at various gauge spacings. The needles may also be mounted at closer intervals. The lining, needles, or both may be shifted laterally as needed to form a selected pattern. For example, in some embodiments, the lining may be shifted laterally while the needles are not, and the needles are maintained in a substantially fixed lateral position as they reciprocate within the lining. Thus, patterns of structures can be produced having groups of tufts or yarns arranged at different intervals in the gauge direction (e.g., along the needle bars or laterally across the lining) and the longitudinal direction (e.g., in the direction in which the lining is supplied).

[0025] According to aspects of the present disclosure, a tufting machine is provided, which includes at least one needle bar with a plurality of needles spaced along its length, a yarn supply system including a pattern attachment (e.g., a single-end yarn supply mechanism), a needle bar shift mechanism (e.g., a servo motor or a rack and pinion drive shift mechanism) configured to control the shift of needles across the backing and connected to at least one needle bar, and an air induction yarn selection system in which a yarn supply path for the yarn is defined therein.

[0026] Further, or alternatively, a backing shift mechanism can be provided, which in various embodiments can be used in combination with the needle bar shift mechanism (controlled independently or separately from the needle bar shift mechanism), and / or can be used as an alternative to the needle bar shift mechanism.

[0027] In embodiments, the needles and / or the backing can be shifted, and the yarn supply system and the yarn selection system can be controlled to present a measured supply length of yarn per tuft in the backing per revolution of the main drive shaft. In embodiments, one yarn can be supplied to each needle for each individual yarn supply device of the yarn supply system. In embodiments, the yarn selection system can be disposed between the yarn supply system and the needles and can include a series of yarn jerkers. In embodiments, the yarn jerkers can be selectively controlled to retract or pull back the non-sewn ends of non-selected yarns (e.g., the extension and retraction of the yarn jerkers can be controlled by controlling the supply of pressurized air to the actuators associated with each yarn jerkers), enabling only the selected yarn (e.g., the desired color or type of yarn) to be supplied to the needles.

[0028] In an embodiment, the yarn supply system of the tufting machine can include a single or double end yarn supply mechanism, which in some embodiments is configured to supply yarn of a tuft length consumed by a turf or shag carpet, field, rug, or other tufted product having a pile height of a selected height, such as based on industry standards for artificial turf or turf fields. The expanded supply roll system may further be provided, which forms a pile height of more than 3 inches. Yarn or tuft lengths may be provided.

[0029] In an embodiment, the tufting machine is controlled by a control system that may include one or more processors and programming for controlling yarn supply, yarn jerker operation, backing supply roll, yarn supply puller roll, needle bar shift mechanism, and / or backing shifter.

[0030] According to another aspect of the present disclosure, a method of operating a tufting system to form a tufted turf or artificial product integrated with a logo or other design is provided. In an embodiment, the tufting system may include a hollow needle tufting machine having a plurality of spaced hollow needles through which a series of different colors or types of yarn may be threaded or the yarn may be directly supplied based on a desired thread up. For example, in an embodiment, if 3 to 4 colors are used in a pattern, the needles may have a yarn thread up sequence of ABC or ABCD, and at least two of the yarns are different colors or types of yarn (e.g., yarns A and B, C and / or D, or any combination thereof can be one color, while the other yarn or yarns of one thread up sequence can be a different color or type of yarn; or each of yarns A, B, C, and D can be a different color and / or type).

[0031] In some embodiments, such as forming a sports carpet like a sports turf field, more colors may be used. For example, in some applications, such as forming a sports turf field, six colors may be used, including at least one green yarn and one white yarn for the majority of the field, with the remaining yarns being accent colors for forming logos, etc.

[0032] In some embodiments, needles can be grouped into sets of needles, which may have different thread-up sequences. For example, in an embodiment, for a tufted turf product, for areas where primarily green yarn is tufted, there may be sets of needles having ABCD, ABCDE, ABCDEF, or other thread-up sequences, where multiple or all of the yarns in the thread-up sequence are one color (e.g., green), while for other areas where different colored or typeed yarns are tufted, another set of needles may have thread-up sequences with multiple different colored or typeed yarns.

[0033] In some embodiments, the needle bar shift mechanism can be controlled to shift the needle across the backing to displace color and / or type yarn as needed, resulting in the ability to present and mix different colors and / or types of yarn on the surface of the tufted product, which can enable enhanced color control in the finished carpet design. For example, in some embodiments, the needle can be shifted by one or more gauge steps or portions so that multiple colors and / or types of yarn can be presented at one or more stitch positions of the pattern being formed, and if a particular color or type of yarn is not desired on the surface, one or more yarn supply devices of the yarn supply system supplying such non-selected color or type of yarn can be controlled to stop supplying that color or type of yarn. Yarn jerkers corresponding to such non-selected yarns can be operated to hold the non-selected yarns together with their needles or to maintain them in another way.

[0034] In some embodiments, non-selective yarn can be pulled back from the backing along with the reciprocating motion of those needles and can be retained within the needles or within the yarn tube connected thereto to help maintain the non-selective yarn with those needles when the non-selective yarn is held down by the yarn jerker.

[0035] In an embodiment, when yarn is selected and held to form a pattern tuft or stitch, the yarn supply system can be controlled to supply a desired length or amount of each selected yarn to form a tuft or stitch of a desired length or pile height, while the yarn jerker is moved to a position that allows enough length of each selected yarn to form a tuft of a selected pile height to be blown and / or flow through the associated needle. In an embodiment, the yarn supply roller of the yarn supply device of the yarn supply system controlling the supply of such selected yarn may be configured with a diameter / size configured to supply a desired or selected amount or length of yarn per revolution that is substantially enough to form a tuft of a given length to form a tuft or stitch of a desired or selected pile height. In the embodiment, as the needle reciprocates within the lining, the selected yarn exits the yarn tube and is guided into the associated needle passage, thereby presenting / inserting the selected yarn into the lining and enabling it to engage with corresponding gauge components (e.g., engaged and cut by a knife or cutting blade, or engaged by other gauge components such as loopers, hooks, level-cut loop loopers, clips, etc.) to form a stitch or tuft within the lining.

[0036] In some embodiments, the lining can be moved in stages, while in other embodiments, the lining can be supplied substantially continuously through the tufting zone or region. In some embodiments, the lining can be shifted so as to roughly align the stitch positions of the pattern being tufted with the yarn of the selected color being carried by the needle, such as when the lining is shifted laterally while the needle is maintained in a substantially fixed position. The lining can be shifted laterally in various increments or steps, which may include shifting the lining by a distance based on the gauge spacing of the needles, although in some embodiments it may not be bound by the gauge spacing of the needles (for example, the lining can be shifted over a distance or length smaller or larger than the gauge spacing between the needles). The lining can be shifted multiple times in both directions across the tufting zone so as to present the yarn of the selected color at the corresponding stitch positions of the pattern, and can be moved along its path of movement according to the pattern steps.

[0037] In embodiments, the supply of the lining can be controlled so that the actual stitch rate at which the lining is supplied constitutes an effective process stitch rate greater than the desired pattern stitch rate of the pattern being formed. In embodiments, the control of the yarn supply by the yarn supply system and the yarn selection system can be controlled by the control system in conjunction with the control of the lining material at a higher effective or actual stitch rate to allow for a substantially increased number of needle penetrations per inch into the lining material (for example, each needle in the threading sequence can be inserted at each stitch position in the pattern). Unselected colors or types of yarn are not placed in the lining, and selected colors or types of yarn can be placed in the lining to form the desired tuft in order to substantially avoid the appearance of missing colors or types of yarn or gaps in the pattern field of the patterned tufted product, or appearing in other ways. Therefore, the finished patterned tufted product can provide a tuft count per inch that substantially matches the desired or specified pattern stitch rate or other stitch count per inch, and as a result, the resulting finished patterned tufted product can be formed with a visible and / or retained surface yarn or tuft density that can roughly match the desired density of the pattern.

[0038] In certain scenarios, the ends of the needle may be configured with flattened and / or extended cut surfaces configured to better cut flat ribbon yarn. For example, in embodiments, the distal end of the needle may be formed with a modified cutting angle and an extended cut surface configured to increase the shear angle and shear surface of the needle for more consistent cutting of flat ribbon yarn used in typical artificial turf applications. Furthermore, in embodiments, the cutting system may include a series of generally flat knives, or in some embodiments, one or more cutting blades may be used instead of a series of knives.

[0039] In embodiments, the knife or cutting blade may be movable between various cutting positions, including a first retracted position and at least a second extended cutting position where the cutting edge of the knife or cutting blade contacts the cutting surface of the needle when the needle penetrates the backing. In embodiments, the knife or cutting blade may be arranged in a module that can be mounted in series along a knife bar and can be moved by a control system to their cutting positions as a set, in groups, or individually as selected yarns are presented at each stitch position. The knife or cutting blade may be kept in a lowered, disengaged or non-cutting position when the needle of a non-selected yarn penetrates the backing at such a stitch position.

[0040] In some embodiments, the knife or cutting blade can be mounted in a position substantially fixed with respect to the stroke or penetration depth of the needle into the lining. In embodiments, the knife or cutting blade can be positioned to engage with the associated or corresponding needle. In embodiments, as the needle penetrates the lining, the cut surface of the needle can engage with the cutting edge of the knife.

[0041] Furthermore, in embodiments, the supply of yarn from the yarn supply system and the operation of the yarn jerker can be controlled by a control system to operate according to the position or sequence of rotation of the main shaft. In embodiments, the position or sequence of rotation of the main shaft can be associated with stitches or tufts of a pattern formed to operate the yarn jerker in first and second directions, for example, between a retraction position and an extension position. For example, in some embodiments, different stitch lengths or yarn amounts constituting the total stitch length of each selected yarn supplied to form a tuft or stitch of a desired pile height can be supplied at increasing or decreasing rates between different parts of the tufting cycle or at different times based on the rotation or position of the main shaft (for example, in embodiments, the yarn supply device of the yarn supply system can be operated to supply different percentages or amounts of yarn in light of where the main shaft is in its rotation, as opposed to supplying a substantially constant amount of yarn during one rotation of the main drive shaft). In embodiments, such control of the supply of different amounts or lengths of yarn between different parts of the rotation of the main shaft can enable enhanced color control in the finished pattern / design.

[0042] Various aspects of the present disclosure may include a tufting machine for forming artificial turf or turf products having a patterned design, the tufting machine comprising: a needle bar having a plurality of needles arranged therein, wherein the needles include hollow needles; a yarn supply system configured to supply a plurality of yarns to the needles, the yarn supply system being moved in a reciprocating motion toward and away from a backing that moves along a travel path through the tufting machine to introduce selected yarns into the backing as the needles penetrate the backing to form a tuft; at least one shifting mechanism for shifting at least a portion of the needles or for shifting the backing laterally relative to the backing's travel path; and a yarn selection system positioned along a yarn travel path between the yarn supply system and the needles, configured to pull back and / or hold back non-selected yarns supplied to one or more needles by the yarn supply system.

[0043] In an embodiment, the tufting machine may further include a cutting system comprising at least one knife or cutting blade positioned below the lining and configured to cut the selected yarn as it is transported into the lining along with the reciprocating motion of the needle into the lining.

[0044] In embodiments, the tufting machine may further include a control system configured to control the operation of a yarn supply system for supplying to the needles a length of each selected yarn sufficient to form a tuft of a predetermined pile height, the operation of a yarn selection system, and the operation of at least one shift mechanism to enable the presentation of different colors or types of yarn to each of a plurality of stitch positions in the pattern being formed.

[0045] In embodiments of a tufting machine, the yarn selection system further comprises a plurality of yarn jerkers adapted to engage with yarn supplied to a needle, and a plurality of actuators each connected to at least one yarn jerker and adapted to move the yarn jerker between their extended and retracted positions; each yarn jerker is movable between an extended position that allows selected yarn to pass from the yarn supply system through the needle and a retracted position that retracts and / or holds non-selected yarn supplied by the yarn supply system into one or more needles.

[0046] In embodiments of a tufting machine, the control system includes programming configured to dynamically advance the operation of the yarn supply system and the yarn jerker or yarn selection system prior to the next stitch placement step of the pattern being formed.

[0047] In embodiments of a tufting machine, at least one needle bar may have a series of openings spaced apart along it and communicating with passages extending through the corresponding needles; the yarn is guided into the needle passages through the openings of at least one needle bar.

[0048] In some embodiments of the tufting machine, the needles are arranged along at least one needle bar at gauge intervals selected based on the gauge of the tufting machine's artificial turf or turf product.

[0049] In some embodiments, the tufting machine may further include a series of yarn tubes mounted along the upper surface of at least one needle bar, each communicating with a corresponding needle positioned along at least one needle bar, and an air-guided yarn feeder connected to an air supply unit and configured to guide airflow through the yarn tubes to assist in feeding the yarn through them. In other embodiments, yarn tubes may not be used.

[0050] In an embodiment of the tufting machine, the shift mechanism includes a rack and pinion shift mechanism.

[0051] In embodiments of the tufting machine, at least one knife or cutting blade has a substantially flat cutting surface or cutting edge.

[0052] In embodiments of the tufting machine, each needle comprises a body with a defined internal passage, a first end that is received within a needle bar, and a second end having a flattened cut surface that is terminated at the tip and configured to cut flat ribbon yarn or filament.

