Tufting machine and method

Abstract

A tufting machine for selectively forming tufts of yarn containing different colors or types of yarn to form a patterned tufted article such as a carpet. A series of needles are shuttled in and out of a backing material being fed through the tufting machine and are engaged by a series of gauge elements to pick up loops of yarn from the needles. The gauge elements would be selectively controlled by an activator to extend or retract the gauge elements to a position or elevation sufficient to pick up or not pick up loops of yarn from the needles. The yarn feed to the needles would be further controlled to backlob yarns not picked up by the gauge elements, while the backing feed would be controlled to allow the formation of tufts at an increased rate that exceeds the pattern stitch rate for the pattern of the tufted article being formed.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This patent application claims the benefit of U.S. Provisional Application No. 63 / 149,957, filed February 16, 2021.

[0002] (Incorporated by reference) U.S. Provisional Patent Application No. 63 / 149,957, filed February 16, 2021, is specifically incorporated by reference herein as if set forth in its entirety.

[0003] FIELD OF THE DISCLOSURE TECHNICAL FIELD This disclosure relates generally to tufting machines and methods of forming tufted fabrics. In particular, this disclosure relates to tufting machines including selectively controllable gauge elements and modules or gauge blocks for carrying such gauge elements, and methods of forming patterned tufted fabrics. [Background technology]

[0004] In the tufting field, particularly with respect to commercial and hospitality carpets, there is an increasing demand for the production of carpets and rugs with new visual patterns, including the use of multiple different colors, in an effort to keep up with changing consumer tastes and increased competition in the market. Carpet designers and manufacturers are therefore increasingly focused on creating newer, different, and more eye-catching patterns for carpets, rugs, and other tufted fabrics, including patterns having selective placement and display of specific colors or types of yarn within the pattern area, with the resulting tufted fabric being formed with a substantially true pattern density of visible tufts of the pattern. In particular, it has become desirable to replicate as closely as possible the look and feel of patterned carpets, rugs, or other fabrics formed on a loom, but in such a way that they can be created and formed therein on a wide tufting machine, allowing for increased efficiency in the production of such patterned tufted carpets, rugs, and / or other fabrics.

[0005] In addition, it is generally desirable to increase the operating speed of tufting machines and increase the output therefrom. This means that gauge parts such as loopers or hooks and other parts such as needles are subjected to increased machine cycles. As a result, these gauge parts and the modules or blocks which carry such gauge parts are subjected to a higher incidence of wear and required replacement.

[0006] It can therefore be seen that a need exists for systems and methods for forming tufted fabrics, such as carpets and rugs, that address these and other related and unrelated problems within the art. Summary of the Invention [Means for solving the problem]

[0007] Briefly, the present disclosure relates to a tufting machine and method for forming patterned tufted articles in which the placement and pile height of yarn or stitch tufts formed in a backing may be selectively controlled to enable the formation of patterned tufted articles, such as carpets, with flowable, multi-color and / or multiple pile height patterns and with a variety of pattern effects, including the formation of tufted articles having a substantially woven or loom-formed appearance.

[0008] In one aspect, the tufting machine will typically include a control system for controlling the operating elements of the tufting machine to form or create a tufted article according to a desired and / or designed pattern. The resulting tufted article can include a variety of pattern effects including having a plurality of varied or different pile heights, different types of tufts in the same and / or varying rows of tufts, and other texture effects, and placement of various colors and / or types of yarns visible at selected locations and pile heights across the backing, and in at least some embodiments, the resulting tufted article is provided with a retention and / or visible color / stitch density per inch that substantially matches the desired or prescribed pattern density or stitches per inch of the pattern being formed / tufted.

[0009] In an embodiment, the tufting machine will include one or more needle bars having a series of needles mounted therealong. The needles may be arranged in a straight line, alternating, or other arrangement. As the backing material is fed through the tufting zone of the tufting machine, the yarn will be introduced therein as the needles are shuttled in and out of the backing material. A shifting mechanism may further be provided to shift the needle bars laterally across the tufting zone, and multiple shifting mechanisms may be utilized, as desired. The shifting mechanism will generally be operable in response to commands or communications from a control system to incrementally move or shift the needle bars laterally across the backing according to programmed and / or designed pattern shift steps for the pattern being tufted, thereby presenting the carried yarn to a tuft or stitch location along / across the backing.

[0010] Tufting machines will generally further include at least one yarn feed mechanism or attachment for controlling the feeding of yarn to their respective needles. Such yarn feed mechanisms or pattern attachments may be, for example, but are not limited to, Yarntronics, such as those manufactured by Card-Monroe Corp. TM or Infinity TM / Infinity IIE TM The yarn feed attachments may include a variety of roll, scroll, servo scroll, single end, or double or multiple end yarn feed attachments. Other types of yarn feed control mechanisms may also be used. At least one yarn feed mechanism or pattern attachment may be operated to selectively control the feeding of yarn to its needles to form tufts of yarn, which may include forming tufts having a selected pile height and / or forming no tufts, to create a desired carpet pattern appearance.

[0011] In some embodiments, the control system may further comprise or operate in conjunction with a stitch distribution control system as disclosed in U.S. Patent No. 8,359,989 (the disclosure of which is incorporated herein by reference as if fully set forth), through which control of the backing feed and the operation of the shift mechanism for shifting at least a portion of the needles may be coordinated with control of at least one yarn feed mechanism such that various yarns may be presented at various stitch locations or pixels, and yarns that are to be presented on the front side or surface of the tufted article may generally be fed in sufficient amounts to form tufts of the desired height, while non-appearing yarns that are not to be presented in the tufting areas will be backlobbed or otherwise pulled down sufficiently and / or pulled out of the backing. For each pixel or stitch location of the pattern, a series of yarns may be presented, and yarns that are visible or not selected to be visible at such stitch locations may be hidden and pulled down sufficiently so as not to interfere with the selected yarns that are visible. In some embodiments, this can include pulling the non-emerging or non-selected yarns out of the backing, or leaving a sufficient portion of the non-emerging yarns within the backing to hold or sew the non-selected or non-emerging yarns against the backing such that interference with the yarn face side of the pattern or the retained visible tufts is substantially minimized. Thus, in embodiments, only the desired or selected yarns / colors to be placed at a particular stitch location can be retained at such stitch location, while the remaining yarns / colors can be hidden so as not to be revealed or shown in the pattern area currently being sewn. The control system can further control and coordinate the operation of the gauge component assemblies with at least the yarn feed according to instructions for the pattern being formed to control the selective formation of yarn loops and / or tufts, and their length or pile height.

[0012] Additionally, in embodiments, the gauge component assembly will generally comprise a series of gauge components including, for example, but not limited to, loopers, hooks, level cut loop loopers, cut / loop clips, etc., that will be provided below the tufting zone and be movable in a first direction to be reciprocated to engage the needles as the needles penetrate the backing material and pick up loops of yarn therefrom. In some embodiments, each of the gauge components may be selectively further movable in a direction that is generally perpendicular to the direction of its reciprocation, for example, moved substantially perpendicular to the stroke or reciprocation of the needles up and out of the backing, i.e., in an up and down motion, and moved in a reciprocating motion toward and away from the needles to selectively pick up and form loops of yarn in the backing material. Additionally, the vertical movement of the gauge components can be controlled to form varying loops of yarn in the backing material with varying pile heights, including the formation of loops of different pile heights, or even no loops of yarn in the backing. In still further embodiments, other configurations and / or combinations of loop pile loopers, cut pile hooks, cut / loop hooks, level cut loopers or hooks, and / or other gauge components may also be used.

[0013] For example, in some embodiments, the gauge parts can include loopers or hooks, each of which is slidably mounted within the gauge module or gauge block and includes a body having a first portion and a second portion, which can include an elongated throat terminating in a pointed proximal end or bill. The first portion of the body can extend through the gauge block or module and can be connected to an actuator at a distal end. In some embodiments, each of the gauge modules can include a module or block body having a first or rear section adapted to couple or mount along a gauge bar and a second or front section having at least one channel or passage formed therethrough through which the gauge part may be received. The module can further include a replaceable insert that can be received within the passage or channel formed in the module body, the replaceable insert further including a slot or recess adapted to receive and guide the gauge part during movement of the gauge part through / along the passage of the module block. Alternatively, the insert may be integral with the module, such as by being bonded or otherwise substantially permanently attached or fastened to the body of that module or gauge block, and in some embodiments may be substantially attached while still allowing for at least useful removal thereof if required.

[0014] In embodiments, the replaceable inserts will be formed from hardened materials that may include, but are not limited to, various metal carbides, metals, ceramics, and / or synthetic materials, while the body of the module can be manufactured from lighter materials such as aluminum and / or other metals and various composite or synthetic materials. The inserts may further include openings or slots configured to receive guide pins or other positioning devices, and one or more fasteners for securing the insert within the gauge module. The openings will generally be further configured to allow adjustment of the insert in at least one direction, e.g., longitudinally, and / or in multiple directions, e.g., longitudinally and / or laterally, to adjust the position of the insert and thus the placement or positioning of the gauge components across and / or along the gauge module. The inserts may further be interchangeable to allow easy removal of the insert and thus replacement of one or more of the gauge components received therein, e.g., to replace worn or broken gauge components or to change the spacing between the gauge components.

[0015] As a further alternative, in some embodiments, the module or gauge block itself can be removed and replaced with other gauge blocks or modules, each including a set or series of gauge parts mounted therein, to provide for alteration of the gauge spacing between gauge parts, changes in the type or size of gauge parts being used, or replacement of substantially all or at least most of worn or damaged gauge parts as a unit. In addition, the guide slots or recesses formed in the insert will generally be configured to receive the bodies of the gauge parts with a clearance sufficient to permit substantially free sliding movement of the gauge parts therethrough, but not to permit excessive shifting or twisting of the gauge parts that would create misalignment of the bills or throats of the gauge parts and their respective needles. The slots or recesses of the insert can further terminate at a rear end or portion that can be configured or adapted to permit edges of the bodies of the gauge parts to be seated against and / or include a base or engagement area along which they may slide to help maintain a desired alignment of the gauge parts as they are reciprocated or moved through the module.

[0016] The gauge parts can additionally be positioned to engage the needle, including being positioned substantially in line, offset or alternating, and / or in other configurations, as needed to engage in in-line, alternating, and / or dual needle bar arrangements. In embodiments, each of the gauge parts can further be positioned at an angle relative to the needle as it penetrates the backing. For example, in some embodiments, the gauge parts can be positioned and / or extendable / retractable along a travel path that is oriented at an angle that can range from about 1° to about 10° from normal to the needle and / or its stroke or vertical motion, while in other arrangements, no offset, i.e., a 0° angle, can be provided. The offset of the gauge parts relative to the needle can further be varied such that the gauge parts can be extended and retracted along a travel path that is angled or offset relative to the needle as needed to minimize potential engagement with the needle when the gauge parts are moved, depending on the spacing and / or arrangement of the needle.

[0017] In various embodiments, the actuators driving the movement of the gauge components can comprise hydraulic, electric, air, or pneumatic cylinders, motors, or other similar actuators. The actuators of each of the gauge components can be selectively controlled according to pattern instructions to move the gauge component to a desired vertical position relative to the associated needle for pick-up of a yarn loop from the needle, including picking up the yarn loop at different points in the needle stroke to form loops / tufts of different pile heights, and being retracted to a "non-sew" position where the yarn loop will generally not be picked up. In further embodiments, the actuators can be controlled / triggered to move that gauge component along with such captured yarn loops to provide other pile heights and / or other effects, for stretching or pulling the captured loop thereon, tip shearing or other pattern or texture effects, etc.

[0018] In various aspects, the gauge component can be further coupled to its respective actuator by a connector or gate configured to extend between the actuator shaft or rod and a distal end of an associated or corresponding gauge component. In some embodiments, the connector or gate can include an arm or link having a first end portion configured to engage or connect to a drive rod of the actuator, an intermediate section protruding from the first end portion, and a second end portion that would generally be configured to engage the distal end of the associated gauge component. As each actuator is activated or deactivated, it extends or retracts its actuator shaft to move its associated gauge component in a desired direction relative to the needle.

[0019] For example, in some embodiments, the actuator can actuate the gauge component in a direction generally perpendicular to the directional reciprocation of the needle into and out of the backing, such as to adjust the height of the gauge component relative to the needle as the gauge component is reciprocated toward and away from the needle. In other embodiments, actuation of the actuator and movement of the connector can serve to control movement of the gauge component toward and away from the needle in a direction substantially along the directional reciprocation of the gauge component toward and away from the needle.

[0020] Additionally, in embodiments, the connector or gate linkages or arms can be further received within a housing or support structure. In one exemplary embodiment, such housing or support structure can include a body formed from a durable, lightweight material, such as a carbon-filled nylon material or other similar composite or plastic material selected to provide durability and support for the linkages or arms while allowing for reduced weight. Other materials, including various metals, synthetics, and / or composites, can also be used. While the configuration of the support structure or housing can be further varied to accommodate linkages of varying configurations and / or sizes as needed, in various embodiments, the connector linkages or arms can further have a reduced thickness or structure, and in some embodiments can include a skeletonized structure, to further aid in reducing weight. The connector linkages or arms are received within channels or passages formed within the connector housing and move through the channels or passages when the actuator is engaged and disengaged, transferring this movement to their associated or corresponding gauge components.

[0021] In some aspects of the disclosure, a tufting machine is provided that includes at least one needle bar having needles mounted therealong, a backing feed roll that feeds the backing material, an insert having a series of slots each in which one of the gauge components is slidably received, at least one yarn feed mechanism that feeds yarn to the needles, and a gauge component assembly positioned below the backing material.

[0022] In some embodiments, the gauge part assembly may include at least one module carrying a series of gauge parts in a reciprocating motion toward and away from engagement with the needle when the needle is reciprocated into the backing material, the at least one module including a module body that may be cast, molded, or otherwise formed from a metal, polymer, composite, or synthetic material, or combination thereof, and that may have a first hardness. The module body may be adapted to be mounted along the gauge bar and configured with a passage defined therethrough. An insert is mounted to the module body on either side of the passage, each insert having a series of spaced apart slots formed therein, each of the slots configured to slidably receive at least a portion of one of the gauge parts therein. In embodiments, the insert may be cast, molded, or otherwise formed from a metal or metal carbide or powdered metal material having a hardness greater than the hardness of the module body, and the slots are formed or defined therein. In an embodiment, each of the gauge components can include a body at least partially received in opposing slots of the insert and movable through the passage of the modular body in an additional direction relative to the stroke of the needle, the body of each gauge component having a first portion extending through the passage of at least one module and a second portion having a throat configured to pick up a loop of thread from the needle.

[0023] In an embodiment, the tufting machine will include a series of actuators coupled to the gauge parts for controlling movement of the gauge parts through the module body, and a control system including programming for controlling at least one yarn feed mechanism and, in coordination with controlling the operation of one or more of the actuators, controlling the feed of yarn to the needles to thereby extend or retract selected ones of the gauge parts so that the throats of selected ones of the gauge parts are moved between non-sewing and engaged positions relative to the stroke of the needles into the backing material to selectively form tufts of yarn in the backing material according to a pattern being formed.

[0024] In various embodiments of the tufting machine, the gauge components comprise level cut loop loopers, loop pile loopers, cut pile hooks, or cut / loop clips, and / or combinations thereof. In still further embodiments of the tufting machine, the actuators can comprise hydraulic or pneumatic cylinders, servo motors, or other types of actuators.

[0025] In yet other embodiments of the tufting machine, the gauge part assembly may further include a series of connectors extending between each gauge part and an actuator associated with the gauge part, each of the connectors including a coupling portion received within the housing and movable therethrough.

[0026] In some embodiments, the housing of each connector comprises a body formed from a polymer, a composite, or a synthetic material, or a combination thereof, which may have a channel extending therethrough, and each link comprises a metal, or a composite material, or a combination thereof.

[0027] In other embodiments, the body of each housing can comprise a composite material including a polymer or plastic with interdigitated fiber filling material and have a channel defined therein along which the coupling is movable, and each connector coupling comprises a hardened metal body coupled to the body of the housing and having a proximal end configured to engage a first portion of one of the gauge parts and a distal end configured to be engaged by an actuator associated with the gauge parts to transfer movement by the actuator to the gauge part.

[0028] In still further embodiments, each of the at least one modular insert comprises a first insert and a second insert, each including a tab or flange portion that may cover and / or be mounted to a top or first or bottom or second surface of the modular body. In other embodiments, the body of each insert may have an upper or proximal portion, a lower or distal portion, and a middle section extending therebetween and extending along a passageway defined through the modular body, wherein the slots of the first or left insert are spaced from, opposed to, and substantially aligned with corresponding slots of the second or right insert.

[0029] In addition, in an embodiment, the tab or flange portion of each of the first and second inserts is configured to cover the upper surface of the module body and includes a slotted opening adapted to receive a fastener therethrough for adjustably mounting each of the first and second inserts to the module body, the inserts being positioned at selected intervals from each other and at selected locations relative to the passages defined through the module body. In addition, the inserts can be molded into the module body, or surrounded, encapsulated, or otherwise substantially integrated. The inserts can also include tab or flange portions that can engage opposing surfaces of the module body, and a plate or intermediate section can be provided therebetween. The intermediate section can be connected to the tab or flange of the insert, and the slot of the insert is at least partially formed therein and extends along it. Alternatively, a bearing plate of the support can be received along the first and second side surfaces of the passage between the tab or flange of the insert.

[0030] Thus, in some aspects of the disclosure, a gauge part assembly for a tufting machine includes at least one module having a modular body with a passage defined therethrough, and a series of gauge parts received in the passage of the modular body, each gauge part including a body with a first portion and a second portion having a throat, the gauge parts being carried with their modules in a first direction toward and away from engagement with associated needles of the tufting machine to pick up loops of yarn from the needles along the throats of the gauge parts, and the gauge parts being selectively movable in a second direction along the passage of the modular body. The first and second modular inserts are disposed along opposite sides of the body passageway, each insert formed from a material having a hardness greater than the hardness of the metal or composite material of the modular body and having a series of spaced apart slots configured to receive at least a portion of one of the gauge parts therealong, the slots of the first and second inserts being substantially aligned across the passageway, and each actuator of the plurality of actuators is coupled to a first portion of an associated gauge portion of the series of gauge parts and adapted to move its associated gauge part in a second direction through the at least one modular passageway, whereby the gauge part is extended or retracted through the modular body to move a throat of the gauge part between an extended position for engaging and picking up a loop of thread from the needle and a retracted position for substantially avoiding picking up the loop of thread from the needle.

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

[0032] In yet another embodiment, the gauge component assembly can include first and second inserts each comprising a body molded or cast from a metal, carbide, or powdered metal material and including a tab or flange portion having a slot formed therein. Still further, the body of each of the first and second inserts further comprises upper and lower tab or flange portions that engage upper and lower surfaces of the module body, with the slot extending through the upper and lower tab or flange portions.

[0033] In an additional embodiment, the gauge component assembly may include first and second inserts each molded or cast from a metal, carbide, or powdered metal material and comprising a body including a tab or flange portion having a slot formed therein, and the module body of at least one module comprises a metal or composite material that is molded or cast to form the module body with the first and second inserts substantially integral therewith.

[0034] In some aspects of the disclosure, a method of operating a tufting machine is disclosed, and according to one exemplary embodiment of the disclosure, as the needles of the tufting machine are reciprocated in and out of the backing, an actuator of a gauge component can be selectively engaged or disengaged to move the gauge component between a fully retracted or non-stitching position, in which the gauge component does not engage an associated or corresponding needle, and therefore will not form any yarn loops, and varying extended or raised positions, including a fully extended position. In the raised or extended position, the gauge component engages the needle at its take-off portion and picks up a loop of yarn from the needle as the needle passes in and out of the backing material. The loop of yarn picked up from the needle can have a varying pile height or length depending on the position and / or movement of the gauge component relative to its associated or corresponding needle. For example, in the fully raised position, smaller or reduced length yarn loops can be formed to create lower pile heights, or even substantially hidden yarn loops in the backing, including such loops being substantially removed by control of the yarn feed. Longer yarn loops can be picked up and formed by the loopers as they are moved to the lowered position, pulling the yarn loops therewith, as needed, to create higher or higher pile height yarn tufts in the backing. In addition, the actuators can be further controlled to selectively lower or retract their corresponding gauge components, along with the yarn loops captured thereon, to form even longer yarn loops, such as for tip shear, and to enable additional patterning effects.