[0053] In an embodiment of a tufting machine, as the needle moves back and forth in and out of the lining, the feeding of selected and unselected yarns is controlled by a yarn feeding system, and a yarn jerker moves between a retracted position and an extended position to allow the insertion of selected yarn into the lining to form loop pile or cut pile tufts of the selected yarn according to the pattern to be tufted.

[0054] In another embodiment, the tufting machine includes a plurality of needles configured to penetrate the lining; a yarn feeding system configured to selectively feed a plurality of yarns to the needles; a yarn selection system having a plurality of yarn jerkers adapted to be movable between an extended position that allows the selected yarns to pass from the yarn feeding system to the needles and a retracted position that pulls back and / or holds the unselected yarns supplied to one or more needles by the yarn feeding system; and a mechanism for shifting the needles across the lining or shifting the lining relative to the needles. The system comprises at least one shift mechanism, the needles being hollow needles, each having a first end and a second end, with a passage defined between the first end and the second end through which one or more yarns are fed, the feeding of selected and unselected yarns is controlled by the yarn feeding system as the needles reciprocate in and out of the lining, the yarn jerker moves between a retracted position and an extended position to allow the insertion of selected yarns into the lining to form loop pile or cut pile tufts of selected yarns according to the pattern to be tufted.

[0055] In an embodiment, the tufting machine may further include a cutting system comprising at least one knife or cutting blade configured to cut selected yarn to form a yarn tuft on the backing.

[0056] In an embodiment, the tufting machine may further include a control system having programming configured to control the operation of a yarn feeding system for feeding selected yarn to a needle, and programming configured to dynamically advance the yarn feeding by the yarn feeding system and the movement of the yarn jerk between an extended position and a retracted position prior to the next stitch placement step of the pattern being formed.

[0057] In an embodiment, the tufting machine may further comprise at least one needle bar to which needles are attached, and the needles are arranged along the at least one needle bar at gauge intervals selected based on the gauge of the artificial turf or turf product manufactured by the tufting machine.

[0058] In one embodiment, the tufting machine may further include an air supply unit and an air-guided yarn feeder coupled to the air supply unit for guiding the yarn through a needle.

[0059] In embodiments of a tufting machine, at least one shift mechanism may include a rack and pinion shift mechanism.

[0060] In an embodiment of the tufting machine, the second end of each needle includes a tip and has an opening through which one or more yarns exit the needle, and a flattened cut surface configured to cut flat ribbon yarn or filament.

[0061] In embodiments of the tufting machine, the tufting machine is configured to produce panels of tufted turf or artificial grass products having an integrated design (e.g., a logo), or including part of a larger design, which can be attached to one another to form a sports carpet or artificial grass or turf field.

[0062] In another embodiment, a method is provided comprising: moving a lining along a path; feeding a plurality of yarns from a plurality of yarn feeders to each of a plurality of needles along the path; causing the needles to reciprocate in and out of the lining; shifting the lining or the needles transversely with respect to the movement of the lining's path; selectively controlling the yarn feeders to substantially stop or slow down the feeding of unselected yarns to the needles; activating one or more yarn jerkers to engage with, hold, or pull back unselected yarns so that the unselected yarns are substantially held in the needles; selectively controlling the yarn feeders and yarn jerkers when the movement of the lining along its path is controlled to allow the presentation of different yarns at each of a plurality of stitch positions; and forming a plurality of tufts of selected yarns in the lining, wherein the yarns are artificial turf or turf yarns having one or more colors such that a design, accent feature, logo, or one or more of these is integrated therein.

[0063] In one embodiment, shifting the lining or shifting the needles involves shifting the lining support over which the lining moves.

[0064] In an embodiment, the method may involve moving at least one cutting blade to engage with the cut surface of each needle as the needle penetrates the lining, thereby cutting the selected yarn and forming a tuft of the selected yarn in the lining.

[0065] In another embodiment, a tufted artificial turf or turf product can be provided, comprising a backing and a plurality of spaced tufts of artificial turf or turf yarn formed on the backing to define a patterned area or a pattern to be formed along the backing, wherein the artificial turf or turf yarn comprises a plurality of different colors, and only selected colors of the artificial turf or turf yarn shown at each stitch position of the pattern to be formed are presented for cutting and held on the backing, and the artificial turf or turf yarn is arranged in a thread-up sequence having at least two different colors of artificial turf or turf yarn and two of the same color.

[0066] Accordingly, embodiments of tufting machines or systems and methods for forming patterned tufted products (such as carpets, rugs, artificial turf or turf, and / or other tufted products) having patterned designs (e.g., logos, pictures, fields of various colors, and combinations thereof) directed toward the needs discussed above and other needs are disclosed. The aforementioned and other advantages and aspects of embodiments of this disclosure will become apparent and more readily understood from the following detailed description in conjunction with the accompanying drawings. Furthermore, it should be understood that both the above summary of the disclosure and the following description are illustrative and intended to provide further explanation without limiting the scope of this disclosure. [Brief explanation of the drawing]

[0067] The accompanying drawings are included to provide a further understanding of the embodiments of the present disclosure, are incorporated into this specification and constitute part thereof, illustrating embodiments of the present disclosure and serving to illustrate the principles of the embodiments discussed herein, together with the detailed descriptions. There is no intention to provide more detail in the structural details of the present disclosure than is necessary for a basic understanding of the exemplary embodiments discussed herein and the various ways in which they may be carried out. [Figure 1A] This is a perspective view of an embodiment of a tufting system or apparatus based on the principles of the present disclosure. [Figure 1B]This is a perspective view of an embodiment of a tufting system or apparatus based on the principles of the present disclosure. [Figure 1C] This is a perspective view of a portion of the tufting zone of an embodiment of a tufting system or device that schematically illustrates the use of a lining shift mechanism according to the principles of the present disclosure. [Figure 2A] Embodiments of a tufting system or apparatus based on the principles of this disclosure are shown, specifically regarding the tufting zone or region. [Figure 2B] Embodiments of a tufting system or apparatus based on the principles of this disclosure are shown, specifically regarding the tufting zone or region. [Figure 2C] Embodiments of a tufting system or apparatus based on the principles of this disclosure are shown, specifically regarding the tufting zone or region. [Figure 2D] Embodiments of a tufting system or apparatus based on the principles of this disclosure are shown, specifically regarding the tufting zone or region. [Figure 2E] Embodiments of a tufting system or apparatus based on the principles of this disclosure are shown, specifically regarding the tufting zone or region. [Figure 2F] Embodiments of a tufting system or apparatus based on the principles of this disclosure are shown, specifically regarding the tufting zone or region. [Figure 2G] Embodiments of a tufting system or apparatus based on the principles of this disclosure are shown, specifically regarding the tufting zone or region. [Figure 2H] Embodiments of a tufting system or apparatus based on the principles of this disclosure are shown, specifically regarding the tufting zone or region. [Figure 3A] This disclosure illustrates an embodiment of a hollow needle in a tufting system or apparatus based on the principles of this disclosure. [Figure 3B] This disclosure illustrates an embodiment of a hollow needle in a tufting system or apparatus based on the principles of this disclosure. [Figure 3C] This is a schematic perspective view showing a needle stroke support assembly of a tufting system or device according to the principles of this disclosure. [Figure 3D] Figure 3C is a cross-sectional view of the needle stroke assembly. [Figure 3E] Figures 3C-3D are exploded perspective views of the needle stroke assembly. [Figure 4A] Embodiments of a yarn feeding system for a tufting system or apparatus based on the principles of this disclosure are shown. [Figure 4B] Embodiments of a yarn feeding system for a tufting system or apparatus based on the principles of this disclosure are shown. [Figure 4C] Embodiments of a yarn feeding system for a tufting system or apparatus based on the principles of this disclosure are shown. [Figure 4D] Embodiments of a yarn feeding system for a tufting system or apparatus based on the principles of this disclosure are shown. [Figure 5A] Embodiments of a yarn selection system for a tufting system or apparatus based on the principles of this disclosure are shown. [Figure 5B] Embodiments of a yarn selection system for a tufting system or apparatus based on the principles of this disclosure are shown. [Figure 5C] Embodiments of a yarn selection system for a tufting system or apparatus based on the principles of this disclosure are shown. [Figure 6A] Embodiments of a cutting system for a tufting system or apparatus based on the principles of this disclosure are shown. [Figure 6B] Embodiments of a cutting system for a tufting system or apparatus based on the principles of this disclosure are shown. [Figure 6C] This is an exploded perspective view of a cutting system comprising individually operable knives for a tufting system or apparatus according to the principles of the present disclosure. [Figure 7A] Embodiments of a knife module for a cutting system, tufting system, or apparatus based on the principles of this disclosure are shown. [Figure 7B] Embodiments of a knife module for a cutting system, tufting system, or apparatus based on the principles of this disclosure are shown. [Figure 7C] Embodiments of a knife module for a cutting system, tufting system, or apparatus based on the principles of this disclosure are shown. [Figure 8A] Examples of multicolor tufted fabrics and backstitches formed by a tufting system or apparatus and method according to the principles of this disclosure are shown. [Figure 8B] Examples of multicolor tufted fabrics and backstitches formed by a tufting system or apparatus and method according to the principles of this disclosure are shown. [Figure 8C] Examples of multicolor tufted fabrics and backstitches formed by a tufting system or apparatus and method according to the principles of this disclosure are shown. [Figure 9A] This disclosure presents an example of a sports carpet, particularly illustrating an exemplary embodiment of a tufted turf or artificial turf field and its backstitch, in which multiple colors and designs are integrally formed as part of the tufted turf or artificial turf field using a tufting system or apparatus and method according to the principles of this disclosure. [Figure 9B] This disclosure presents an example of a sports carpet, particularly illustrating an exemplary embodiment of a tufted turf or artificial turf field and its backstitch, in which multiple colors and designs are integrally formed as part of the tufted turf or artificial turf field using a tufting system or apparatus and method according to the principles of this disclosure. [Figure 10A] Examples of multicolor tufted fabrics and their backstitches are shown, particularly an example of a sports carpet using flat yarn and / or filament formed by a tufting system or apparatus and tufting method according to the principles of this disclosure. [Figure 10B] Examples of multicolor tufted fabrics and their backstitches are shown, particularly an example of a sports carpet using flat yarn and / or filament formed by a tufting system or apparatus and tufting method according to the principles of this disclosure. [Figure 11A]Examples of multicolored tufted fabrics and their backstitches are shown, particularly examples of shag-style carpets or rugs formed by tufting systems or apparatus and tufting methods according to the principles of this disclosure. [Figure 11B] Examples of multicolored tufted fabrics and their backstitches are shown, particularly examples of shag-style carpets or rugs formed by tufting systems or apparatus and tufting methods according to the principles of this disclosure. [Figure 12] Examples of multi-color tufted artificial turf or grass products having a seamless design formed by a tufting system or apparatus and a tufting method according to the principles of this disclosure are shown. [Modes for carrying out the invention]

[0068] This disclosure can be more readily understood by referring to the following detailed description, examples, drawings, and claims, as well as the descriptions before and after them. However, it should be understood that this disclosure is not limited to any particular apparatus, system, and / or method disclosed unless otherwise specified, and is therefore subject to change. Furthermore, it should be understood that, unless otherwise defined, all technical and scientific terms used herein have the same meaning as generally understood by those skilled in the art to which this disclosure belongs, and that the terms used herein are solely for the purpose of describing, and not intended to limit, any particular aspect of the systems, features, elements, methods, and embodiments discussed herein. Accordingly, the following description is provided to illustrate, and not to limit, the principles of this disclosure.

[0069] For example, and used throughout, the singular forms “a,” “an,” and “the” refer to multiple objects unless the context clearly indicates otherwise. Thus, for example, a reference to “processor” can refer to two or more such processors unless the context indicates otherwise. The terms “or” and “and / or” as used herein should be interpreted as inclusive or as meaning either one or any combination thereof.

[0070] Furthermore, as used herein, the terms “includes,” “contains,” “have,” “possess,” or other variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, article, or apparatus that includes a list of features is not necessarily limited to those features alone, and may include other features not expressly listed or that are inherent to such process, method, article, or apparatus. Moreover, unless expressly stated otherwise, “or” refers to an inclusive OR and not an exclusive condition.

[0071] Spatially relative terms such as “downward,” “below,” “low,” “upward,” and “up” may be used herein to facilitate explanation in order to describe the relationship between one element or feature and another, as shown in the figures. It will be understood that spatially relative terms are intended to encompass different orientations of a device, system, or component in use or operation, in addition to the orientation shown in the figures.

[0072] The dimensional information in the following description should be understood to include dimensional variations that normally occur in manufacturing, and terms such as “approximately,” “about,” and “substantially” may be used to modify the dimensional information in the following description. It will be recognized that some variations in dimensions provided with respect to various features may occur without affecting their function or usability. Ranges may further be expressed herein as from one particular value “about” and / or to another particular value “about.” Where such ranges are expressed, the alternative aspects include from one particular value and / or to the other particular value. Similarly, when a value is expressed as an approximation using the antecedent “about,” it will be understood that the particular value forms an alternative aspect.