[0035] The needles can generally be further shifted laterally relative to the longitudinal movement of the backing through the tufting strip to present different colors or types of yarn at each stitch location of the pattern being formed in the backing material. For example, the needles of the needle bar or multiple needle bars can be threaded with a series of desired colors in various thread-up sequences. In addition, the backing material can typically be activated at an actual or effective stitch rate that is substantially greater than the prescribed or desired pattern stitch rate for the pattern being formed. As a result, as the needles are shifted, a desired number of different colors or types of yarn can be presented at each stitch location. By controlling the positioning and / or movement of the gauge components, yarn loops can be selectively formed in the backing material, which formation of such yarn loops can be further controlled in some embodiments to form varying pile heights of the resulting tufts. For example, in various aspects, a series of different colors or types of yarn can be presented at each stitch location as the needle bar is shifted, and if a tuft of a particular color or type of yarn is not selected to be sewn at that stitch location, the corresponding gauge component can be held in a retracted or lowered position such that loops of such non-selected yarn are generally not formed.

[0036] In addition, as the needles are shuttled out of the backing, the yarn feed therefor can also be controlled to cause non-selected yarns to be retracted, backlobbed, or otherwise pulled back or out of the backing material along with the needles, and to cause some loops of yarn to be retracted, backlobbed, or pulled back to a sufficient extent to prevent such yarns from being presented at that stitch location in the finished patterned article. Control of the backing material at higher operating, effective, or actual stitch rates allows for the formation of a substantially increased number of stitches of yarn presentation into the backing material so as to substantially avoid missing colors or types of yarn or gaps being created, presented, or otherwise appearing in the pattern areas of the patterned tufted article. The finished patterned tufted article can thus be provided with a density of tufts per inch that substantially matches the desired or prescribed pattern stitch rate; i.e., for a pattern designed with a pattern stitch rate of 8, 10, or 12 needles per inch, or other number of stitches per inch, the resulting finished patterned tufted article can be formed with a density of visible and / or retained face yarns or tufts per inch that can approximately match the pattern stitch rate.

[0037] The foregoing and other advantages and aspects of the embodiments of the present disclosure will become apparent and will be more readily understood from the following detailed description and claims, taken in conjunction with the accompanying drawings. Moreover, it is to be understood that both the foregoing summary of the disclosure and the following detailed description are exemplary and are intended to provide further explanation without limiting the scope of the disclosure. The present specification also provides, for example, the following items: (Item 1) A tufting machine, comprising: at least one needle bar having a plurality of needles, the plurality of needles being mounted along the at least one needle bar; a backing feed roll for feeding the backing material; at least one yarn delivery mechanism for delivering yarn to the needles; a gauge component assembly positioned below the backing material, the gauge component assembly comprising: at least one module carrying a series of gauge parts in a reciprocating motion toward and away from engagement with the needle as the needle is reciprocated into the backing material, the at least one module comprising: a modular body formed from a metal, a polymer, a composite, or a synthetic material, or a combination thereof, and having a first hardness, the modular body adapted to be mounted along a gauge bar and having a passageway defined therethrough; inserts positioned along the module body on either side of the passage; Equipped with each of the inserts having a slot in which one of the gauge parts is slidably received, each of the slots configured to slidably receive at least a portion of one of the gauge parts therein; the insert comprises a metal or metal carbide material having a second hardness greater than the first hardness of the module body; at least one module, each of the gauge components including a body at least partially received in opposing slots of the insert, the body being movable through a passage of the module body in an additional direction relative to the stroke of the needle, the body of each gauge component having a first portion extending through the passage of the at least one module and a second portion having a throat configured to pick up a loop of thread from the needle; a series of actuators coupled to the gauge components for controlling movement of the gauge components through the module body; a gauge component assembly comprising: Control system including programming Equipped with The programming controls the at least one yarn feed mechanism to control the feeding of the yarn to the needles in coordination with controlling the actuation of one or more actuators to extend or retract selected ones of the gauge parts, whereby the throats of the selected ones of the gauge parts are moved between a non-sewing position and an engaged position relative to the stroke of the needle into the backing material to selectively form tufts of yarn in the backing material according to a pattern being formed. (Item 2) a shifting mechanism for shifting the at least one needle bar laterally across the backing material; The control system is adapted to present a series of threads at selected stitch locations along the backing material as the needles are shuttled in and out of the backing material and to withdraw unselected threads. shifting the at least one needle bar by the shift mechanism; feeding the backing material by the backing feed roll; Control of the actuator coupled to the gauge component; and Controlling the at least one yarn delivery mechanism that delivers the yarn to the needles; and further comprising programming for adjusting Such unselected loops of yarn are not picked up by one of said gauge components; 2. The tufting machine of claim 1, wherein the backing material is moved through a tufting zone at an operating stitch rate, the operating stitch rate being greater than a pattern stitch rate for the pattern being formed to provide a number of retained tufts per inch of face yarn in the backing material approximately equal to the pattern stitch rate. (Item 3) Item 2. The tufting machine of item 1, wherein the gauge components comprise a level cut loop looper, a loop pile looper, or a cut pile hook. (Item 4) Item 2. The tufting machine of item 1, wherein the actuator comprises a hydraulic or pneumatic cylinder. (Item 5) 2. The tufting machine of claim 1, wherein the gauge part assembly further comprises a series of connectors extending between actuators associated with each gauge part, each of the connectors including a coupling portion received within a housing and movable through the housing. (Item 6) Item 6. The tufting machine of item 5, wherein the housing of each connector comprises a polymer, a composite, or a synthetic material, or a combination thereof, and further includes a channel extending through the housing, and each link comprises a metal, a composite material, or a combination thereof. (Item 7) the body of each housing further comprises a composite material including a polymer or plastic with a fiber-filled material and has a channel defined therein; 6. The tufting machine of claim 5, wherein the couplings are movable along the channel, and the couplings of each connector comprise a hardened metal body coupled to a body of the housing, the hardened metal body having a proximal end configured to engage a first portion of one of the gauge parts and a distal end configured to be engaged by an actuator associated with the gauge part to transfer movement by the actuator to the gauge part. (Item 8) each of the at least one modular insert comprises a first pair of inserts mounted to upper and lower surfaces of the modular body along a first side of the passage of the modular body and a second pair of inserts mounted to the upper and lower surfaces of the modular body along a second side of the passage of the modular body; the second pair of inserts are spaced apart from and face the first pair of inserts; 2. The tufting machine of claim 1, wherein the slots of the inserts of the first pair of inserts are disposed in opposing and substantially aligned relationship with the corresponding slots of the inserts of the second pair of inserts. (Item 9) 9. The tufting machine of claim 8, wherein the inserts of the first and second pairs of inserts are configured to cover the upper and lower surfaces of the modular body, each including a slotted opening adapted to receive a fastener therethrough for adjustably mounting each of the first and second pairs of inserts to the modular body, the inserts being positioned at selected intervals from one another and at selected locations relative to the passage defined through the modular body. (Item 10) Item 2. The tufting machine of item 1, wherein the at least one needle bar comprises a pair of needle bars, each of the pair of needle bars having a series of needles mounted in series and spaced apart relation therealong. (Item 11) 1. A gauge component assembly for a tufting machine, said gauge component assembly comprising: a plurality of modules, each module including a module body and having a passageway defined therethrough; a series of gauge parts slidably received within each of said modules, each of said gauge parts having a throat terminating in a bill, said gauge parts being carried with their modules in a first direction toward and away from engagement with needles of the tufting machine along their throats to selectively pick up loops of yarn from needles, each of said gauge parts being selectively movable in a second direction along the paths of their modules; first and second inserts mounted to the module body of each module on either side of the passage defined through the module body, each insert formed from a metal or metal carbide material having a hardness greater than a hardness of the module body and having a series of slots formed therein, the slots of the first insert and the slots of the second insert being substantially aligned across the passage and configured to define a contact area along at least a portion of one of the gauge components slidably received therein; a plurality of actuators, each of the plurality of actuators coupled to an associated one of the gauge parts and adapted to move its associated one of the gauge parts in the second direction through the passageway of the module, whereby the gauge parts are extended or retracted to move the throat of the gauge part between an extended position for engaging and picking up a loop of thread from the needle and a retracted position for substantially avoiding picking up the loop of thread from the needle; a connector extending between each actuator and its associated one of the gauge components, each connector having a housing formed from a polymeric material with a coupling portion encased therein; and The gauge component assembly comprises: (Item 12) Item 12. The gauge component assembly of item 11, wherein each housing further comprises a composite material including a polymer or plastic with a fiber-filled material and has a channel defined therein along which the coupling is movable, and the coupling of each connector comprises a hardened metal body extending through the housing and has a proximal end configured to engage a portion of one of the gauge components and a distal end, the distal end configured to be engaged by the actuator associated with each gauge component to translate movement by the actuator to the gauge component. (Item 13) Item 12. The gauge component assembly of item 11, wherein an upper portion of each of the first and second inserts is configured to cover an upper surface of the modular body and includes a slotted opening adapted to receive a fastener therethrough for adjustably mounting each of the first and second inserts to the modular body, the inserts being disposed at a selected spacing from one another and at a selected location relative to a passageway defined through the modular body. (Item 14) Item 12. The gauge component assembly of item 11, wherein the insert comprises a metal carbide material having a hardness of at least 75+RC. (Item 15) Item 12. The gauge component assembly of item 11, wherein the insert comprises a metal carbide material and the module body comprises an aluminum material. (Item 16) 1. A gauge component assembly for a tufting machine, said gauge component assembly comprising: at least one module having a module body having a passageway defined therethrough; a series of gauge parts received within the passage of the module body, each gauge part including a body with a first portion and a second portion having a throat, the gauge parts being carried with their modules in a first direction toward and away from engagement with an associated needle of the tufting machine to pick up loops of yarn from a needle along the throat of the gauge part, the gauge parts being selectively movable in a second direction along the passage of the module body; inserts disposed along opposite sides of the passageway in the modular body, each insert being formed from a material having a hardness greater than a hardness of the metal or composite material of the modular body and having a series of spaced apart slots configured to receive at least a portion of one of the gauge parts; Multiple actuators and Equipped with a gauge component assembly, wherein each actuator is coupled to a first portion of an associated gauge section of the series of gauge components and adapted to move its associated gauge component in the second direction through the passage of the at least one module, whereby the gauge component is extended or retracted through the module body to move the throat of the gauge component between an extended position for engaging and picking up a loop of thread from the needle and a retracted position for substantially avoiding picking up a loop of thread from the needle. (Item 17) Item 17. The gauge component assembly of item 16, further comprising a connector extending between each actuator and its associated gauge component, each connector having a housing formed from a polymeric material with the coupling portion encased therein. (Item 18) Item 17. The gauge component assembly of item 16, wherein the module body of the at least one module is molded or cast from metal or composite material. (Item 19) Item 19. The gauge component assembly of item 18, wherein each of the inserts is molded or cast from a metal, carbide, or powdered metal material and comprises a body with a tab or flange portion, the slot being formed in the tab or flange portion. (Item 20) 20. The gauge component assembly of claim 19, wherein the body of each of the inserts further comprises upper and lower tabs or flange portions that engage upper and lower surfaces of the module body, the slots extending through the upper and lower tabs or flange portions. (Item 21) Item 17. The gauge component assembly of item 16, wherein each of the inserts comprises a body molded or cast from a metal, carbide, or powdered metal material, the body comprising a tab or flange portion, the slot being formed in the tab or flange portion, and the module body of the at least one module comprises a metal or composite material, the metal or composite material being molded or cast so as to be substantially integral with the module body to form the module body. [Brief description of the drawings]

[0038] The accompanying drawings, which are incorporated in and constitute a part of this specification and are included to provide a further understanding of the embodiments of the present disclosure, illustrate embodiments of the present disclosure and, together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show structural details of the present disclosure in more detail than may be necessary for a basic understanding of the exemplary embodiments discussed herein and the various ways in which they may be practiced. Those skilled in the art will further recognize and understand that, according to common practice, the various features of the drawings discussed below are not necessarily drawn to scale, and the dimensions of the various features and elements of the drawings may be expanded or reduced in order to more clearly illustrate the embodiments of the present disclosure described herein.