[0073] As used herein, the terms “tuft” and “stitch” encompass both cut pile tufts or stitches and loop pile tufts or stitches of yarn, and the term “tufting” encompasses both the act of forming cut yarn or cut pile stitches or tufts of yarn and the act of forming loops or loop pile stitches or tufts of yarn.

[0074] As used herein, the term “yarn” encompasses yarns, threads, filaments, fibers, and / or combinations thereof used to form tufted products, which may include, but are not limited to, carpets (e.g., cut pile, loop pile, cut-and-loop pile, shag, etc.), rugs, artificial turf or wood, and other similar tufted products. For example, but not limited to, such yarns may include yarns of natural fibers such as cotton, wool, or other similar fibers, as well as synthetic fibers or filaments such as nylon, polypropylene, acrylic, and / or other polymer materials, or combinations thereof. They may also include two or more yarns supplied to each needle. For example, in the manufacture of sports carpets such as artificial turf or wood, the yarn may include a combination of at least one filament (e.g., polymer monofilament) and a ribbon yarn having a flat structure.

[0075] Referring to the drawings, similar figures indicate similar parts throughout several figures, and Figures 1 to 6D show exemplary embodiments of a tufting system or apparatus configured according to the principles of the present disclosure, and various operating components and / or features thereof. Figures 8A to 12 show examples of tufted products manufactured using the tufting system or apparatus and methods of the present disclosure, and examples of the backstitch thereof. In various embodiments, such tufted products may include carpets and rugs (e.g., shag carpets and loop or cut pile tufted carpets or rugs of selected pile height), sports carpets including but not limited to artificial turf or grass (grass, turf) for fields and / or various landscaping applications, and other types of tufted products.

[0076] In some embodiments, as shown in Figures 1A-2H, the tufting system or apparatus may comprise a tufting machine 10 that can include a plurality of needles 12 that can be mounted in series along a needle bar 11. In embodiments, the plurality of needles may comprise hollow needles. The tufting machine 10 (Figures 1A-1B) may further include other operating components such as a needle bar drive assembly or system 20, a lining supply system 25, a yarn supply system 60, a yarn selection system 70, and a cutting system 80, as well as a control system 15 for controlling their operation. In embodiments, the needles 12 may comprise hollow needles configured to penetrate the lining material B and deliver and / or implant a series of yarns Y supplied through each needle into the lining B as the lining B moves along a travel path P (Figures 1A-1B) through the tufting machine 10, thereby forming a plurality of stitches or yarn tufts within it. Furthermore, in embodiments, the tufting machine may include or be connected to an air supply source, such as a compressor or blower, which supplies pressurized air to blow yarn into and through the needle, and in embodiments, may also be used to drive other components of the tufting machine.

[0077] In some embodiments, the tufting machine 10 can supply a series of different colors and / or types of yarn to each needle, which can then be selectively implanted or tufted into a backing material to form a tufted patterned article. In some embodiments, the yarn tufts may generally consist of cut pile tufts (however, in other embodiments, loop pile tufts may also be formed). In some embodiments, the tufts may be formed with different or varying pile heights to provide texturing or other patterning effects. In some embodiments, different colors and / or types of yarn can be selectively presented by the needles to one or more of a plurality of stitch positions in a pattern being tufted to form a tufted article such as carpets, rugs, artificial turf or grass, and other tufted products having a tufted pattern design.

[0078] In embodiments, such tufted products can be formed with a selected design (e.g., a logo or part of a logo, text, markings, or other designs), which in embodiments may include, but are not limited to, fields or portions of a designed pattern having different colors or types of yarn, texturing, and / or other pattern effects. Such a selected design can be integrated as part of the tufted product during tufting without the need to separately form the design from the rest of the field and then attach the design to the field (e.g., cutting and sewing separately created designs onto a tufted turf field).

[0079] For illustrative purposes only, exemplary embodiments of the systems and methods of this disclosure are shown and discussed with respect to the formation of tufted products such as sports carpets, which in embodiments include patterned artificial turf or turf products, which include patterned designs such as text, logos, images, fields of various colors, and combinations thereof, which can be manufactured within a tufting zone or space defined by a tufting machine frame. Furthermore, in the embodiments illustrated and discussed herein, yarn is shown as artificial turf filaments, which can generally be formed from polymer or plastic materials and may have a substantially flat structure that can mimic the appearance and feel of grass or turf after installation. However, it will be understood by those skilled in the art that other types of yarn can also be used.

[0080] For example, in embodiments such as those shown in Figures 9A and 12, such tufted products can be formed as panels with integrated patterns or designs and assembled together as part of a larger tufted product. Examples include forming sections or strips of artificial turf or turf for a sports field using base-colored grass filaments or yarn (usually green, but other colors can also be used), and including additional colored yarns for designs or parts of designs such as team or sponsor logos, hashes or yard markings, or sideline markers. The panels can be easily matched and joined together (joined together at seams) to form a finished tufted installation with integrated design or pattern features.

[0081] For example, the patterned tufted artificial turf or grass product shown in Figure 12 can be formed in a much larger section or field, by utilizing a large / full-size tufting machine configured and operated to perform embodiments of the method for forming tufted products according to the principles of this disclosure, thereby incorporating substantially entire multi-color pattern designs, such as an eagle and flag design shown incorporated within a green artificial turf or grass field. Thus, substantially pattern designs can be tufted within an artificial turf or grass field or a section thereof, where the transition between the design and the rest of the artificial turf or grass field is substantially seamless, eliminating the need to form the design separately, then cut the turf field, and sew the design onto the field to create a finished patterned artificial turf or grass field.

[0082] It will also be understood that other tufted products, including carpets and rugs, can be formed using the tufting systems or apparatus and methods of this disclosure. For example, shag carpets or other types of carpets or rugs with increased pile height can be formed with various designs, images, logos, etc., including multiple colors or types of yarn.

[0083] In embodiments such as those shown in Figures 2A-2C, 2E, and 3A, the needles 12 can be mounted along the needle bar 11 in an inline arrangement with the needles positioned at desired or selected intervals (e.g., intervals from about 1 / 2 inch to about 1 inch or other intervals). In some embodiments, the needles can be positioned according to desired gauges or intervals (e.g., in some embodiments, gauge intervals of about 3 / 8 inch or more), including various half-gauges or other intervals. Furthermore, in other embodiments, the needles can be positioned in other configurations, such as staggered along one or two needle bars. While a single needle bar is illustrated in some embodiments where the needles can generally be positioned inline along the needle bar, this disclosure is not limited to tufting machines having only one needle bar or needle arrangements including only a single inline row of needles.

[0084] In embodiments, the needles can be arranged at intervals that can be selected based on the tufting gauge of the tufted product. For example, in embodiments, the needles can be arranged at gauge intervals that match the selected gauge of the tufting machine. For example, to produce a tufted product having a desired or selected 3 / 8-inch gauge, the needles can be arranged at gauge intervals of approximately 3 / 8 inches; for a tufted product having a desired or selected 1 / 2-inch gauge, the needles can be arranged at gauge intervals of approximately 1 / 2 inches; for a tufted product having a desired or selected 3 / 4-inch gauge, the needles can be arranged at gauge intervals of approximately 3 / 4 inches; and for a tufted product having a desired or selected 1-inch gauge, the needles can be arranged at gauge intervals of approximately 1 inch. In other embodiments, gauge spacings of approximately 1 / 4 inch, 3 / 8 inch, 1 / 2 inch, 5 / 8 inch, 3 / 4 inch, 7 / 8 inch, 1 inch, 1 1 / 4 inch, 1 3 / 8 inch, 1 1 / 2 inch, 1 5 / 8 inch, 1 3 / 4 inch, 1 7 / 8 inch, and / or 2 inches can be used. Thus, in embodiments, the needle bar can be configured such that the needles are positioned at substantially true gauge spacings that roughly match the desired or selected gauge of the tufting machine.

[0085] As shown in Figures 1A and 1B, in the embodiment, the tufting machine 10 generally includes a frame 16 having an upper part 17A and a lower part 17B, a tufting zone or region T defined therein, and a lining material support or shuttle 18 over which the lining material B can move and be positioned along the tufting zone. The tufting machine 10 further includes a main drive shaft 19 (Figure 1A) positioned along the frame 16 and typically extending laterally thereto. In the embodiment, the main drive shaft 19 can be coupled to a needle bar drive assembly or system 20 for driving the reciprocating motion (up and down motion) of needles 12 mounted along it, causing the needles 12 to penetrate and withdraw into the lining material B as the lining material passes through the tufting zone or region, thereby inserting a yarn tuft into the lining material.

[0086] In the embodiment, the main drive shaft 19 is operably connected to both ends of the main drive shaft and can be driven by one or more electric motors M mounted on both ends of the frame of the tufting machine to drive the rotation of the main drive shaft. One or more motors can be controlled by the control system 15 of the tufting machine, and the rotational speed and position of the main drive shaft are monitored by the control system 15 by sensors such as encoders. During operation, each rotation of the main drive shaft can cause the needle to penetrate the backing material and then withdraw it from the backing material. In other words, each rotation of the main drive shaft can cause one needle reciprocating cycle, also called a tufting cycle, which includes a downward stroke and an upward stroke of the needle. In the embodiment, the control of various operating systems or components can further be associated with the rotation or position of the main drive shaft.

[0087] As shown in Figures 2C and 2G, in embodiments, at least one presser foot 22 may be provided along the tufting zone adjacent to the needle. The presser foot may include a substantially flat plate 23, which in embodiments may have a ridged or wavy configuration along its front edge 24, with a plurality of recesses 21 defined along it, as shown in Figures 2C, 2D, 2G, and 3A-3B. As the needle 12 reciprocates to penetrate and withdraw from the lining material B, the needle can be received within the recesses 21 and guided through and through the lining material along a substantially linear path of movement. In embodiments, the recesses 21 may be configured to have open ends to help orient or guide the needle through them as it shifts and reciprocates.

[0088] In other embodiments, the retaining foot 22 may have a substantially straight or flat front edge 24 (for example, without recesses or ridges along it). The needle 12 can reciprocate to penetrate and withdraw from the lining material without needing to be received in a recess 21.

[0089] As shown in Figures 1A and 1B, the lining material B can be advanced longitudinally by the lining material feeding system 25, past needles that reciprocate along its travel path or feeding direction P. In embodiments, the lining material feeding system 25 may include a spike roll and a feed roller 26 that can be driven by a motor 27 (e.g., a servo motor or stepper motor, or other drive device). Furthermore, in some embodiments, the lining material feeding system may also include a gear reducer coupled to the lining material feed roll to help control its rotation, and thus the feeding of the lining material B along its travel path P. The lining material feeding system 25 can generally be controlled (e.g., by a control system 100), and in embodiments, a lining material feeding controller may be provided, programmed and configured to feed the lining material B (Figure 2A) under tension below the needles 12 through the tufting zone T of the tufting machine 10.

[0090] Alternatively, in the embodiment, the lining material feed roll can be driven from the main drive shaft, for example by using a timing belt or other linkage connecting the lining material feed roll to the main drive shaft and / or its motor, thereby substantially directly driving the lining material feed roll with the operation of the main drive shaft.

[0091] The lining material feeding system 25 can be controlled to move the lining material B in a controlled motion, for example, in an embodiment, in a stepping motion. As the needle 12 reciprocates to penetrate and withdraw from the lining material, a series of yarns Y can be positioned or inserted into the lining material by the needle to form a yarn tuft therein. Optionally, the lining material can be fed substantially continuously through the tufting zone.

[0092] In embodiments, a needle bar drive assembly or system 20 for reciprocating a needle 12 may include a series of bearing assemblies 31 and a series of push rods 32 coupled to the main drive shaft 19 so as the main drive shaft 19 is rotated by the operation of one or more drive motors, the push rods 32 are driven in a substantially up-and-down motion or cycle that reciprocates in a first or vertical direction as indicated by arrows 33 / 33′. As further shown in Figures 2B, 2G, and 3C, in embodiments, the needle bar 11 may be coupled or connected to each of the series of push rods 32 by push rod feet 32A, thereby transporting or moving the needle bar in a vertical reciprocating motion or cycle as the push rods 32 move due to the operation of the main drive shaft 19 of the tufting machine 10. Furthermore, as shown in Figure 3D, the push rods may be connected to the push rod feet by bearing assemblies 30. As a result, the needles 12 mounted along the needle bar 11 are transported in a reciprocating motion or stroke that penetrates and withdraws from the lining material B between an upward or top position and a downward or bottom position that penetrates the lining material B.

[0093] In some embodiments, the needle bar 11 can reciprocate along its stroke while remaining generally fixed to lateral movement, allowing the needles 12 to penetrate and withdraw from the lining material B. For example, in some applications, the needles can be spaced at intervals based on the gauge of the tufting machine, and in some embodiments, the lateral position of the needles is substantially fixed to the movement of the tufted product and the lining material B along its movement path P. The lining material B can be shifted under the needles as the needles reciprocate and maintain their lateral position to form a patterned tufted fabric.

[0094] As further shown in Figures 2B-2E, 2G, and 3C, in other embodiments, the needle bar 11 can generally be slidably coupled or connected to the push rod 32 of the needle bar drive assembly or system 20, such as by a series of sliding brackets 34 of the bearing assembly 31. In embodiments, the needle bar 11 can be coupled to the guide rail 36 by a bracket or linkage 36A, which can be slidably received within a bracket 34, which may be formed together with or as part of the push rod feet 32A (Figure 2H) to which the ends of the push rods are attached. The guide rail 36 can guide the lateral or lateral shift movement of the needle bar 11, as indicated by arrows 37 and 37' (Figure 2E), when the needle is shifted or moved laterally across the lining material B under the control of the shift mechanism.