[0039] [Figure 1] FIG. 1 is a side elevational view of one exemplary embodiment of a tufting machine with a selectively controllable looper assembly in accordance with the principles of the present disclosure.

[0040] [Diagram 2] FIG. 2 is a side elevational view of the tufting zone of the tufting machine of FIG.

[0041] [Diagram 3] FIG. 3 is a perspective view of the tufting machine of FIGS. 1-2.

[0042] [Figure 4] FIG. 4 is a perspective view of an exemplary embodiment of a gauge module or gauge block and gauge components according to the principles of the present disclosure.

[0043] [Diagram 5] FIG. 5 is a cross-sectional view of the gauge module or gauge block and gauge components of FIG.

[0044] [Figure 6] 6A-6B are plan views of the gauge module or gauge block of FIGS. 4-5.

[0045] [Figure 7] 7A-7B illustrate an embodiment of a connector for connecting a gauge component to its actuator in accordance with the principles of the present disclosure.

[0046] [Figure 8] 8A-8B illustrate another embodiment of a connector for connecting a gauge component to its actuator according to the principles of the present disclosure.

[0047] [Figure 9] 9A-9B illustrate yet a further embodiment of a connector for connecting a gauge component to its actuator according to the principles of the present disclosure.

[0048] [Figure 10] 10A-10B are perspective views of a series of needles and a portion of their respective gauge components in one exemplary embodiment according to the principles of the present disclosure.

[0049] [Figure 11] 11A-11C are side elevational views illustrating an embodiment of the operation of selectively actuatable gauge components according to the principles of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0050] Referring now to the drawings, in which like numerals denote like parts throughout the several views, FIGS. 1-11C generally illustrate an embodiment of a tufting machine 10 and method for forming a patterned tufted article according to the principles of the present disclosure, where the placement of stitches or tufts 5 of yarn Y can be at desired locations in a backing material B that can be controlled. Such tufts or stitches can be formed with a sculpted, multiple pile height tuft appearance and can be placed with enhanced selectivity and / or control for the creation of further variation or flowable pattern effects. For example, tufted articles can be formed with tufts of yarn formed with varying pile heights to provide a sculpted look, and with different colors or types of yarn for the creation of multi-color patterns of various geometric and / or flowable designs. Additionally, it will be understood that various numbers of different types and / or colors of yarn (i.e., two colors, three colors, five colors, six colors, etc.) can be used to form patterned tufted articles of multiple pile heights according to the principles of the present disclosure.

[0051] As generally illustrated in Figure 1, in one embodiment, a tufting machine 10 includes a frame 11 which may include a head or upper portion 12 that houses a needle bar drive 13 and defines a tufting zone T. The needle bar drive mechanism 13 (Figures 1 and 2) typically includes a series of push rods 14 which may be connected by connector rods 17 to a needle bar drive 16 (such as a gear box / assembly) or similar mechanism shown in Figure 1, which in turn may be connected to and driven by, for example, one or more drive belts or drive chains 19 to a main drive shaft 18 of the tufting machine, which itself is driven by a motor, such as a servo motor. Alternatively, the push rod 14 of the needle bar drive mechanism 13 can be connected directly to the main drive shaft 18 via a connector rod 17 so as to be driven directly from the main drive shaft or by an independent drive system (not shown).

[0052] An encoder or similar sensor may additionally be provided to monitor rotation of the main drive shaft and report the position of the main drive shaft to a control system 25 (FIG. 1) which controls the operation of the tufting machine 10. The control system 25 may generally comprise a tufting machine control including a computer / processor or system controller 26 with an operator interface 26A, such as a touch screen, keyboard, mouse, etc., through which an operator can input patterns, make adjustments, etc. In some embodiments, the control system 25 may comprise or include a stitch distribution control system such as disclosed in U.S. Pat. No. 8,359,989, the disclosure of which is incorporated herein by reference as if fully set forth, and the controller 26 further includes programming for a control method for forming tuft patterns including engraved-like patterns having tufts formed at multiple pile heights and with various color / stitch placement control patterns as disclosed in U.S. Pat. No. 8,359,989.

[0053] The control system 25 will generally include programming that allows for monitoring and control of the operating elements of the tufting machine 10, such as the needle bar drive mechanism 13, the yarn feed attachment 27, the backing feed roll 28, the main drive shaft 18, the needle bar shift mechanism 40 (FIG. 3), and the gauge component assembly 30 mounted below the tufting zone T of the tufting machine, in accordance with calculated / determined pattern instructions, as discussed more fully below. The control system 25 (FIG. 1) may further receive, execute, or store pattern information in memory storage of the system controller 26. In response to the developed / programmed pattern instructions, the control system 25 will control the operating elements of the tufting machine 10 to form a desired tuft pattern in the backing material B as the backing material is threaded through the tufting zone T by the backing feed roll 28 in the direction of arrow 33, as shown in FIGS. 1-3.

[0054] In some embodiments, the system controller 26 of the control system 25 can generally be programmed with instructions (including a series of pattern steps) for forming one or more desired patterns for one or more tufted articles, which steps can be created or calculated manually or through the use of a design center or design software as will be understood by those skilled in the art, or the system controller 26 can receive such patterns via input from a disk, USB, or other external drive, or through a network connection. Alternatively, the controller 26 can include image recognition software that allows scanned and / or designed pattern images (such as designed patterns including pile heights and other features such as the placement of loop pile and cut pile tufts in a pattern indicated by different colored or similar markers or indicators, for example), as well as photographs, drawings, and other images, to be input, programmed, recognized, and processed by the control system (including receiving input from a design center, or through various design software systems, or via a scanner or other imaging device 31 (FIG. 1)). The control system can recognize and identify various pattern features (including color and / or differences) in the texture of the designed pattern image that indicate texture effects such as placement or location of loops and / or cut pile tufts, and can assign selected yarns to them.

[0055] Additionally, in embodiments, the control system 25 may operate with, comprise or include a stitch distribution control system, as disclosed in U.S. Patent No. 8,359,989 (incorporated herein by reference as if fully set forth). For example, but not by way of limitation, the control system may incorporate programming to provide the functionality of such a stitch distribution control system, or a separate stitch distribution control may be coupled to the control system. The control system may also be provided with software / programming to enable reading and recognition of the colors of the input scanned pattern, and the control system may assign feed positions for the yarn being fed from the feed creel to various of the needles based on the thread-up sequence of the needles in the needle bar to optimize their feeding for the best use of the various colors of yarn in the creel to form the pattern area recognized from the pattern image. The control system may further include programming that enables it to create a pattern area or pattern mapping, which includes a series of pattern pixel or tuft / stitch placement location mappings that identify spaces or locations where various colors of yarn and / or cut / loop pile tufts will be selectively placed to form the imaged pattern. The desired pattern density (i.e., the desired number of stitches per inch that should appear on the face side of the finished patterned tufted article) can also be selected and the actual effective or working process stitch rate for the pattern can be calculated to achieve the desired woven stitch rate appearance of the pattern.

[0056] The control system 25 of the present disclosure may further include programming to receive, determine, and / or execute various shift or cam profiles, or may calculate suggested shift profiles based on scanned, input, or other designed pattern images or pattern files. For example, in one non-limiting embodiment, a designed pattern file image, photograph, drawing, etc. may be loaded, scanned, or otherwise input at the tufting machine or by a network connection, and the control system may read, recognize, and calculate the pattern steps / parameters (including control of yarn feed, control of backing movement and / or needle shuttle to form tufts in the backing at an effective stitch rate that achieves a desired pattern density, cam / shift profile, and yarn placement that matches the scanned and / or designed pattern image), and then control the operation of the tufting machine to form this selected pattern. The operator can additionally select or modify the stitch rate, yarn feed, selected cam profile, or calculated shift profile, such as by indicating whether the pattern should have 2, 3, 4, 5, 6 or more colors, or the desired number of pattern repetitions, and / or the operator can manually calculate, input, and / or adjust or change the creel assignments, shift profiles, and / or color mappings created by the control system, as needed, via manual override control / programming.

[0057] As shown in Figures 1-3, the tufting machine 10 will further include one or more needle bars 35 attached to and driven by the push rod 14. The needle bars 35 move a series of needles 36 in a reciprocating motion (indicated by arrows 37 / 37') in and out of the backing material B to carry or insert the yarn Y into the backing. In some embodiments, the needles can be arranged in a single linear row along one or two needle bars. In other embodiments, the needles 36 can be mounted in an alternating arrangement along a single needle bar or along a pair of needle bars, with offset rows of needles spaced laterally along the length of each needle bar and alternating across the tufting zone of the tufting machine. The needle bars 35 may further be laterally shiftable across the width of the backing material to shift or step the needles 36 in a direction transverse to (or generally perpendicular to) the longitudinal path of travel through the tufting machine. Thus, although one exemplary embodiment may be shown in the figures including a single needle bar 35 (with a linear row of needles 36 disposed therealong), the present disclosure is not limited to the use of a single needle bar or any particular configuration of needles. Instead, it will be understood by those skilled in the art that additional arrangements of dual needle bars and single needle bars (both of which may be further shifted) having spaced rows of needles 36 that may be disposed in a linear, or alternating or offset configuration may also be utilized in a tufting machine 10 incorporating a system according to the present disclosure.

[0058] Each of the needles generally includes a shank or body 38 that terminates in a pointed end 38A and includes a take-off point or area 39 where the gauge part 32 may engage and pick up the yarn Y from the needle, as shown in Figures 10A-11A. As the needle is reciprocated in a substantially vertical motion in the direction of arrows 37 and 37' (Figure 2), the needle will penetrate in and out of the backing material B along the stroke to a desired or predetermined penetration depth, carrying the yarn Y therewith, and be selectively engaged by the gauge part 32 of the gauge part assembly 30 to pick up a loop L of yarn from the needle, as shown in Figures 11A-11C. In addition, a shifting mechanism 40 can also be coupled to the needle bar 35 (or multiple needle bars) when used to shift the needle bar laterally across the tufting strip in the direction of arrows 41 and 41' according to calculated or computed pattern instructions, as illustrated in Figure 3. The shift mechanism 40 may be a Smart Step, such as those manufactured by Card-Monroe Corp. TM The needle bar shifter may include a type shifter, or alternatively may include various other types of shifting mechanisms, including servo motor or hydraulic controlled shifters and / or pattern cam shifters as are conventionally used. Additional shifting mechanisms may also be used, including backing material or jute shifter shifters operable separately or in conjunction with the needle bar shifter to shift the backing material laterally relative to the needles.

[0059] As further illustrated in FIG. 1, one or more yarn feeding mechanisms or attachments 27 can be mounted to the frame 11 of the tufting machine 10 for controlling the feeding of yarn Y to each of the needles 36 during operation of the tufting machine. For example, as shown in FIG. 3, a series of different types or colors of yarn (Y1-Y4) can be fed to each of the needles in a selected thread-up sequence or order (e.g., ABCD), with the thread-up sequence generally being determined or selected based on the pattern being performed. Additionally, while one yarn feeding unit 27 is shown along one side of the tufting machine 10 (for illustrative purposes), in other embodiments, multiple yarn feeding units can be mounted on one or both sides of the tufting machine for feeding yarn to the needles 36 of one or more needle bars 35.

[0060] There are a variety of yarn feeding attachments that can be utilized with the stitch distribution control system of the present disclosure to control the feeding of different yarns Y to various ones of the needles 36. The pattern yarn feeding attachment or mechanism 27 (FIG. 1) can comprise a conventional yarn feeding / drive mechanism, such as a scroll pattern attachment having a roll or series of rolls that extend at least partially along the tufting machine and are driven by a motor under the direction of a control system 25, which controls the feeding of the yarns across the tufting machine to form pattern repeats and / or multiple pile heights and / or other texture effects across the width of the backing material. Such yarn feeding mechanisms or attachments include the Quick Thread ... TM , Enhanced Graphics TM , and / or multiple pile height scroll yarn feed controls / attachments.

[0061] In some embodiments, the Infinity TM and Infinity IIE TMOther types of pattern yarn feed attachments having multiple yarn feed drives 45 as shown in FIG. 1, each including a motor 46 and feed roll 47, can be used to control the feeding of a particular set of repeating yarns to selected needles, including the use of individual yarn feed rolls or drives 45 to control the feeding of a single yarn (or end) or multiple ends of a yarn (i.e., 2-4 or more yarns) to needles 36, such as single and multiple end / servo scroll attachments including systems. Thus, although FIG. 1 shows a yarn feed such as a single or multiple end type yarn feed mechanism 27, it will be understood by those skilled in the art that the pattern yarn feed mechanism utilized to control the yarn feed may include single or double end yarn feed controls, scrolls, rolls, and / or the like attachments, and / or various combinations thereof, and may be mounted along one or both sides of the tufting machine. Still further, in an embodiment, the control system 25 can provide yarn feed compensation and / or yarn feed modeling to help control, reduce or minimize the amount of unretained / unappeared yarn being fed, avoiding over-feeding of yarn and thus minimizing waste during the tufting operation.

[0062] The yarn feed attachment allows for the presentation of several different colors or types of yarn into the backing, and the selective pick-up and retention of loops of select or desired ones of the presented yarns (e.g., yarns selected to appear on the front side of the finished patterned article), and can be controlled to selectively feed the yarns to their respective needles in coordination with other operating systems of the tufting machine (including backing feed, shifting of the needle bars, and operation of the gauge component assembly 30) to form tufts of such yarns with a select or desired pile height. Additionally, surface or face yarns or tufts that are to appear on the face side of the tufted article can be controlled to be fed in a sufficient amount to form such tufts of a selected color or type of yarn at a desired or specified pile height, while non-appearing yarns that are to be hidden in certain color and / or texture areas of the pattern will be backlobbed and / or pulled substantially lower or out of the backing material to a sufficient degree to avoid such yarns interfering with the face yarns or retained tufts that are visible in the pattern areas and to avoid creating undesirable spaces or gaps between the retained yarns or face yarns.

[0063] In an embodiment, each color or type of yarn that may be placed / tufted at each pixel or stitch location may generally be presented at any such pixel or stitch location for tufting, and only the yarn selected to be presented or appear at the pixel or stitch location is retained and formed at the desired pile height. Thus, for a four-color pattern, for example, each of the four color yarns A, B, C, and D that may be tufted at a particular pixel or location may be presented at such pixel, and only the selected yarn or yarns of the pattern, e.g., only the "A" yarn, may be retained, while the remaining unselected selected yarns B, BC, BD, and / or other combinations may be presented and backlobbed / pulled back and / or removed from the backing at such pixel or stitch location. Thus, when a yarn is presented at a pixel or stitch location, if the yarn should be retained or appear at the pixel or stitch location, the yarn feed 27 may be controlled to feed a certain amount of yarn to form a tuft of yarn at the pixel or stitch location. If the presented yarn should not be retained or appear at a pixel or stitch location, it can be controlled such that a loop or tuft may not be formed or may be pulled back and / or removed. If no yarn is selected for insertion at a particular pixel or stitch location, the gauge components can also be controlled to selectively pick up or not pick up loops of yarn presented at a particular pixel.

[0064] As further shown in FIGS. 1-3, the gauge component assembly 30 is generally mounted below the bed 34 and tufting zone T of the tufting machine 10. As the needles penetrate the backing material, they are engaged by a series of gauge components 32 of the gauge component assembly 30 to form loops L (FIGS. 2-3) of yarn Y to form tufts 5 of a selected color or type of yarn with a selected length or pile height. The gauge components 32 of the gauge component assembly 30, in various embodiments, can include a series of loopers or hooks 50, each of which can be slidably mounted within a gauge module, gauge block, or other holder, which can be mounted along with a gauge bar 52 or similar mount or attachment for coupling to a drive mechanism 53, which drives reciprocating motion of the gauge in a first direction toward and away from the needles 36, as indicated by arrows 54 and 54' as shown in FIGS. 1-3. It will further be understood by those skilled in the art that various other types of gauge components may also be used, including cut pile hooks, loop pile loopers, level out loop loopers, cut / loop clips, or other gauge components.

[0065] As shown in FIGS. 4-5 , in one embodiment, the gauge components 32 can include loopers or hooks 50, each having an elongated body 55 that can be slidably mounted within and movable through its gauge module 51. The body 55 of each looper or hook 50 includes a first portion 60 and a second portion 61 including an elongated throat 62 which, in one embodiment, may generally extend at an angle relative to the intermediate portion 56 of the body 55 as shown in FIGS. 4-5 and may terminate in a generally pointed proximal end or bill 63. For example, the throat 62 and proximal end 63 may be configured similarly to a loop pile looper. Other configurations of gauge components may also be used. As further shown in FIGS. 4-5, the first portion 60 of the body of each looper or hook 50 may generally have a slot or recess 64 protruding through and formed therein the gauge module or block 51, whereby the looper or hook may be engaged and / or coupled to an actuator 66, such as by a gate or connector 67 (FIG. 2).

[0066] 4-5 illustrate one embodiment of a gauge module or gauge block 51, which includes a body 75 that may have a substantially rectangular or square configuration as shown, although other configurations can be used, into which a series or set of gauge components 32, such as loopers or hooks 50, are received. In some embodiments, the module body 75 of each gauge module 51 will be formed from a metal or metal alloy material, although various composite, synthetic, and / or other materials can also be used. For example, without limitation, the body of the gauge module can be made from light-gauge steel, e.g., mild steel or tool steel, or aluminum, or other similar lightweight, yet substantially rigid and durable materials. In embodiments, the module body can be cast, molded, or otherwise formed. The material from which the body of the gauge module is formed can further be selected to provide the gauge module with a reduced weight, while still providing sufficient durability and stiffness to hold and / or substantially maintain the gauge parts in their aligned condition or position for engaging the take-off portions of the needles during reciprocation of the gauge parts into and out of engagement during operation of the tufting machine.

[0067] Generally, as illustrated in FIGS. 4-6B, the module body 75 of each gauge module 51 will include a first front or front section 76 and a second rear or back section 77. The rear section 77 of the body 75 of each gauge module 51 will generally be further configured to engage and mount to a gauge bar as illustrated in FIG. 3. For example, the rear section of the body may include tabs or other positioning devices 77A (FIG. 5) for aligning the gauge module along the gauge bar and will further include at least one fastener opening therebetween as shown at 78 in FIGS. 6A-6B. A removable fastener, such as a socket, hex screw, or other similar removable fastener or attachment device, will be inserted through the fastener opening 78 and into a corresponding opening 79 (FIG. 6B) in the gauge bar to releasably mount the gauge module 51 to the gauge bar. As a result, in some embodiments, the gauge module in which the gauge parts are contained can be removed and replaced as a unit without necessarily having to replace individual gauge parts, for example to facilitate replacement of broken or damaged gauge parts or to change the gauge spacing or placement of gauge parts in a tufting machine.

[0068] As further shown in FIGS. 4-6B , a passageway 80 is generally formed through the body 75 of each gauge module 51, the passageway 80 being generally positioned along an intermediate portion 81 of the body between the first and second sections 76 / 77 of the body. The passageway 80 may be sized and / or configured to receive a plurality of gauge components therein, such as loopers or hooks 50. In an embodiment as illustrated in FIGS. 4-5 , the body 55 of each of the loopers or hooks 50 may generally be received within and extend through the passageway 80, such that a first portion 60 of each of the loopers or hooks generally projects downwardly beyond a lower or bottom surface 82 of the module body 75, while a second portion 61 of each looper or hook may extend / project upwardly from and above an upper or top surface 83 of the module body 75.