[0095] In one exemplary embodiment, the needle bar 11 may be mounted to engage with or slidably supported by a series of linear bearing assemblies, which may include a series of linear bearings, on the push rod 32 of the needle bar drive assembly or system 20. Thus, the needle 12 can reciprocate perpendicularly in a first direction, as indicated by arrows 33 / 33', to penetrate and withdraw from the lining material B. In addition to shifting the lining material B, the needle 12 can be shifted laterally, as indicated by arrows 37 and 37'.

[0096] Furthermore, in embodiments such as that shown in Figure 3C, a series of needle stroke support assemblies 90 can be provided to support the push rod 32 during its vertical reciprocating motion in each needle stroke. Although an embodiment showing one needle stroke assembly 90 with one push rod 32 is illustrated, it will be understood that tufting machines generally use multiple push rods and needle stroke assemblies, and furthermore, needle stroke assemblies can be used in various types of tufting machines and are not limited to machines having only hollow needles.

[0097] In some embodiments, as shown in Figures 3C to 3E, each needle stroke support assembly 90 may include one or more upper support plates 91a and struts or lower support plates 91b that can be attached to a portion of the tufting machine frame. For example, in some embodiments, the upper support plate 91a may include a substantially flat plate that can be positioned along the tufting zone along the head of the tufting machine or along the lower portion of the upper frame, and the lower support plate 91b may be attached to the lower surface of the upper support plate 91a, as shown in Figures 3D to 3E, and function as a support or brace for the needle stroke support assembly.

[0098] In the embodiment, the upper support plate 91a may further include an opening 92 into which the push rod 32 is received. In the illustrated embodiment, the push rod 32 is received in a bearing assembly 30 which can be mounted in the opening 92 of the upper support plate, thereby securing the push rod within the upper support plate and helping to support the push rod during its linear vertical reciprocating motion during each needle stroke. In the embodiment, the bearing assembly 30 may include one or two sections, for example, as shown in Figure 3D, which include an upper section positioned on the upper surface of the upper support plate and a lower section along the lower surface of the upper support plate, and these can be mounted together.

[0099] As shown in Figures 3D to 3E, a push rod foot 32a, fitted to receive the distal end of a push rod 32 therein, is positioned below the upper support plate 91a and can be configured to engage and mount along the needle bar 11 to mount the push rod to the needle bar. In embodiments, the push rod foot may include a push rod foot assembly 93 which includes the push rod foot 32a and a collar or clamp 94 mounted along the upper surface of the push rod foot, which is fitted to receive and clamp the distal end of a push rod therein to secure the push rod to the push rod foot. In embodiments, the collar or clamp can be mounted on the upper surface of the push rod foot with an adapter plate positioned between them as needed.

[0100] Furthermore, in some embodiments, each needle stroke assembly 90 may further include a first guide 95 configured to engage with a second guide 96, which is mounted along a lower mounting plate and can be mounted on a pushrod foot as shown in Figure 3E. In some embodiments, the first guide 95 may include a linear bearing slide, and the second guide 96 may include a linear bearing guide that moves along the linear bearing slide as the pushrod reciprocates during the needle stroke. In other embodiments, the first or second guide may include a track formed from a low-friction material that can be received in a channel or similar guide having a low-friction surface. In some embodiments, the pushrod foot may include a linear bearing slide or track, and the lower support plate may include a linear bearing guide.

[0101] In some embodiments, the adapter 97 can be mounted along either or both of the pusher rod foot and the lower plate. For example, as shown in Figures 3D-3E, an adapter that includes a plate in an embodiment can be mounted on the rear surface of the pusher rod foot to attach a second guide 96 (e.g., a linear bearing channel) to the pusher rod foot.

[0102] In the embodiment, the needle stroke assembly 90 is configured to guide the linear vertical reciprocating motion of the push rod 32, and thus the needle bar 11 during each stroke of the needle bar. In the embodiment, as shown in Figure 3D, the push rod 32 extends through a bearing assembly 30 mounted in an opening 92 in the upper support plate 91a of the needle stroke assembly and is received in the push rod foot 32a. In the embodiment, each of the push rods 32 can be supported by the upper support plate 91a and by the engagement of a first guide 95 mounted along the lower support plate 91b and a second guide 96 mounted on their push rod feet, which can help guide the linear motion of the push rod 32 during each needle stroke.

[0103] Furthermore, in some embodiments, the support and guidance of the push rod's movement during each needle stroke by the needle stroke support assembly can act to reduce the pressure or force transmitted to the pusher rod by the engagement of the knife and needle. Generally, the force generated by the knife striking the needle to form a cut pile tuft (especially when cutting yarn used to form artificial turf or grass) creates pressure on the pusher rod, which over time can cause excessive wear and / or damage to the bushing of the push rod and may cause vibration or other undesirable movement of the pusher rod. The needle stroke assembly 90 can help reduce the pressure or force applied to the pusher rod and guide their linear motion, which can help increase production speed and extend the life of the push rod and its bearing assembly. In some embodiments, the needle stroke support assembly can facilitate the reciprocating motion of the needle over extended or longer needle strokes to enable the formation of tufts with even greater pile heights.

[0104] In various embodiments, the support plate 91a may have different dimensions, such as different thicknesses or configurations, to accommodate the movement of the push rod along needle strokes of different lengths. In some embodiments, the support plate may be slidably mounted to the tufting machine frame and configured to move along with the movement of the push rod and needle bar.

[0105] In some embodiments, the shift mechanism 40 can be coupled to the needle bar 11 and controlled to shift or move the needles laterally relative to the travel path P (Figure 2A) of the lining B through the tufting machine 10. In some embodiments, multiple shift mechanisms can also be used to shift the needles 12 laterally across the lining B to form a tufted pattern (e.g., located on the opposite side of the tufting machine). In embodiments, the shift mechanism 40 can be driven by one or more servo motors or other actuators under the control of the control system 15. For example, in embodiments, the shift mechanism 40 may include a cam or motor-driven shifter, a servo motor-driven rack and pinion shift mechanism (such as Card-Monroe Corp.'s Smart Tech Shifter®), or other shifters.

[0106] In embodiments, the needles 12 can be shifted / moved laterally in a desired or specified number of shift steps or jumps, which can form a desired pattern based, for example, on the gauge interval between each needle 12, or a multiple thereof. For example, in embodiments, the needles can be shifted by 1, 2, or more gauge increments, or a portion thereof, according to the pattern indication of the tufted pattern to be formed. In some embodiments, the shift mechanism 40 can also shift the needles by other selected or desired step lengths or distances, including moving the needles by 1 / 2 gauge or other off-gauge steps or intervals.

[0107] In some embodiments, as shown in Figure 1B, a shift mechanism 40 for shifting the lining B may be provided. For example, in embodiments, the shift mechanism 40 (including, in embodiments, a servo-driven shift mechanism, a cam-driven shift mechanism, a servomotor-driven rack and pinion shift mechanism such as Card-Monroe Corp.'s Smart Tech Shifter®, or other shifters) may be coupled to the lining support or shuttle 18 and may be controlled by a control system to shift the lining B laterally (e.g., across or along the tufting zone). In embodiments, the lining B may be shifted together with or independently of the shift of the needles 12. In some embodiments, the lining B may be shifted while the needles 12 are maintained in a substantially consistent lateral position with respect to the travel path P of the lining B through the tufting machine 10.

[0108] As generally shown in Figures 1B-1C, the shift mechanism 40 can be coupled to a shuttle 18 or lining support 18 over which the lining B passes and is supported as it is fed through the tufting machine along its travel path P. The shift mechanism 40 can shift the lining B laterally relative to its travel path P. For illustrative purposes, Figure 1C shows one shift mechanism 40, but it will be understood that multiple shift mechanisms can also be used and mounted at one or both ends of the tufting machine.

[0109] In some embodiments, the shuttle 18 may include a carriage 38 that can be coupled to a shift mechanism 40, with one or more plates 41 mounted within the frame, or, in some embodiments, integrated with the frame 38. In some embodiments, at least one plate 41 may be positioned along each side of the carriage 38 and may have an upper surface 41a on which the lining B is supported. In other embodiments, an additional plate may be mounted along the bottom of the shuttle 18.

[0110] In some embodiments, as shown in Figure 1C, the shuttle 18 can be incorporated as part of the lining feed system 25. For example, in some embodiments, the frame may include a pair of plates or supports 39 positioned to extend across the tufting zone of the tufting machine, and the lining feed rolls 26 can be attached to the supports 39 along the upstream end 38a and downstream end 38b of the frame 38 of the shuttle 18. In some embodiments, additional lining feed rolls (e.g., additional spike rolls) may also be positioned along the shuttle 18 adjacent to the plates 41. The end 26a of the lining feed rolls 26 can be coupled to a motor or linked to the main drive shaft of the tufting machine to drive the rotation of the lining feed rolls.

[0111] As further shown in Figure 1C, in some embodiments, the bearing guide 42 can be mounted along the frame 38. In some embodiments, the bearing guide 42 can be mounted on the underside of the plate 41. In some embodiments, the bearing guide 42 may include a linear guide configured to engage with a corresponding slide or bearing mounted along the frame to guide the shuttle 18 as the shuttle is moved by the shift mechanism 40 and shifted laterally across the tufting zone. Also in some embodiments, the bearing guides 42 and / or their corresponding slides can be mounted on an additional plate located below the frame or the shuttle 18.

[0112] In embodiments, as shown in Figure 1C, the frame 38 of the shuttle 18 can be coupled to a rod or drive shaft 43 extending through the frame of the tufting machine 10, with its first or proximal end 43a coupled to a lining shift mechanism 40 at its second or distal end 43b. In embodiments, the drive shaft 43 may include multiple sections or parts and may be coupled to the shuttle 18 and / or shift mechanism 40 by mounting blocks, brackets, or other similar connectors. As shown in Figures 2C and 2D, in embodiments, the lining B is generally engaged between the upper surface of the shuttle 18 and the presser foot 22 as the needle 12 penetrates the lining B during the tufting operation. The lining B can be held in place relative to the upper surface of one or more plates 41 as the lining B is shifted laterally by the shift mechanism 40. In embodiments, the lining B can be shifted in increments based on the gauge spacing of the needles, or based on multiples or fractions of such gauge spacing of the needles 12 to reposition the lining to insert a desired color or type of yarn into a selected stitch position. After a tuft or stitch is formed on the backing B and the needle 12 retracts, the backing B can be moved in the direction of its travel path P. For example, in addition to being fed or moved longitudinally along its travel path P through the tufting machine 10, the backing B can be shifted laterally relative to the needle 12 to allow for the near-presentation of multiple different colors and / or types of yarn within a selected pixel or stitch position. In some embodiments, the shifting of the backing can further allow for the retention of different numbers of yarn tufts in the longitudinal and transverse directions of the pattern, as needed.

[0113] In addition, in the embodiment, the lining B can be shifted laterally by less than a full gauge increment, for example, the lining can be shifted by 1 / 2, 1 / 4, 3 / 8, or other parts of the gauge spacing of the needle 12. For example, the gauge spacing of the needle 12 can be set from 3 / 8 inch to 1 / 2 inch, and the lining B can be shifted by 1 / 4 inch to 7 / 16 inch or other fractions of the gauge increment relative to the pattern.

[0114] As shown in Figures 2B-3B, each of the needles 12 can be positioned along one end of a transport path or pathway 44 through which the yarn is fed from the yarn supply system to be inserted into the lining B through the needle. In embodiments, each of the needles 12 may include a hollow needle having a body 45 which can be formed as a hollow tube having a length of, for example, about 3-4 inches or more. The body 45 can define a hollow passage or channel 46 through which the yarn Y is fed. Other lengths of the body 45 (e.g., 4-6 inches, or longer or shorter than 3-4 inches) may also be used. In embodiments, multiple yarns may be fed through the passage 46 of each needle. For example, 1-3 yarns may be fed together through each needle, but in some embodiments, an additional number of yarns may also be fed. The body 45 of each needle may more generally include a first or proximal end 47 that can be received in an opening along the lower surface of the needle bar 11 and communicate with an internal passage and / or yarn tube for receiving yarn, and a second or distal end 48 at the opposite end of the body 45.

[0115] In embodiments, the needle 12 may be formed with an extended length to provide an extended passage and / or to allow for an increase in the length of yarn inserted into the backing material as needed (e.g., to form a tuft with an increased pile height). Thus, in embodiments, a yarn tuft may be formed that has different pile heights and can contain multiple yarns within the same tuft, and in some embodiments, a yarn loop pile tuft may be formed in addition to or instead of a cut pile tuft formed in the backing material.