[0069] Additionally, one or more inserts 85 may be mounted on both sides, e.g., upper and lower surfaces, of each module body at positions or locations aligned along a passageway 80 defined through the overall body of each gauge module, as generally shown in FIGS. 4-5. The inserts would be configured to engage and guide the gauge components as they are moved through and along the passageway of the gauge module body. For example, in some embodiments as illustrated in FIGS. 4-6A, a pair or set of inserts 85A and 85B may be provided, with one of the inserts (e.g., a first insert 85A) mounted along a first left or front side 80 of the passageway 80, while an insert (e.g., a second insert 85B) is mounted along a second right or rear side 80B of the passageway 80, each of the inserts 85A and 85B generally positioned to substantially face, face to, and be in parallel relationship with the gauge component 32 engaged and movable therebetween. In some embodiments, such as those shown in FIGS. 4-5, a pair of first inserts can be mounted along the top and bottom surfaces of the module body along the first or left side of the aisle, and a pair of second inserts 85B can be mounted along the top and bottom surfaces of the module body along the second or right side of the aisle.

[0070] Each of the inserts 85 will generally be formed from hardened metal or metal alloy materials, metal carbides, ceramics, and / or powdered metal materials, including metal powders including tungsten, titanium, or other materials with a hardness greater than that of the gauge module body material. For example, in some embodiments, the inserts can be formed from metal carbide materials having a hardness of about 74+RC or greater, while the module body can be formed from mild steel. In other embodiments, the inserts can be formed from ceramics, powdered metal materials including tungsten, titanium, or similar hard metal components, metal carbides, or other materials with a hardness of about 74+RC to about 85+RC or greater.

[0071] Each of the inserts 85 may further include an insert body 86 having a tab or flange portion 87 that extends either forwardly or rearwardly from the passageway of the gauge module body and generally rests on and engages with the upper and lower surfaces 83 / 82 of the module body, as shown in FIG. 5. Additionally, as shown in FIGS. 4 and 6A-6B, each of the inserts 85 may also include at least one opening or slot 89 formed along its tab or flange portion through which a fastener, such as a set screw 90 or other similar removable fastener, may be received. The slot or opening 89 formed in the tab or flange portion of the insert may generally be aligned with a corresponding slot or locating opening 91 formed along the upper and / or lower surfaces 83 / 82 of the module body to aid in locating and mounting each insert to its module body and along its gauge module passageway. 6B, the inserts can be shifted laterally across the module body generally parallel to the passages 80, and the inserts can be further adjustable toward and away from one another across the passages of the gauge module body, after which fasteners can be inserted therein and tightened to secure the inserts 85 to their module body. Additional locating guide pins 92 can be further received within slots on locating openings 93 formed along respective flange or tab portions 87 of the inserts to further aid in positioning the inserts along and across the passages of the module body, as needed.

[0072] In additional embodiments, the inserts 85 can be substantially integrated with their modules. The inserts can be bonded, molded, encapsulated, and / or otherwise attached to the bodies of their modules, with the inserts being substantially integrated with the module bodies to form a substantially monolithic structure of the module body, with the inserts forming or defining a portion of the module body's passages. For example, in some cases the inserts can be positioned or received within and substantially permanently mounted to the module body's passages, while in other embodiments the inserts can be molded or cast as part of the module body itself, defining passages and slots for loopers or hooks, and can be coated or treated with a hard metal coating, such as a carbide or other substantially wear-resistant coating. In such cases, the gauge components can be provided in pairs with their gauge modules, and can be replaced as a set by removal and replacement or substitution of the gauge modules and gauge components as a unit. In other embodiments, the inserts can be substantially engaged or locked to their modules, with limited ability to detach (or remove) one or more of the inserts as required for maintenance.

[0073] Additionally, as shown in Figures 4 and 6A-6B, the inserts will generally further include a series of slots or slits 95 spaced in series along the body 86 of each insert, generally along its rear portion 88. Each of the slots 95 will generally be sized or configured to receive a gauge component 32 therein, such as a hook or looper 50, as shown in Figures 4 and 5. The insert slots 95 will also generally be spaced at selected intervals, such as gauge intervals for the gauge components, with each slot 95 of the first insert 85A generally aligned with a corresponding or associated one of the slots 95 of the second insert 85B, as shown in Figure 6A. The aligned (corresponding or associated) slot of each insert receives at least a portion of the respective body of the gauge component received therein (e.g., a portion of the front 55A and rear 55B edges of the body 55 of each looper or hook 50), and the insert defines a reduced or minimized area or profile contact area 98 between the gauge module and the looper or hook.

[0074] In addition, as shown, for example, in Fig. 6A, ends 96 of slots 95 can be further formed with a substantially flattened (or slightly curved or arcuate) configuration to define a seat 97 against which the first and second edges of each of the loopers or hooks received in each slot can be positioned and supported for mounting the loopers or hooks within the inserts and then securing the inserts to their respective gauge modules with the loopers or hooks received therein. The slots of the inserts will help guide the loopers or hooks as they are extended or retracted or otherwise moved through their gauge module passages and maintain the alignment of the loopers or hooks (and thus their throats and bills) with the needles as the needles are shuttled in and out of the backing material and engaged by the loopers or hooks.

[0075] In another embodiment, each of the inserts 85 may include an insert body 86 having a first top or upper portion and a second lower or bottom portion, with a middle section extending between and connecting to the first and second portions of the body of each insert. At least one of the upper and / or lower portions of the body of each insert may be further formed as a tab or flange that extends forwardly or rearwardly from the middle section and passage of the gauge module body and generally covers and engages the upper and lower surfaces 83 / 82 of the module body, helping to position and secure each insert within the passage of its gauge module. The first and second inserts 85A / 85B may thus have a substantially unitary structure including upper and lower portions, with slots extending through their upper and lower portions and along the middle body section to allow further engagement and guidance of at least a portion of the first and second edges of the looper or hook. In embodiments, the inserts of such structures can be molded or cast to have a substantially unitary body, which allows for a reduction in parts and reduces the need for separate inserts on the upper and lower surfaces of the module body and along the opposing sides of the passageway, while allowing for increased contact points / area between the inserts and the loopers or hooks for improved consistency and / or control of movement.

[0076] Alternatively, the first, second, and intermediate body sections of each insert can be formed as separate components and mounted together along the passage of the modular body. For example, in still further embodiments, intermediate guide or bearing plates can also be used to help guide the movement of the loopers or hooks, the guide or bearing plates extending along the passage between the inserts positioned along the upper and lower surfaces of the modular body. Such guide or bearing plates can provide a body or surface along which the first and second or front and rear edges of the loopers or hooks can straddle / slide as they are moved along the passage of the modular body. The guide or bearing plates can also act as connecting members or sections between the inserts or each pair or set of inserts 85A and / or 85B. Such guide or bearing plates may be formed from a similar high hardness material (e.g., hardened metal or carbide or powdered metal or other high hardness material) to provide a hardened surface against which one or both of the looper or hook edges can slide; or, in some cases, may be easily replaceable and act as a sacrificial plate that may protect the module body along the side of the passageway.

[0077] During operation of a tufting machine as disclosed in embodiments of the present disclosure, the loopers, hooks, or other gauge components are moved in multiple directions, reciprocated into and out of engagement with the needles, while being moved in a second direction through the gauge module or gauge block (e.g., vertically between raised and lowered positions for engaging the needles (including being moved to a sewing position), and in some operations, moved after a loop of yarn has been picked up from the needle to form an extended or longer length loop). The tufting machine thus enables the formation of highly detailed tuft patterns that may include varying pile heights and other sculpted and multi-color pattern effects. However, such repeated cyclical movement of the gauge components causes fairly rapid wear of the gauge components, particularly the gauge module, as the loopers, hooks, or other gauge components slide and their edges frictionally engage the body of the module. As these components wear, their ability to engage the needles, form yarn loops, and create tuft patterns with substantial precision may be diminished. For example, the gauge components may become misaligned and / or may not engage the needles properly or with a desired level of precision, requiring more frequent replacement of the gauge components / gauge modules.

[0078] The use of metals (such as high hardness heat treated steels), metal carbides, ceramics, and / or other hardened metallic materials, including powdered metals including tungsten, titanium or other similar high hardness materials that provide the insert with a hardness of at least 75+RC or greater, and the configuration of the insert that defines a contact area 98 between the looper or hook and the gauge module with a minimized area or profile, substantially increases the wear life for the gauge module and the looper or hook. The high hardness insert protects the gauge module from direct contact and high speed wear as the looper or hook is cycled therethrough, while the reduced size of the contact area 98 defined by the insert is configured to substantially consistently guide and maintain alignment of the looper or hook during such movement while reducing frictional engagement of the insert with the looper or hook. The loopers or hooks are also generally pre-hardened or heat treated to harden the looper or hook body, and in some embodiments the surfaces of the looper or hook body can be coated, treated, or bonded with a low friction material to help reduce friction between their engaging and sliding edges 55A / 55B along the slot of the insert, and thus help increase their wear life. For example, in some applications, the wear life of the looper or hook has been found to be well in excess of 50-100 million machine cycles, and in some embodiments, at least about 100-500 million cycles or more.

[0079] The increased hardness of the insert protects the gauge module and allows it to be formed from a substantially lighter and less hard material, such as mild steel, aluminum, or alloys thereof. For example, instead of requiring the gauge module to be formed from a substantially higher hardness material, such as tungsten, and / or to be substantially heat treated to attempt to significantly increase its hardness, the gauge module can be cast, molded, or otherwise formed from a lightweight metal, composite, or other similar material with a hardness that may be substantially lower than that of the insert (e.g., the body of the gauge module can be formed from mild steel or aluminum alloy with a hardness of less than about 60RC), which helps to reduce the weight and cost of the overall gauge component assembly without reducing the operating cycle performance. Such reduction in the weight of the gauge module or block can further provide improved control of the movement of the looper through its passageway and the reciprocating motion of the looper or hook toward and away from the needle, for example, by reducing the inertia that may need to be overcome during reciprocating motion of the looper or hook toward and away from the needle.

[0080] 7A-9B illustrate various non-limiting embodiments of gates or connectors 67 that may be used with gauge parts, such as loopers or hooks 50 (FIG. 4), to connect the gauge parts to their associated actuators 68 (FIGS. 2-3). However, it will be understood by those skilled in the art that the connectors or gates illustrated in the embodiments of FIGS. 7A-9B are not limited to use with a particular tufting type machine or with a particular type of gauge part, but may be used with a variety of different types of gauge parts, including loopers or hooks 50 as illustrated in FIGS. 4-6B and 10A-11C, and may also be used with a variety of other types of gauge parts, such as level cut loop loopers or hooks and / or other gauge part arrangements.

[0081] Generally, as illustrated in Figures 7A-9B, each of the connectors or gates 67 will generally include a housing or support structure 101 in which a linkage or connector arm 102 may be substantially contained, encased, or housed. The housing 101 of each connector or gate may generally include a first or proximal portion 103, an intermediate portion 104, and a second or distal portion 106. In addition, each connector body may further include a passageway or channel 107 defined therethrough along which the linkage or connector arm 102 may be received and moved. The housing 101 of each connector 67 may generally be formed from a lightweight, durable material, such as a composite, plastic, or synthetic material, or a combination thereof. For example, composite or polymeric materials such as nylon, polyamide, polyamide nylon, or other similar polymeric materials can be used and can be mixed with, comprise, or otherwise include fiber-filled materials such as carbon fiber, glass fiber, or other supporting fibers that can additionally provide reinforcement to the housing body material. The housing body material can be further adapted or selected to not only provide reduced weight to help reduce inertia during start / stop and movement, e.g., extension and / or retraction of a gauge component by its associated actuator, but also to provide resilience and shock reduction or damping or cushioning effects during such movement and start / stop operations.

[0082] As shown in Figures 7A-9B, in some embodiments, the housing 101 of each of the connectors can be overmolded over its linkage or connector arm 102 or can be formed in sections and applied around the linkage or connector arm such that the linkage or connector arm is substantially enclosed or contained within the housing 101. The linkage or connector 102 can further be made from a metal such as steel or other similar high strength material selected to provide sufficient high strength and stiffness to enable each linkage or connector arm to withstand repeated impacts and increased movement cycles during operation of the tufting machine. For example, but not limited to, the linkage or connector arm 102 can comprise a hardened steel material and can further be heat treated or annealed, in some cases, at its ends, in areas of contact and / or engagement with loopers or hooks, and between the connector arm or linkage and its associated actuator or actuator drive shaft or rod, etc.

[0083] In some embodiments, the linkage or connector arm 102 can further include a skeletonized metal body configured to enable a reduction in its weight. In such embodiments, each connector or gate housing 101 can provide additional support and stiffness to the linkage or connector arm 102 to help guide and maintain its consistent reciprocating movement or motion during operation. As a result, the connector or gate 67 can provide a more economical connector or gate design to be used with the additional support and impact resilience and damping effect provided by the housing 101 applied over and / or surrounding or encapsulating the linkage or connector arm, enabling the linkage or connector arm to have a skeletonized or reduced profile and lighter weight.

[0084] As further illustrated in Figures 7A-9B, each of the connectors or gates 67 can be formed with varying sizes and configurations. For example, the middle section of each connector housing can have a shorter or longer span depending on the gauge, distance, travel length, or length of the link or connector arm, and therefore can be varied for different tufting machines and / or tufting applications. By way of example only, as shown in Figures 7B, 8B, and 9B, the connectors or gates can be provided with varying configurations for use with different gauge tufting machines, such as 1 / 8 gauge or 1 / 10 gauge machines, although it should be understood that other gauges (5 / 16, 1 / 16, 1 / 12, 1 / 14, etc.) and / or type machines can also be used. The middle section of the housing through each connector can be further oriented at an angle, in some cases oriented at a downward extending angle, while in other cases oriented at an upward extending angle, with adjacent connectors in opposite angle orientations or configurations minimizing the space or footprint taken up by them.

[0085] The linkages or connector arms 102 (FIGS. 7A, 8A, 9A) of each connector or gate 67 can be further formed to varying lengths as needed or desired. Each linkage generally has a first or proximal end 110, which can be adapted or configured to engage or connect to one or more actuator shafts or drive rods 68 of an associated actuator or actuators, and a generally angled body section or portion 111 that extends through the connector housing along a passage or channel of the housing and terminates at a distal flanged or hooked end 112. The body portion 111 of each linkage may be further positioned and / or aligned within the passage of its housing and may be enclosed within the passage, helping to provide stability and / or to guide movement of the linkage along the channel of its connector housing.

[0086] For example, in some cases, pins or other inserts can be used during formation of the housings around (or over) their connections to align and support the connections in place, and the pins can then be removed. Alternatively, several guide pins can be provided to help maintain and guide movement along one or more portions of the connections or connector arms that include or act as bearings. Still further, in some other embodiments, slots can also be provided along the body of each housing, through which guide pins can be received and help guide movement of the connections, and can further help provide additional impact resiliency.

[0087] In additional embodiments, a guide pin or catch 114A can be inserted through the housing and into the body of the coupling and can engage a slot or guideway or similar means to help guide and control or maintain the movement of the coupling along its connector housing's passageway or channel 107 (FIGS. 7B, 8B, and 9B) without twisting or turning or otherwise becoming misaligned. In yet other embodiments, the guide pin 114A can act as a pivot point about which the coupling or connector arm can be moved or pivoted, rather than moved in a generally linear motion.

[0088] As further shown in FIGS. 7A, 8A, and 8B, the distal hooked end 112 of each of the links or connector arms 102 can be supported by the second or distal end 106 of its connector housing 101 along at least one side of the distal hooked end 112 to help guide and support the hooked end during sliding movement of the link. The hooked end of the link or connector arm will engage a corresponding hooked portion, recess, or slot of a corresponding gauge component, for example, in an embodiment, a slot or recess 64 (FIG. 5) formed in a first portion 60 or distal end of a corresponding (or associated) one of the loopers or hooks 50. In other embodiments, the hooked end of the link can engage a clip for a level cut looper, level cut loop looper, or other movable gauge component. When each actuator is selectively fired or activated / deactivated, the movement of its actuator shaft or drive rod will be transferred to the associated one of the gauge components via the link or connector arm of its corresponding connector or gate. The connector or gate can thus provide an economical, rigid, and high strength connection between each of the actuators and its associated gauge component, which can be removed or changed as needed without having to replace the actuator associated with it.

[0089] 2 and 11A-11C, the actuators may comprise hydraulic, pneumatic, electric, or pneumatic cylinders 68, each of which includes a cylindrical rod or shaft 69 that would generally be connected to an associated (or corresponding) one of the loopers or hooks by a connector or gate 67. In some embodiments, the actuators may further be used to control the operation of two or more loopers or hooks 50. Additionally, other types of actuators may be used, including solenoids, motors, or other similar actuation mechanisms as would be understood by one of ordinary skill in the art.

[0090] Each of the actuators will generally be coupled to a control system 25, which will selectively control their actuation to control the firing and / or movement of each of the loopers relative to the needle. The actuators will be controlled to selectively extend and retract their loopers or hooks, whereby the position of their throats / bills will be varied in a second direction relative to the reciprocating movement of the needle into and out of the substrate material, and relative to the movement of the loopers or hooks in the direction of arrows 54 / 54'. For example, in an embodiment, the loopers or hooks will be moved in a substantially vertical (i.e., generally up and down) movement relative to the needle as illustrated by arrows 71 and 71' in Figures 2, 4A, and 5A-5C as the loopers or hooks are reciprocated in the direction of arrows 54 and 54' toward and away from the needle 36. The actuators can be controlled not only to extend and retract the loopers or hooks between extended and / or non-sewing positions, but can further be selectively controlled to extend and / or retract the loopers or hooks to a series of varying positions or heights relative to the needle stroke or penetration depth. Thus, the position or location of the looper or hook throat relative to the needles can be controlled and varied to cause pickup and / or formation of yarn loops from selected ones of the needles at varying pile heights or lengths, as shown in Figures 11A-11C, or to cause no yarn pickup.

[0091] For example, in the fully extended position, selected ones of the loopers or hooks 50 can pick up loops of yarn from needles engaged by them, and those loops can generally be formed with a first selected or desired pile height, while others of the loopers or hooks can be extended or retracted to positions or locations between the fully extended and retracted positions to pick up and form loops of yarn with a second or other different length or pile height. Some of the loopers or hooks can also be moved by their actuators to a fully lowered or retracted position to place them in a non-sewing position, whereby the throat / bill of such loopers or hooks is located below the end of the needle's full penetration depth or stroke, and therefore will not pick up loops of yarn from their corresponding (or respective) needles. In other operations, the actuators can be selectively controlled or triggered to retract or lower the loopers or hooks after a loop of yarn has been captured by them, pulling down such captured loop of yarn and stretching it for additional patterning effects, such as for tip shear and / or other textural effects, or to create a higher pile or increased length of yarn.

[0092] As shown in Figures 10A-10B, each of the gauge components 32, such as loopers or hooks 50, may generally be arranged in sets or groups, each contained within a module 51, which provides a plurality of gauge components mounted in series along the gauge bar and spaced at prescribed intervals (e.g., 1 / 10, 1 / 8, 5 / 16, etc. gauge intervals) across the tufting strip. The gauge components 32 will be positioned to engage the needles (including being arranged in substantially straight, offset, alternating, and / or other configurations as necessary depending on the configuration of the needles in the needle bar or multiple needle bars; for example, where the needles are arranged in straight, alternating, and / or other configurations along a single or dual needle bar). Each of the loopers or hooks 50 may further be positioned at an angle or offset relative to the needles penetrating the backing such that they move or are extendable / retractable along a travel path 71 / 71' that is angled relative to the needles and / or their take-off points. Such offset movement of the loopers or hooks can additionally be varied as necessary depending on the needle spacing and / or placement to minimize potential engagement of the loopers or hooks by the needles as the loopers are retracted.

[0093] For example, in some embodiments, the looper or hook can be positioned and / or moved along the travel path at an angle / offset shown as θ in FIG. 10B that can range from about 1° to about 10° or more from vertical and / or relative to the stroke of the needle when the looper or hook is retracted, while in one exemplary embodiment, an angle of about 4° to 6° relative to the path or direction of the needle's reciprocating motion when the needle completes its stroke or reciprocating motion in and out of the backing can be provided between the looper or hook and the needle with substantially no offset, i.e., about a 0° angle relative to the needle. Thus, when a looper or hook is extended to a sufficient position / altitude to engage the needle's take-off area 39 (FIGS. 10A-11A), its throat / bill will generally be properly aligned (or positioned) to engage and pick up a loop of yarn from its corresponding needle. As the loopers or hooks are retracted, they may generally be moved further along an offset travel path so that their throats / bills are positioned or located at a position outside the needle travel path to minimize potential inadvertent thread pick-up when the loopers or hooks are being moved to and / or are in the retracted, non-sewing position.