[0116] As shown in Figure 3B, in an embodiment, the distal end 48 of each needle 12 can terminate at a tip 49, defining an opening 50 which may be substantially elliptical in an embodiment, through which the yarn Y can exit the internal passage of the needle 12. In an embodiment, the opening 50 may have a cutting surface 51 formed around it, which may be configured to provide a shear surface through which the yarn can be cut. For example, in an embodiment as shown in Figure 3B, the distal end 48 of the needle 12 may include a cutting surface 51 with a flattened cutting angle formed around the opening 50. The opening 50 may further include a reduced area or recess 52 on its upper side opposite the tip 49 of the needle. In an embodiment, the recess 52 and cutting surface 51 of each needle 12 may be configured to provide a larger, substantially flattened shear surface through which the yarn, such as artificial turf or turf yarn or multiple combined ends of filaments or yarn, can be engaged by the cutting system.

[0117] In embodiments for forming turf fields, landscaping fabrics, etc., the yarn may include artificial turf or turf yarn. Such artificial turf or turf yarn may generally include one or more filaments, which in some embodiments can be combined with one or more ribbon yarns. Artificial turf yarn can also typically be formed from a variety of polymer materials and may have a substantially flat structure to substantially replicate grass blades. In embodiments, the configuration of a recess 52 and an opening 50 formed at the distal end 48 of the needle 12, as well as a cut surface 51 defined around it, may generally be configured to guide and present such artificial turf filaments or yarn supplied through each needle in a substantially flat and straight arrangement, enabling a cleaner cut of such artificial turf or turf yarn and helping to avoid fraying or other problems if the yarn is not cut cleanly.

[0118] In embodiments, as commonly shown in Figures 2F-2H, the yarn may include multiple yarns Y (e.g., ends of two or more yarns Y) supplied to each needle 12 for insertion together into the backing material B. In embodiments, the multiple yarns may be supplied directly to the passages 46 of each needle. As shown in Figure 2F, in embodiments, the needle bar 11 may be configured to include needles 12 arranged at selected gauge intervals and openings 57 of passages 58 formed along the top of the needle bar 11 and communicating with the upper ends of the needles 12. Each yarn Y may be supplied directly to the passages 46 of their associated needles through the openings 57. For example, Figure 2F shows two ends of yarn supplied directly to the openings 57 for supply to the needles 12.

[0119] Furthermore, in some embodiments, a yarn guide 53 (Figures 2G-2H) can be mounted adjacent to the needle bar 11. The yarn guide 53 may have a plurality of openings 54 defined along it that can be configured to receive two or more yarns Y therein. The needle bar 11 may further have openings 55A located on each side of an opening 57 leading to an internal passage 58 formed through the needles 12, and may include a series of defined air passages 55 therein to supply airflow to the needles.

[0120] In an embodiment, the air passage 55 can be connected to an air-guided yarn supply device 59 of the yarn selection system 70, which may include a plurality of air injectors 67 that can be connected to the opening 55A or the air passage 55 via an air line 68 coupled to an air supply source. The air injectors 67 supply airflow into the needle bar 11 that is guided into the needles 12 along the air passage 55 as the yarn (e.g., 1 to 3 or more yarns per needle) is supplied through and within the needle passage 46 to deliver the yarn to the backing material B. The airflow can be selectively controlled by a control system to supply air as needed to deliver the yarn to the backing material to form a yarn tuft.

[0121] In embodiments such as when multiple yarns Y (e.g., two or more yarns) are tufted by each needle 12, supplying air from both sides of the needle bar can help deliver each yarn through the needle substantially simultaneously, substantially consistently, and in embodiments, at the same delivery rate. Furthermore, the yarns can be consistently supplied to their associated needles without the use of a funnel to supply the yarn to the hollow needles.

[0122] In other alternative embodiments, as further shown in Figure 2E, multiple yarn tubes 56 can be mounted along the needle bar 11. The yarn tubes 56 can generally be received through openings 57 formed along the top of the needle bar 11, and each can generally be aligned with a corresponding needle 12 mounted along the bottom of the needle bar. In embodiments, each yarn tube 56 may include an elongated body 58 extending downward from a first or proximal end to a second lower distal end that is received through the opening in the needle bar 11. The distal end of the yarn tube can further be aligned with and communicate with the first or proximal end of its associated needle. Yarn can be supplied into the yarn tubes 56 from a yarn supply system through a yarn selection system, and the yarn is guided diagonally through the tube into the needle 12 with which it communicates. In the embodiment, the yarn tube 56 can be oriented at an angle to the needle 12, and the angle and length of the yarn tube are configured to help retain the unselected yarn within each needle (or at least within the yarn tube 56 for easy reinsertion into the needle) during periods when the supply of selected yarn is stopped or substantially slowed down and such unselected yarn is not inserted into the backing material.

[0123] As shown in Figures 1A and 4A-4C, a yarn supply system 60 is provided to control the supply of a series of yarn Y from a supply source (e.g., a creel, cone, etc.) to each needle 12. In embodiments, the supply of yarn to each needle 12 can be controlled so that the yarn is carried with the needle as it reciprocates in and out of the backing material B, and at least selected yarn is supplied through the needle 12. The yarn supply system 60 can supply each needle with a sufficient length of yarn to form a tuft of the desired pile height as the needle moves through the backing material B toward a lower bottom position of its reciprocating stroke or cycle, and the needle can be engaged by one or more knives or cutting blades of a cutting system mounted beneath the backing material along the tufting zone T of the tufting machine. The supply of yarn to the needles 12 can further be controlled so that unselected yarn (e.g., yarn not tufted at a particular stitch position of the pattern) is substantially pulled back and / or held or otherwise maintained within each needle.

[0124] In embodiments, the yarn supply system 60 may include one or more yarn supply attachments or mechanisms 61 that can be mounted adjacent to the upper end of the frame 16 of the tufting machine 10, as shown in Figure 4A. In embodiments, as shown in Figures 4A-4C, the yarn supply mechanism 61 may include, for example, an individual or single-end yarn supply or a multi-end yarn supply pattern attachment. In embodiments, such a yarn supply mechanism 61 may further include a unit or modular structure that includes a housing and / or frame into which a series of motor-driven yarn supply devices 62 are mounted or received. In embodiments, multiple yarn supply mechanisms may be mounted along the frame of the tufting machine to supply at least one yarn per needle, or in embodiments, two or more yarns to each needle. In some embodiments, a single yarn may be supplied to each needle by one of the relevant yarn supply devices 62, and in other embodiments, multiple yarns may be supplied to each needle or a series of needles by one of the relevant yarn supply devices 62. Furthermore, other yarn supply mechanisms may also be used.

[0125] In embodiments as shown in Figures 4B-4D, each yarn supply device 62 may include a motor 65 and one or more supply rolls 63, each configured to supply at least one or more strands of yarn to a selected needle. In embodiments, the yarn supply rolls 63 of the yarn supply device 62 may be arranged in a set of two or three yarn supply rolls, which may be arranged in an engaging relationship (for example, the supply rolls may have gear teeth that engage in a mutual meshing arrangement). In some embodiments, the yarn supply rolls 63 may include a driven roller 64A that can be driven by the motor 65 and two supply rollers 64B / 64C on which the yarn can extend to supply the yarn along its path. The two supply rollers 64B / 64C may be driven by the rotation of the driven roller 64A. In embodiments, the yarn supply rollers 64B / 64C of the yarn supply device 62 may be configured to supply a selected or predetermined amount or length of yarn for each individual tufting or stitching cycle to enable the formation of a tuft or yarn having a selected or desired pile height.

[0126] For example, as shown in Figure 4D, in some embodiments, the supply rollers 64B / 64C may have an enlarged size or diameter that can be selected to supply a desired or selected length of yarn with each of its rotations. For example, in some embodiments, the supply rollers 64B / 64C may have a diameter of up to about 1 inch or more that can be selected to supply a set length of yarn (e.g., about 4 to 5 inches) per rotation. Other quantities or lengths of yarn can also be supplied using supply rollers of various other sizes to form tufts of other pile heights. In some applications such as artificial turf or turf in sports fields, a standard pile height of at least 2 1 / 2 inches may be required to provide sufficient filler, resilience and other parameters. The system and method can provide greater pile heights and further variation in the pile height of the formed tufts that meet or exceed such criteria.

[0127] Furthermore, in embodiments, increasing the size of the feed rollers in each yarn feeding device can further assist in the feeding of yarns such as polymer yarns or filaments commonly used in artificial turf or grass. In embodiments, the driven roller 64A of the yarn feeding device may be configured to have a smaller diameter than the feed rollers 64B and 64C to compensate for the potential reduction in torque in yarn feeding due to the increased size of the feed rollers. The size of the driven roller 64A can be varied in relation to the size of the feed rollers 64B / 64C to adjust the torque applied to the yarn feed and / or the desired amount of yarn fed per revolution of the feed roller.

[0128] In some embodiments, each of the yarn feeders 62 may be configured to feed one or more yarns to one or more associated needles 12. In some embodiments, a single yarn may be fed to each needle, and in some embodiments, multiple yarns may be fed to each needle for tufting into the backing B. For example, in some cases (such as when forming artificial turf or turf products), two, three, four, or more yarns (e.g., artificial turf filaments) may be fed together to the needles 12 before being received by the yarn feeder system 60, or combined in the yarn feeder system, so that each needle inserts two to four or more yarns per tuft.

[0129] The yarn feeding mechanism 61 can be operated according to the programming or pattern instructions of the pattern to be executed by the tufting machine 10, and controls the feeding of yarn Y along the path or path 44 to each needle 12 or a series of needles. The feeding of yarn Y can be controlled to form tufts of selected or desired pile heights, and further, it can be controlled to keep the yarn within the needles 12 while substantially slowing down or stopping the selected yarn or yarn loops, thereby avoiding insertion of unselected yarn into the backing B. The pile height of the remaining tufts of the selected yarn can be further controlled by the amount of yarn fed by the yarn feeding mechanism 61, which feeds out lengths of yarn as needed to create tufts of different heights. Thus, various surface effects can be formed for each tuft or stitch, and texture patterns with high / low and / or shaded pattern effects can be tufted / created, in addition to shift or different color placement effects.

[0130] Furthermore, in the embodiments, it is understood that multiple yarn feeding mechanisms or units are also provided and can be mounted along one or both sides of the tufting machine. For example, one or more yarn feeding mechanisms can be mounted along the front side of the tufting machine to feed a series of yarns to the needles of a first or upstream needle bar, and an additional set of one or more yarn feeding mechanisms can be mounted on the rear or downstream side of the tufting machine to feed a series of yarns to the needles of a downstream or second needle bar.

[0131] In some embodiments, front and rear yarn feeding mechanisms are provided to feed yarn to alternating needles of the needle bar. For example, the front yarn feeding mechanism can feed yarn to odd-numbered needles, and the rear yarn feeding mechanism can feed yarn to even-numbered needles.

[0132] Furthermore, in the embodiment, the tufting machine 10 may include puller rolls 66 (Figures 1A, 2A, and 2C) positioned downstream of the yarn feeding mechanism 61, along the travel path or path 44 of the yarn Y. The puller rolls 66 have grooved rollers that engage with and pull the yarn fed out from the yarn feeding mechanism, providing substantially consistent yarn feeding. The rotation of the puller rolls 66 is controlled by the control system 15, which can control the pulling of the yarn Y from the yarn feeding rolls 63 of one or more yarn feeding mechanisms 61, feeding them along their travel paths to their associated needles.

[0133] In some embodiments, the tufting machine may further include an air-guided yarn feeder 59 configured to help guide / feed the yarn into and along the passage 58 of the needle 12. In some embodiments, the air-guided yarn feeder may include an airline 68 connected to a series of air injectors, nozzles, or other devices 67, which can be connected to an air supply source and are positioned along the yarn path or travel path or path 44 from the yarn feeder system 60 into the needle 12 and are configured to supply / guide a flow of pressurized air toward the yarn. In some embodiments, the air-guided yarn feeder may supply a flow of pressurized air that can be guided through the needle 12 along the yarn tube 56, helping to guide the yarn through the needle and consistently feed each yarn (or more yarns) toward the associated needle at a substantially simultaneous and substantially consistent feed rate. In some embodiments, the air-guided yarn feeder may supply a substantially continuous flow of air that can be discharged into the atmosphere through an opening at the distal end of the needle.

[0134] Furthermore, in embodiments such as those shown in Figures 5A–5D, the tufting machine may further include a yarn selection system 70 that can operate to selectively pull back or hold yarn that has been fed from the yarn feeding system 60 to the needle 12. In some embodiments, the yarn selection system 70 may include a series of yarn jerkers 71 positioned along the travel path or path 44 of the yarn Y from the yarn feeding mechanism 61 or the pattern attachment of the yarn feeding system 60 to the needle 12. One or more of the yarn jerkers 71 may be coupled to an actuator 72, such as an air cylinder. The yarn jerkers 71 are selectively controlled to extend or retract along a selected length or travel amount (for example, in embodiments, a travel amount from about 1 / 2 inch to about 2 inches (although other distances may also be used)) and can pull back or pull out the yarn from the needle.

[0135] In the embodiment, the actuator 72 may include an air cylinder, each containing an extendable piston rod 73 (Figure 5C). As shown in Figures 5C-5D, in the embodiment, each of the yarn jerkers 71 may include a body 74 having an opening 76 defined therein. The yarn Y can extend through the opening 76. The body 74 of each yarn jerker may be further connected to the piston rod 73 of the associated actuator 72. The actuator can be selectively controlled to extend and retract the piston rod, and thus move the yarn jerker 71 between an extended position and a retracted position. In the embodiment, the yarn jerker 71 can move up and down, and when the yarn jerker is retracted, the yarn extending through it can be pulled back or retracted.

[0136] In other embodiments, the actuator 72 may be formed together with or incorporated into a jerker module, each formed of multiple bores that receive a piston rod (for example, a yarn jerker can be coupled to a jerker module). The yarn jerker 71 may comprise a one- or two-part structure. For example, in an embodiment, as shown in Figures 5B-5C, each body 74 of the yarn jerker 71 may include a yarn holder portion 74a with an opening 76 for yarn to pass through, and a mounting portion 74b that can be coupled to the yarn holder portion 74a (for example, by key engagement or other locking arrangement, or by a fastener, etc.) and to the distal end of one piston rod 73 of the actuator 72.

[0137] In embodiments, other types of actuators can also be provided. For example, in some embodiments, the jerker module (or its actuator) may comprise a double-acting air cylinder configured without mechanical spring return, using air supplied to different portions of the bore of the jerker module to cause selective movement of a piston along the bore, thereby controlling the extension and retraction of the yarn jerker. Providing or forming the jerker module as a double-acting cylinder can, in embodiments, help increase the timing or speed of the yarn jerker's operation because no spring is used. Furthermore, lower pneumatic pressure for the operation of the yarn jerker can also be utilized to operate the double-acting cylinder.

[0138] Furthermore, in embodiments such as that shown in Figure 5A, the actuator 72 (shown as a cylinder) may be connected to an air supply source by a multi-way valve 77, such as a three-way valve. The valve 77 of each actuator may include an intake port 78a connected to an air supply source by an airline or conduit to supply air to the actuator, a first outlet port 78b through which air is guided to control the expansion and contraction of a connected yarn jerker, and a second outlet port 78c which can act as an air bleed to release excess air. In some embodiments, the second outlet port 78c may be connected by an airline to one of the air injectors 67 of an air-guided yarn feeder to supply air to the air injector to assist in feeding the yarn to the associated needle. In embodiments, an air injector located along the opposite side of the needle bar may be connected to an air supply source and may receive air directly from the air supply source.

[0139] The selective operation of the yarn jerker, along with the control of the selected yarn feeder of the yarn feeder system, can help control the amount of selected yarn fed to each needle to ensure that a sufficient length of each selected yarn is provided to form a tuft of the desired pile height (which may depend on the specific structure, application, and / or use of the artificial turf or turf field). In embodiments, the control of the yarn by the yarn jerker and the yarn feeder system can keep the yarn within the needle both when it is cut and when it is not selected for insertion into the backing.

[0140] In addition, in the embodiment, the application of pressurized airflow by the air-inducted yarn feeder can keep the yarn within its paths or travel paths 44 by maintaining it within and through the passages 55 of the needle bar 11 and the passages 46 of the needles 12. For example, yarns commonly used in artificial turf or turf tend to be flatter (e.g., to mimic grass blades) and have a natural resilience that tends to snap or spring back when cut, and the application of air by the air injector through the passages 55 of the needle bar 11 can help the yarn selection system 70 and the yarn feeder 60 substantially prevent the yarn from flying out of the needles by extending the yarn travel path or path 44 within and through the needles, allowing the yarn to remain in contact with the corresponding needles within its path.

[0141] Furthermore, in some embodiments, the cutting system 80 may be located below the lining support or shuttle 18. As shown in Figures 6A-6B, in some embodiments, the cutting system 80 may include a series of knives 81, each having a cutting edge 82. In some embodiments, the knives may be positioned substantially flat with respect to the needle, and in some embodiments, they may be mounted on modules or holders 84, each mounted along a knife bar 86.

[0142] For example, as shown in Figures 7A-7C, in an embodiment, a series of knives 81 can be mounted in a module 84 which may include a body 87 having a front portion 87a containing a series of slots 88 in which individual knives 81 can be received, and a rear portion 87b configured to be mounted along a knife bar. In the exemplary embodiment shown in Figures 7A-7C, the module is shown with a series of mounting tabs 89a, but other mounting devices may also be used. In an embodiment, the knives can be secured in predetermined cutting positions within the slots by fasteners 89 (Figure 7B), such as set screws or other fasteners.

[0143] In embodiments, the module can be positioned within a fixture for locating the knife 81 at a predetermined cutting position, which may be based on the needle stroke length or the needle penetration depth into the backing to form a tuft of a selected pile height. The knife can be secured within the module using fasteners, after which the module can be mounted along the knife bar. The knife can be positioned relative to the needle's downstroke or penetration depth to position the knife for cutting the yarn supplied through the needle as the needle penetrates the backing.

[0144] In another embodiment, as shown in Figure 6C, each knife 81 can be mounted on its own module 84, and multiple knives 81 and modules 84 are individually mounted along the knife bar 86. Each module 84 may include a module body 87 having a front portion 87a and a rear portion 87b configured to be mounted along the knife bar 86. For example, in an embodiment, one or more mounting tabs 89 may be provided along the surface of the rear portion 87a to assist in positioning the module along the knife bar, and the knife module can be secured to the knife bar with fasteners such as set screws.

[0145] Furthermore, as further shown in Figure 6C, in an embodiment, the body 87 of the knife module 84 may have a generally Y-shaped or C-shaped configuration of a knife holder assembly having an opening 84a defined along the front portion 87a of the body. In an embodiment, the knives of each module shown in Figure 6C can be slidably received within a knife mounting assembly 85. In an embodiment, the knife mounting assembly 85 may include a first portion 85a into which a knife 81 can be mounted (e.g., by fasteners) and a second portion 85b configured to receive the knife 81 therein and which can be mounted on the front portion 87a.

[0146] In an embodiment, the second portion 85b may be configured as a guide that slidably receives each knife, allowing each knife to selectively move vertically between a series of extended, engaged, or cutting positions and a retracted, disengaged, or uncutting position relative to the stroke of the needle. In an embodiment, when the knife is in its extended cutting position, the knife can cut the yarn carried by the needle to form cut pile tufts of the selected yarn on the backing, these tufts may have varying pile heights. In another embodiment, the knife can be selectively moved to its retracted position to form loop pile tufts of the selected yarn on the backing.

[0147] In one embodiment, the actuator 83 can be associated with each individual knife, for example, its piston rod or other drive shaft 83a can be coupled to the first part 85a and selectively actuated by a control system to move the associated knife between its series of extended engagement or cutting positions. Other types of actuators (in addition to or instead of the cylinder shown in Figure 6C) can be used.

[0148] In an embodiment, the first portion 85a of the knife mounting assembly can be configured to allow the knife to move along it. For example, when the actuator is engaged by a control system, the knife associated with it extends or retracts and moves along the first portion 85a of the knife mounting assembly (e.g., along a channel or passage in the first portion), which guides and supports the movement of the knife between the extended and retracted positions.

[0149] In embodiments, the knife 81 can be positioned in alignment with the associated or corresponding needle 12. In embodiments, the knife 81 can further be mounted in a substantially fixed position along the knife bar 86, and the cutting edge 82 of the knife engages with the needle 12 to cut the yarn carried by the needle and is positioned to a height for forming a tuft of such yarn having a selected pile height. Generally, the knife 81 can be positioned such that its cutting edge 82 is positioned at a selected height relative to the stroke of the needle 12, and as the needle penetrates the backing B, the cut surface 51 of each needle engages with the associated cutting edge of the knife, and the introduced (e.g., blown through the needle) yarn is cut by the knife.

[0150] In an embodiment, the knife 81 can be held in a stationary position as the needle 12 penetrates the backing B. When the needle 12 reaches a selected penetration depth, the cut surface of the needle can engage with the cutting edge of the knife. In an embodiment, the cutting edge 82 of the knife can engage with the cut surface of the needle at a selected shear angle to facilitate a more flat artificial turf or turf yarn with a substantially clean cut. In an embodiment, the shear angle between the cut surface of the needle and the cutting edge of the knife can be substantially flat or oriented at a slight shear angle.

[0151] In some embodiments, the knife bar 86 can be coupled to at least one actuator 83 (Figure 6C) that can control the movement of the knives 81 between their disengaged and cutting positions. Furthermore, in some embodiments, one or more of the knives 81 can be coupled to associated actuators (such as air cylinders) and individually controlled to move between a non-cutting or disengaged position and one or more cutting positions in order to selectively cut the yarn as it is planted in the backing B. In other embodiments, all of the knives 81, or at least some of them, can be moved together as a set or group of knives to a cutting position for cutting the yarn.

[0152] In embodiments, the knife 81 (Figures 6A-6C) can generally be positioned in a location fixed laterally to the needle 12. The knife 81 can be moved in a substantially linear path in a vertical direction, which can be substantially in line with the cutting surface 51 of the needle 12. For example, in embodiments, the cutting edge 82 of the knife 81 can be substantially centered with the cutting surface 51 formed at the distal end of the needle 12. The cutting edge 82 of the knife 81 can engage with the cutting surface 51 of the needle at a substantially flat or slight shear angle, for example, to facilitate a substantially clean cut of flatter artificial turf or turf yarn.

[0153] Furthermore, in some embodiments, a cutting blade or a series of cutting blades may be provided instead of the knives of the cutting system. The cutting blade may have an elongated cutting edge configured to engage with and cut multiple yarns. In embodiments, multiple cutting blades may be used instead of a group or set of knives.

[0154] In embodiments, the tufting machine 10 may include a control system 15, which may include programming for controlling the operation of various operating systems and / or components of the tufting machine, such as a yarn feeding system, a lining feeding system, a needle bar drive system, a yarn selection system, a cutting system, a shift mechanism (for shifting the needle, the lining, or both the needle and the lining), and components of each such system, in order to produce tufted products patterned according to a selected pattern. The control system 15 may further be configured to control the supply of compressed air from an air supply source (e.g., a blower, compressor, or other compressed air source) to various operating systems or components of the tufting machine.

[0155] In some embodiments, the supply of compressed air may include, or be in communication with, a distribution device such as a manifold that can be configured to supply air to different operating components of the tufting machine, such components may include, but are not limited to, one or more actuators that control the operation of the yarn jerker, actuators for the knives of the cutting system, an air-inducted yarn feeder, and / or other components.

[0156] In some embodiments, the various operating systems of the tufting machine 10 can be controlled by a control system 15 based on programming configured to receive and execute / perform desired patterns. In some embodiments, the control system 15 may include a controller 100, schematically shown in Figure 1A as including a control cabinet connected to the tufting machine 10, which may have a user interface 101 such as a touchscreen or keyboard. In other embodiments, the controller 100 may be integrated into the tufting machine 10, for example, mounted on a frame or otherwise included in the tufting machine, while in other embodiments, the controller may be a standalone unit, a more remote controller, or a central server / controller.

[0157] In embodiments, the controller 100 may include one or more processors and memory that can be configured to receive and store pattern information, and may further include programming or instructions adapted to control the operation of the hollow needle tufting machine and its various operating components. For example, in embodiments, the controller of the control system may include programming or instructions executed by one or more processors to selectively control the yarn supplied to the needles in conjunction with the engagement / selective operation of the knife and yarn jerker, and / or the shifting of the needles (and in some embodiments, the shifting of the backing) to form a desired pattern with multiple colors and / or types of yarn, based on the received or programmed pattern information, in order to enable a substantially consistent yarn supply to each needle.

[0158] Furthermore, in some embodiments, the control system can control the supply to the lining so as to supply the lining at an actual stitch rate that is substantially equivalent to the pattern stitch rate designed or adjusted for the pattern being tufted, or to configure an effective process stitch rate that can be increased compared to a desired stitch rate for the designed pattern. In some embodiments, the lining may be supplied at an effective process stitch rate determined by multiplying the desired stitch rate for the pattern by the number of colors in the pattern or the number of colors used in the needle threading sequence (the desired stitch rate may be determined from the stitch rate of the designed pattern based on the fraction of yarn supplied to each needle to form each tuft, the thickness and / or weight of the yarn, and other factors).

[0159] In some embodiments, the control system may further include programming adapted to apply dynamic precedent parameters to the precedent actions of various operating components of the hollow needle tufting machine based on the operating speed (RPM) of the main shaft of the hollow needle tufting machine. For example, based on the rotation of the main shaft of the tufting machine, the control system may precede the action of one or more operating components, such as engaging a selected yarn jerker, engaging an air blower (e.g., switching it on and off), yarn supplying a selected yarn to each needle, moving a knife between a cutting position and an unengaged or uncutting position, shifting, and other operating elements, before or prior to the next stitch or tuft placement step for the pattern.

[0160] In an embodiment, the control system can control the yarn supply system (e.g., control a selected yarn supply device or its yarn supply mechanism or unit) to deliver a portion of the length of yarn supplied to each needle during each stitch or individual sewing operation within a portion of the rotation of the main shaft of the hollow needle tufting machine.

[0161] In some embodiments, the tufting machine can be configured to provide a single-level cut-pile tufted fabric, and the control system may include programming that allows yarn feed control to be used to control the formation of a multi-level loop-pile tuft of yarn, without necessarily requiring the knife for cutting the yarn loops to move from a cut (cylinder extended) position to a loop (cylinder retracted) position.

[0162] In embodiments, the length of the tufting machine, the needle spacing, and the number of needles can vary depending on the product being manufactured and the desired manufacturing speed. For example, in embodiments, the tufting machine can be configured to manufacture carpets, turf, rugs, or other articles of a selected size or range of sizes. For example, in embodiments, the needles can be arranged at gauge spacings that can substantially match a selected or desired gauge of the tufting machine, including, for example, needle gauge spacings of about 1 / 4 inch to 3 / 8 inch or more, 1 / 4 inch, 5 / 16 inch, 3 / 8 inch, 7 / 16 inch, 1 / 2 inch, 5 / 8 inch, 9 / 16 inch, 3 / 4 inch, 7 / 8 inch, 1 inch or more, and in some embodiments can be used to form tufted products of substantially true gauge that can be matched to the tufting machine.

[0163] As an example, in embodiments of a method according to the principles of the present disclosure, the method may utilize a tufting machine comprising a pattern attachment with a single-ended or double-ended yarn feeding mechanism or an expanding roll system to enable the yarn feeding mechanism to feed yarn of a length that can correspond to a selected tuft length or pile height for artificial turf, turf or shag carpet, field, and / or rug. For example, in an embodiment, the tufting machine may feed tuft lengths with pile heights greater than 3 inches.

[0164] In embodiments of the method, the yarn passes through a series of yarn jerkers controlled by a control system to act in an appropriate / selected sequence based on the rotation of the main shaft (e.g., actuated based on the position of the main shaft during the tufting cycle). In embodiments, an actuator (e.g., a cylinder) can be controlled to move the yarn jerkers in two directions (e.g., up / down) between a first extended position and a second retracted position. In embodiments, when the yarn jerkers are retracted, the length of the yarn can be retracted at least partially and held within the corresponding needle so as not to be exposed for cutting. When the cylinder is extended, the yarn jerkers coupled to it are extended, and the yarn is allowed to flow through the needle to form the tuft length.

[0165] In embodiments of the method, the yarn passes through a yarn jerker and can be guided directly to needles by an air-inductive yarn feeder, as shown in Figures 2F, 2H, and 5A, and is pushed through the passages of those associated needles by an air-inductive yarn feed mechanism. In some embodiments, the yarn can be further fed through a series of yarn tubes, each communicating with a corresponding needle. In embodiments, selected yarn, for example, one selected to be used to form a patterned tuft, is guided through the needle bars and their associated needles by an airflow supplied by an air injector of the air-inductive yarn feed mechanism as the needles reciprocate through the backing.

[0166] In embodiments of the method, the yarn is cut by a cutting system. In embodiments, the cutting system may include a series of flat knife blades that are selectively movable to contact the underside of the needle to cut the yarn in order to form a tuft in the lining as the needle penetrates the primary lining. In certain scenarios, the end of the needle may be flattened to better cut the flat ribbon yarn.

[0167] In embodiments of this method, each needle can be fed with a different color or type of yarn of a selected type. In other embodiments, multiple (e.g., two or more) yarns can be fed to each needle. Using the example of use for forming a turf field (e.g., as shown in Figures 9A and 10A), which can include various different colors for forming yard markings, lines, logos, etc., the needle can be fed artificial turf or turf yarn which may include at least one substantially flat ribbon yarn along with at least one filament. In other exemplary embodiments, each needle can be assigned and fed with two or more colors of yarn, such as for forming tufted carpets, rugs, and other tufted products (e.g., for forming a shag carpet as shown in Figure 11A).

[0168] The needle can be threaded with yarn of various assigned colors, which are tufted for the desired pattern according to a selected thread-up sequence. For example, for a pattern using 4 to 8 colors, the yarn can be threaded through the needle in a selected or desired thread-up sequence such as ABCD, ABCDE, ABCDEF, ABCDEFG, ABCDEFGH, feeding two or more different colored yarns to the selected needle in the sequence, and the thread-up sequence can then be repeated along the length of the needle bar. Other thread-up sequences can also be used in other embodiments. Furthermore, in some embodiments, if the pattern requires an extended portion or field of one color, the needles can be grouped or arranged in sets with different thread-up sequences.

[0169] For example, many sports fields today include areas where a logo or other design in different colors is presented. In embodiments, the needles can be provided with thread-up sequences according to the different colors used, and the yarn can be passed through the needles in 4 to 6 colors depending on the portion of the sports field being tufted. In an exemplary embodiment shown in Figure 9A, a section of a sports turf field is shown, which includes five colors: green, white, brown, black, and orange. A five-color thread-up sequence (e.g., ABCDE thread-up) can be used, with at least two needles assigned to primary colors such as green and white, and the other needles assigned to tuft the remaining (accent) colors, brown, black, and orange. In some embodiments, thread-up sequences of six or more colors can also be used, for example, when additional colors or yarns are needed in other areas of the field, and the feeding of such additional yarns is selectively controlled so that they are not presented in areas where they are not needed, or even during some tufting runs.

[0170] In some embodiments, the lining can be shifted in conjunction with or independently of the needles. In some embodiments, the lining can be shifted without the needles being shifted. In some embodiments, the needles are maintained in a substantially consistent lateral position and are not moved laterally with respect to the longitudinal movement path of the lining. Instead, the lining can be shifted in addition to being moved longitudinally. In such cases, the lining can be shifted laterally in various increments or steps, which may include shifting the lining by a distance based on the gauge spacing of the needles, or, in some embodiments, the distance may not be related to the gauge spacing of the needles (for example, the lining can be shifted over a distance or length smaller or larger than the gauge spacing between the needles).

[0171] In the embodiment, the lining can be shifted multiple times both longitudinally and transversely across the entire tufting zone to present yarn of a selected color at the corresponding stitch positions of the pattern and to insert or form tufts at such stitch positions at an actual stitch rate generally equal to the designed or adjusted pattern stitch rate as it moves along its movement path with each pattern step.

[0172] In some embodiments, the longitudinal movement of the lining can be further controlled so that it is fed at an actual stitch rate substantially matching the pattern stitch rate of the pattern being tufted, or, in some embodiments, the actual stitch rate at which the lining is fed can include an effective process stitch rate greater than the desired stitch rate of the pattern. For example, some sports turf applications (e.g., sports fields for football, soccer, lacrosse, or other sports) have a desired stitch rate of about 3-5 stitches per inch due to the filling requirements provided between tufts. In other turf applications, closer spacing may be desired, especially when less filling is required.

[0173] In some embodiments, the backing can be fed at an effective stitch rate that may depend on the selected pattern stitch rate and / or the desired density of the turf product, the number of colors used in the needle thread-up sequence, or a combination thereof. For example, in some embodiments, when a six-color yarn thread-up sequence is used, the backing can be fed at an effective process stitch rate of approximately 18 stitches per inch, even if the pattern requires the use of only three to five colors during a particular tufting run of the tufted product.

[0174] Furthermore, in some embodiments, the backing can be shifted to present each stitch position to a needle carrying yarn of a selected color to be placed at that stitch position, thereby providing closer spacing between tufts. In some embodiments, the backing can be fed at an effective process stitch rate, such as when the needle is shifted, and each needle can selectively present multiple yarns each time the needle penetrates the backing. Thus, larger tufts containing multiple yarns can be selectively formed at each stitch position or pixel of the pattern being formed.

[0175] In embodiments, such a backing feeding method, as shown in Figures 8A, 9A, 10A, 11A, and 12, further allows the surface of the patterned tufted product to be formed with a denser appearance, while the backstitch on the reverse side of the backing can be substantially minimized or reduced, and in some cases, can be formed without any subsequent length of yarn that was not selected to be retained and / or displayed on the surface of the patterned tufted product, as shown in Figures 8B-8C, 9B, 10B, and 11B.

[0176] In some cases, the effective process stitch rate does not have to be based on the gauge of the tufting machine (for example, based on the selected gauge spacing of the needles or the desired gauge of the tufted product). This can provide a fabric structure in which the number of longitudinal tufts does not match the number of transverse or transverse tufts.

[0177] Furthermore, in the embodiment, the needle bar 11 can consist of needles 12 arranged at gauge intervals substantially matching the gauge of the tufting machine, allowing two or more strands of yarn to be fed to each needle while the lining is moved at an effective stitch rate based on the thread-up sequence and yarn feed rate. This makes it possible to present multiple colors of yarn at each pixel or stitch position each time each needle penetrates, forming larger, more retained tuft yarns or strands at each stitch position, and / or forming tufts with less spacing between them. This can provide a richer tuft appearance with less yarn required for backstitching, without subsequent backstitching along the back of the lining, as shown in Figures 8A-8C and 10A-11B.

[0178] In embodiments, shifting the needle with or without shifting the backing, or shifting only the backing while the needle is maintained in the home position, in combination with the needle thread-up, can, in embodiments, allow for increased variability in the formed design. For example, a designer can use a selected / designed shift profile, yarn feed control, and a selected thread-up sequence that stretches / repeats across the width of the machine to plan where logos, accent features, or parts thereof will be placed relative to the finished turf field. After the formation of such strips or panels, the panels can be joined together or otherwise attached together to form a finished field as shown in Figure 9A.

[0179] In one example, as schematically shown in Figures 8A and 8B, the tufting system and method of the present disclosure can be used to form tufted turf and artificial grass products having multiple different colors and / or types of yarn (e.g., two, three, four or more flat ribbon type yarns). Figure 8A shows a cross-section of a tufted turf product in which various different colors are mixed as part of a single tufted turf product. Figure 8B shows the backstitch of the product of Figure 8A, where it can be seen that four different colored yarns have been tufted. The backstitch shows a zigzag shifting motion in which the needle is shifted back and forth. In embodiments, the needle, backing, or a combination thereof may be shifted four times in a first direction (e.g., to the right in Figure 8B) based on the use of four colors in the pattern, and then shifted four times in a second direction (e.g., to the left in Figure 8B). Other shifting motions may also be used.

[0180] By controlling the yarn feed through the operation of the yarn feeder and yarn jerker, and combining this with the shifting of the lining, needles, or a combination thereof, each color or type of yarn can be selectively fed to the corresponding needle, so that only the selected color or type of yarn is actually introduced into the lining. The movement of the lining along its movement path P can be further controlled to feed the lining at an effective or actual stitch rate that is increased above the desired or selected stitch rate of the pattern being tufted. In one example, for a four-color pattern, the effective or actual stitch rate can be about four times the desired or selected stitch rate of the pattern being tufted (for example, the pattern can be designed with a design pattern stitch rate that can be executed as the desired or selected stitch rate by the tufting system). In some cases, this design pattern stitch rate can be adjusted based on achieving a desired weight or other factors to develop the desired or selected stitch rate.

[0181] In the embodiment, the tufting system can therefore tuft only the color or type of yarn to be tufted at a specific stitch position, while unselected yarns can be maintained in a recessed position without needing to be tufted, but without causing gaps or reduced coverage in the tuft. As a result, mixtures of multiple colors or types of yarn can be tufted to form a variety of designs or accent features. Figures 8A and 9A show a four-color pattern turf product including a portion of a football in a green field, along with laces / stripes on the football and a team logo within the football. Furthermore, as shown in Figures 8B-8C and 9B, the backstitches formed on the back of the lining can actually contain only the yarn tufted to the lining, helping to reduce yarn consumption.

[0182] Furthermore, in the embodiment shown in Figure 9A, a strip or panel of turf, such as a 15-foot / 5-yard wide strip, can be tufted entirely or in sections with green, and designs, logos, field accessories, or parts thereof can be inserted at specific intervals in the formation of the strip or panel.

[0183] Figures 10A–12 illustrate additional embodiments of tufted products and their backstitches formed using tufting systems and methods according to the principles of the present disclosure. The tufting systems and methods of Figures 10A–12 use a tufting machine having needles arranged at gauge intervals substantially corresponding to the gauge of the tufting machine, and the lining is shifted while the needles are maintained in a substantially stationary lateral position relative to the longitudinal movement path of the lining, and the lining can be fed at an actual or effective stitch rate based on a desired stitch rate increased (e.g., multiplied) by the number of yarns in the thread up of the needle bar or the number of yarn colors in the pattern.

[0184] Figure 10A shows an example of a sports carpet using various different colored turf or artificial grass yarns, and Figure 10B shows an example of its backstitch. Figure 11A shows an example of a shag carpet including two colored yarns, and Figure 11B shows an example of its backstitch. As can be seen, different types of yarns, including yarns, filaments, etc., of varying thicknesses and materials, can be used to form patterned tufted products using embodiments of the tufting systems and tufting methods of the present disclosure. Unselected or unretained yarn / tufts presented at each stitch position of the pattern are removed as needed, and in some embodiments this may include retaining or pulling back the yarn within an assigned hollow needle, thus providing a cleaner backstitch as illustrated.

[0185] Figure 12 shows an example of an artificial turf or grass field tufted with a substantially seamless, integrally formed design using a tufting machine and tufting method in accordance with the principles of the present disclosure. In Figure 12, an artificial turf or grass field is shown with an eagle design and an American flag background tufted integrally with the rest of the entire tufted artificial turf or grass field, with no seams formed at the transition between the pattern-colored yarns forming the eagle and flag designs and the green base-colored yarns (e.g., green "grass" yarns) that make up the rest of the turf field, nor between the pattern-colored yarns defining the eagle design and the different pattern-colored yarns defining the American flag background of the eagle. Figure 12 shows an embodiment in which narrower sections of the artificial turf or grass field (e.g., sections formed using a sample machine-sized tufting machine) can be installed in succession, but the portion of the design itself within each section is substantially seamless with the green grass portion of each section. In the embodiment, it will be further understood that much larger or wider tufted turf fields or sections thereof, incorporating an overall design such as the eagle and flag design in Figure 12, can also be created using a larger tufting machine.

[0186] By enabling the creation of tufted artificial turf or grass products with an integrated, substantially seamless design or pattern (for example, without seams or substantial color bleeding at the boundaries or transitions between pattern yarns of different colors defining the pattern and base color yarns making up the rest of the turf field), significant savings in time, labor, and cost can be achieved in the installation of artificial turf or grass fields. For example, by utilizing the tufting machine or apparatus and tufting method of this disclosure, the need to separately form designs or patterns of different colors and then cut and sew and / or glue such designs onto the entire turf field during installation can be avoided. This can reduce the installation time of the turf field from several days to, in some cases, far more than a day, and significantly reduce the labor required.

[0187] In some embodiments, during the operation of the tufting machine or apparatus 10, one or more shifting mechanisms coupled to the needle bar and / or backing support or shuttle are used to shift the needle bar and / or backing support to displace the thread-up color or type of yarn on the needle bar, providing the ability to present each color (e.g., four or six or more thread-ups) passed through the needle at each pixel or stitch position, and in some embodiments, this allows for color mixing on the surface of the tufted product / turf to present and hold additional colors as needed to form a design, logo, or field accessory, or part thereof, at selected or desired positions during the formation of the tufted panel or strip. However, if a color or type of yarn is not desired on the surface, the yarn feeding system can be controlled to substantially stop the feeding of such color or type of yarn, and the yarn jerker associated with the yarn can retract the yarn from the needle, thereby providing enhanced color control in the design.

[0188] Furthermore, embodiments of the tufting machine and method of the present disclosure may include a tufting machine for forming artificial turf or turf products having a patterned design, comprising a plurality of needles configured to penetrate a positioned backing during the reciprocating motion of the needles, the needles comprising hollow needles, each having an upper and lower end, with a passage defined between the upper and lower ends, and a yarn feeding system for supplying a plurality of yarns, the yarn feeding system configured to selectively feed one or two yarns to each needle to form a tuft or yarn in the backing, presenting a different color or type of yarn to each of a plurality of stitch positions in the pattern being formed. To enable this, the system includes a shifting mechanism for shifting the needle across the lining or shifting the lining relative to the needle; a yarn selection system including a plurality of yarn jerkers coupled to an air supply and adapted to move between an extended position that allows selected yarn to pass from the yarn feeding system to the needle and a retracted position that retracts and / or holds the yarn supplied to one or more needles by the yarn feeding system; and a cutting system including at least one knife or cutting blade positioned below the lining support and configured to cut the selected yarn as it is carried to the lining along with the reciprocating motion of the needle to and from the lining.

[0189] In the embodiment, the tufting machine may further include a control system configured to control the operation of a yarn feeding system for feeding selected yarn to a needle, and the operation of a yarn jerker.

[0190] In the embodiment, the control system in the tufting machine may include programming configured to dynamically advance the operation of the yarn feed system and the yarn jerker prior to the next stitch placement step of the pattern being formed.

[0191] In embodiments, the tufting machine may further comprise at least one needle bar to which needles are attached, the needle bar having a series of openings spaced apart along its length and communicating with the passages of the corresponding needles, and the yarn is guided through the needle passages through the openings of at least one needle bar.

[0192] In embodiments of the tufting machine, the needles are arranged along at least one needle bar at gauge intervals selected based on the gauge of the tufting machine's artificial turf or turf product.

[0193] In one embodiment, the tufting machine may further include a series of angled yarn tubes mounted along the upper surface of a needle bar, each yarn tube communicating with a corresponding needle, and an air-guided yarn feeding mechanism coupled to an air supply for guiding the yarn through the yarn tubes and needles.

[0194] In an embodiment of the tufting machine, the shift mechanism includes a rack and pinion shift mechanism.

[0195] In embodiments of the tufting machine, at least one knife or cutting blade has a substantially flat cutting surface or cutting edge.

[0196] In an embodiment of the tufting machine, the needle comprises a hollow needle having a body with an internally defined passage, a first end that is received within a needle bar, and a second end that terminates at the tip and has a flattening cutting surface configured to cut flat ribbon yarn or filament.

[0197] In other embodiments, a tufting machine may be provided that is configured to produce panels of tufted turf or artificial grass products having an integrated design (e.g., a logo), or including part of a larger design, which can be attached to one another to form a sports carpet or artificial grass or turf field.

[0198] Furthermore, the disclosure further includes a method adapted to enable the manufacture of single-ended designs within the machine frame of a tufting machine for the manufacture of panels of tufted turf or artificial grass products that include an integrated design (e.g., a logo) or part of a larger design, which can be attached to one another to form a field.

[0199] In embodiments, a method is provided which may include supplying multiple yarns from multiple yarn feeders to each of multiple needles along a travel path; causing the needles to move back and forth in and out of the backing; shifting the backing laterally or shifting the needles with respect to the movement of the backing along the travel path; selectively controlling the yarn feeders to substantially stop or slow down the supply of non-selected yarns to the needles; activating one or more yarn jerkers to engage with and pull back the non-selected yarns; and selectively controlling the yarn feeders and yarn jerkers when the movement of the backing feeder along its travel path is controlled, so as to enable the presentation of different yarns at each of multiple stitch positions in order to form an artificial turf or turf product in which one or more of a design, accent feature, logo, or a part thereof is integrated.

[0200] In some embodiments, the method further includes moving a plurality of hollow needles in and out of the lining in a reciprocating motion, selectively supplying a plurality of yarns to each of the hollow needles as they move in and out of the lining in a reciprocating motion, and shifting the lining laterally with respect to the longitudinal movement path.

[0201] Furthermore, using the tufting machines, apparatus and methods of this disclosure, a variety of tufted articles can be manufactured, including artificial turf or grass, which may have a variety of colors, designs, letters, or other patterns, and which can be formed into sections or panels configured to be mounted as part of a larger field or patterned article.

[0202] This disclosure is described herein with respect to examples illustrating the principles and aspects of this disclosure. However, those skilled in the art will understand that a wide range of additions, deletions, changes, and modifications, ranging from minor to substantial, can be made to the examples presented without departing from the spirit and scope of this disclosure. All such modifications that do not depart from the spirit of this disclosure are intended to be within the scope of any aspect and / or claim provided by this disclosure.

Claims

1. A tufting machine for forming artificial turf or turf products having a pattern design, A needle bar comprising at least one needle bar with a plurality of needles positioned along it, wherein the needles include hollow needles, A yarn supply system configured to supply multiple yarns to a needle, wherein the needle moves in a reciprocating motion toward and away from the lining as it moves along a path through a tufting machine, so as the needle penetrates the lining, the selected yarn is introduced into the lining. At least one shift mechanism for shifting the lining laterally, A yarn selection system positioned along the yarn movement path between the yarn supply system and the needles, the yarn selection system configured to pull back and / or hold non-selected yarn supplied to one or more of the needles by the yarn supply system, A tufting machine comprising a cutting system including at least one knife or cutting blade positioned below the lining and configured to cut the selected yarn as it is delivered to the lining by the reciprocating motion of the needle entering and exiting the lining.

2. The tufting machine according to claim 1, further comprising a control system configured to control the operation of the yarn supply system for supplying to the needle a length of each selected yarn substantially sufficient to form a tuft of a predetermined pile height, the operation of the yarn selection system, and the operation of the at least one shift mechanism for enabling the presentation of different colors or types of yarn to each of a plurality of stitch positions in a pattern to be formed.

3. The tufting machine according to claim 2, further comprising: a plurality of yarn jerkers adapted to engage with yarn supplied to the needle; and a plurality of actuators, each connected to at least one yarn jerker, adapted to move the yarn jerker between an extended position that allows selected yarn from the yarn supply system to pass through the needle and a retracted position that pulls back and / or holds unselected yarn supplied by the yarn supply system within the needle.

4. The tufting machine according to claim 3, wherein the control system includes programming configured to dynamically advance the operation of the yarn supply system and the yarn jerker or the yarn selection system prior to the next stitch placement step of the pattern to be formed.

5. The tufting machine according to claim 1, wherein the at least one needle bar is spaced along it and has a series of openings communicating with passages extending through corresponding needles, and the yarn is guided into the needles through the openings of the at least one needle bar.

6. The tufting machine according to claim 1, wherein the needles are arranged along the at least one needle bar at gauge intervals selected based on the gauge of the artificial turf or turf product of the tufting machine.

7. The tufting machine according to claim 1, further comprising an air-guided yarn feeder connected to an air supply source and configured to guide the flow of air through the at least one needle bar to assist in the supply of yarn through the needles.

8. The tufting machine according to claim 1, wherein the shift mechanism comprises a rack and pinion shift mechanism.

9. The tufting machine according to claim 1, wherein the at least one knife or cutting blade has a substantially flat cutting surface or cutting edge.

10. The tufting machine according to claim 1, wherein each needle comprises a body having an internally defined passage, a first end that is received in a needle bar, and a second end that terminates at the tip and has a flattening cutting surface configured to cut flat ribbon yarn or filament.

11. It is a tufting device, Multiple needles configured to penetrate the lining, A yarn supply system configured to selectively supply multiple yarns to a needle, wherein the needle comprises a hollow needle, each of which has a first end and a second end, and a passage is defined between the first end and the second end through which one or more yarns are supplied, and the yarn comprises multiple different types of colored yarns. A shifting mechanism for shifting the needle across the lining or for shifting the lining relative to the needle, A yarn selection system comprising a plurality of yarn jerkers, each movably adapted between an extended position that allows selected yarn from the yarn supply system to pass through the needles and a retracted position that pulls back and / or holds unselected yarn supplied to one or more of the needles by the yarn supply system, A tufting machine in which, as the needle moves back and forth in and out of the lining, the supply of selected and unselected yarns is controlled by the yarn supply system, and the yarn jerker moves between its retracted and extended positions, allowing the selected yarns to be inserted into the lining to form loop pile or cut pile tufts of selected yarns according to the pattern to be tufted.

12. The tufting machine according to claim 11, further comprising a cutting system including at least one knife or cutting blade configured to cut selected yarn to form a cut pile tuft of yarn on a backing.

13. The tufting machine according to claim 11, further comprising a control system having programming configured to control the operation of the yarn supply system for supplying selected yarn to the needle, and programming configured to dynamically advance the supply of yarn by the yarn supply system and the movement of the yarn jerker between an extended position and a retracted position prior to the next stitch placement step of the pattern to be formed.

14. The tufting machine according to claim 11, further comprising at least one needle bar to which the needles are attached, wherein the needles are arranged along the at least one needle bar at gauge intervals selected based on the gauge of the artificial turf or turf product manufactured by the tufting machine.

15. The tufting machine according to claim 11, further comprising an air supply source and an air-inductive yarn supply device coupled to the air supply source for guiding the yarn through the needle.

16. The tufting machine according to claim 11, wherein each second end of the needle includes a tip, an opening through which one or more yarns exit the needle, and a surrounding flattening cutting surface configured for cutting flat ribbon yarn or filament.

17. The tufting machine according to claim 11, wherein the tufting machine is configured to produce a tufted turf or artificial turf product having an integrated design (e.g., a logo) for the tufted turf or artificial turf product.

18. It is a method, Move the lining along the path of movement. Supplying multiple yarns from multiple yarn supply devices to each of multiple needles along their respective paths, The needle is moved back and forth through the lining. Shifting the lining laterally or shifting the needle in relation to the movement of the lining's path, To selectively control the yarn feeder to substantially stop or slow down the supply of non-selected yarn to the needle, and to activate one or more yarn jerkers to engage with, hold, or pull back, the non-selected yarn so that it is substantially maintained within the needle. Selectively controlling the yarn feeder and yarn jerker when their movement along the lining's path is controlled, so as to enable the presentation of different yarns at each of multiple stitch positions, and This includes forming multiple tufts of selected yarn into a lining, The method includes an artificial turf or turf yarn that includes one or more colors such that the yarn forms a tufted artificial turf or turf product in which one or more of a design, accent feature, logo, or a part thereof is integrated.

19. The method according to claim 18, wherein shifting the lining or shifting the needle includes shifting a lining support over which the lining moves.

20. The method according to claim 18, further comprising moving at least one cutting blade to engage with the cut surface of each needle as the needle penetrates the lining, thereby cutting the selected yarn to form a tuft of the selected yarn in the lining.

21. Tufted artificial turf or turf products, Lining and, The aforementioned lining comprises multiple tufts of artificial turf or turf yarn spaced apart, The artificial turf or turf yarn includes a base color yarn and one or more pattern color yarns of a different color from the base color yarn. The base color and the selected colors of one or more pattern color yarns are held in the backing material at selected stitch positions within the artificial turf or grass field, thereby defining at least one pattern area of ​​one or more pattern color yarns formed within the field of base color yarn. A tufted artificial turf or turf product in which the transition between at least one patterned area of ​​the patterned color yarn and the field of the base color yarn is substantially seamless.

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