[0094] In operation, according to some embodiments, tufted articles can be formed in accordance with the systems and methods of the present disclosure, which can include the use of multiple different colors and / or types of yarn to form various patterns and pattern effects, as well as with such patterns including sculpted or multiple pile height effects. For example, the systems and methods of the present disclosure can be operated in conjunction with a stitch distribution control system or thread color placement system as disclosed and illustrated in U.S. Patent Nos. 8,141,505, 8,359,989, and 8,776,703, the disclosures of which are incorporated herein by reference as if fully set forth.

[0095] In such embodiments, the yarn stitches or tufts formed in the backing material may further be formed at an increased or higher actual working or effective process stitch rate as compared to the desired or prescribed fabric or pattern stitch rate for the tufting pattern being formed. If the pattern or fabric stitch rate or density of the pattern being formed requires that the tufted article have the appearance of 8, 10, 12, etc. stitches per inch formed therein and / or shown on its face side, the actual working or effective number of stitches per inch formed during operation of the tufting machine will be substantially greater than the desired or prescribed pattern or fabric stitch rate. Thus, the actual formation of stitches or tufts of yarn in the backing material is accomplished at an increased actual operating or effective process stitch rate, whereby, effectively, a greater number of stitches per inch are formed in the backing material than would be required to be shown in the finished pattern, and those stitches or face yarns that are not desired to be shown or remain on the face side of the pattern region or area being sewn are backlobbed or pulled out of the backing material or pulled down sufficiently to allow such yarns to be retained or sewn within the backing, while substantially avoiding the creation of undesirable or unnecessary gaps or spaces between the retained or face yarns of the pattern (i.e., tufts of yarn that should remain visible or appear in the finished pattern of the tufted article).

[0096] For purposes of illustration, in one exemplary embodiment, the effective process stitch rate can be based on or determined by multiplying the weave or pattern stitch rate of the pattern approximately formed or tufted in the pattern by a selected number of colors. For a pattern having a desired weave or pattern stitch rate of about 10-12 stitches per inch and using 2-4 colors, the effective or operational process stitch rate (i.e., the rate at which stitches are actually formed into the backing material) can be from about 18-20 stitches per inch up to about 40 or more stitches per inch. However, it will be understood by those skilled in the art that additional variations or adjustments of such operational or effective process stitch rates may be made for a particular pattern depending on the type and / or size of the yarn and / or other factors. For example, if a thicker, larger size, or heavier yarn is used, the effective process stitch rate may be subject to additional variations as necessary to account for the use of such larger yarn (e.g., for a four-color pattern, the effective process stitch rate may be further varied, such as being performed at about 25-38 stitches per inch, although further variations may be used as necessary). Thus, while a selected or programmed pattern being implemented may be designed or desired to have 10-12 stitches per inch as the desired pattern density or stitch rate therefor, the system may actually operate to produce as many as 20-48 or more stitches per inch, depending on the number of yarn colors and / or types, but visually from the front side of the finished tufted article, generally only the desired / selected 10-12 stitches will appear.

[0097] In addition, when a series of different colors are being tufted, the needles 36 of needle bar 35 are generally provided with the desired thread-up, for example, for a four-color pattern, A, B, C, D thread-ups can be used on the needles. Alternatively, when two needle bars are used, the needles of each needle bar can be provided with an alternating thread-up sequence, i.e., A / C threads are on the front needle bar and the rear needle bar is threaded with the B / D color thread-up. Additionally, the needles of such front and rear needle bars can be arranged in an alternating or offset alignment. The needle bar or bars will generally be further shifted by control of a needle bar shifter 40 (FIG. 2) in conjunction with control of the backing material and control of the yarn feed according to a shift profile for the pattern being formed, so as to effectively present to the looper or hook each one or each different type of yarn color (i.e., 2, 3, 4, 5 colors, etc.) that can be sewn at a selected pattern pixel or tuft / stitch location by shifting the needle bars laterally relative to the backing material.

[0098] For example, for a four color pattern, each of the 1-4 colors that can be sewn at the next pixel or stitch location is presented to the desired looper or hook as the backing material is moved incrementally approximately 1 / 8-1 / 40 inch per each shift motion or cam movement cycle, i.e., one, two, three, four color yarns, or no yarns can be presented at the selected pixel or stitch location. The loopers or hooks engage to form loops of yarn, and one or more desired yarns are retained to form selected tufts, while the remaining yarns can be pulled down or backlobbed (including being pulled out of the backing material to float along the backing material, pulling these unretained yarns), generally by control of the yarn feed mechanism. Thus, each looper or hook, during each shift sequence and corresponding incremental movement of the backing material, is given the ability to tuft any one of the colors of the pattern, or potentially more than one color (i.e., two, three, four, five, six, etc.), for each pattern pixel or tuft / stitch location associated with it, or perhaps none of the colors are presented to it. As described, if none of the different types or colors of yarn should be tufted or placed at a particular tuft or stitch location or pixel, the yarn feed can be controlled to limit or otherwise control the needle threads that may be presented at such stitch location or pixel to pull back substantially all of the yarn or otherwise prevent such yarn from being placed or appearing at that stitch location, and / or the needle bar can additionally be controlled to skip or otherwise avoid or omit the presentation of a needle / thread to that stitch location or pixel.

[0099] The feed of backing material B can be further controlled, i.e., controlled by the stitch distribution control system in a variety of ways. For example, the tufting machine backing roll 28 can be controlled to hold the backing material in a fixed position for a determined number of stitches or cycles of the needle bar, or can move the backing material at a desired number of stitches per inch, i.e., move about 1 / 40 inch or variations thereof for each penetration, such that when four stitches are introduced into the backing for a pattern with four colors and an effective stitch rate of 40 stitches per inch, it moves about 1 / 10 inch. The movement of the backing material can be further varied or manipulated on a stitch-by-stitch or pixel basis, such that the average movement of all stitches over one cycle substantially matches the calculated incremental movement of the operating or effective process stitch rate. For example, for a four color cycle, the first stitch can be performed at 1 / 80 inch, the next two stitches at 1 / 40 inch, and the fourth stitch at 1 / 20 inch, so that the average movement of the backing over the four stitch cycle will average 1 / 40 inch for each stitch presented, as necessary to achieve the desired stitch / color placement.

[0100] Each different thread / color thread that can be tufted at a particular stitch location or pixel can thus be presented at such stitch location or pixel as the pattern is formed in the backing material. To achieve such presentation of thread at each pixel or stitch location, the needle bar can generally be shifted using a combination of single and / or double jumps or shifts as needed / desired per the calculation or selected cam or shift profile of the pattern to be performed / formed, for example, based on the number of colors being performed in the pattern and the area of ​​the pattern area being formed by each specific color. Such combinations of single and double shift jumps or steps can be utilized to avoid tufting over or engaging tufts already sewn as the needle bar is shifted laterally to advance the backing material at its effective or working stitch rate. The backing can also be shifted by a backing or jute shifter or the like, in conjunction with or separately from the needle bar shifting mechanism.

[0101] When the needles penetrate the backing B, as shown in Figures 1 and 2, the loopers or hooks 50 of the gauge component assembly 30 will be reciprocated towards the needles in the direction of arrow 54 to engage and pick up or pull loops of thread from their associated or corresponding needles. In addition, actuators 66 for the loopers or hooks can be selectively controlled and engaged to cause selected ones of the loopers or hooks to be extended or retracted, so that the bill 63 of the looper or hook and its throat portion 62 are in a desired position relative to the needles 36 as they penetrate and complete their stroke into and out of the backing. 10A-11C, the location or positioning of the bill and / or throat portions of the loopers or hooks can be varied between a fully extended or elevated position and a lowered or retracted "non-sew" position in which yarn loops can generally be substantially prevented from being picked up and / or formed by such loopers or hooks, providing selective pick-up of yarn loops (including not picking up any yarn loops) and control of the length of yarn loops selectively picked up from the yarn presented at each of the stitch locations or pixels in accordance with instructions for the pattern being formed. As a result, the location where selected or desired front yarn loops shown in the "finished" pattern are picked up from the needles by the loopers or hooks can be controlled, and the formation of resulting tufts from such picked up yarn loops remaining in the backing can be further controlled so that they can be formed at a variety of different pile heights.

[0102] The type / color of yarn of each series of yarn presented at each pixel or stitch location that is to be held or shown on the front side of the backing at a particular stitch location will generally be determined by the pattern instructions or programming for the formation of the tuft pattern. Controlling the activation and / or positioning of the looper or hook 50 corresponding to (or associated with) the needle carrying such yarn can enable the tufting machine to selectively pick up and hold a loop of that yarn at each stitch location where such yarn remains according to the pattern to form a resultant tuft of such yarn at a selected pile height. For example, if a presented yarn is not shown or appears, the corresponding looper or hook can be retracted to a non-stitching position such that no loop of yarn is picked up, and the yarn feed therefor can be controlled such that the yarn is not held at the pixel or stitch location. With respect to the retained yarns / colors, i.e., the yarns that appear on the face side of the patterned tufted article, the positions or elevations of the loopers or hooks and the yarn feeding mechanisms that feed these yarns can generally be coordinately controlled to allow pick-up and formation of loops of such yarns sufficient to form tufts of the desired type and pile height.

[0103] Further control of backing feed at increased effective or operating process stitch rates (e.g., the actual rate at which stitches are formed in the backing) according to the principles of the present disclosure further provides an area of ​​more dense or compressed stitches or tufts per inch such that back-lobbed yarns are removed or pulled down to a sufficient degree to avoid creating undesirable spaces or gaps between retained face yarns (those that appear on the face side of the tufted article according to the pattern) or interfering with or showing through such retained face yarns that are formed in the backing material. Additionally, the control system can perform yarn feed compensation and / or modeling of yarn feed to help control and reduce the amount of unretained or unappeared yarns that may "float" on the back side of the backing material, further helping to reduce / minimize excess yarn feed and / or waste.

[0104] In addition, the yarn feed mechanism which controls the feeding of each of the yarns to each of the needles can be selectively controlled to backlob or pull the yarns carried by the needles or by the reciprocating motion of the needles substantially out of the backing material, generally retracting or pulling back / pulling down some of the yarn loops to a substantially lower position to avoid such unselected yarn ends from occupying selected stitch locations or otherwise interfering with the placement of yarns shown in particular color areas being formed according to selected face yarns or patterns.

[0105] For example, in some embodiments, when a selected or particular looper or hook is retracted to a fully retracted or "non-sew" position, a loop will generally not be picked up from the needle associated with such fully retracted looper or hook, while the yarn feed is correspondingly controlled such that the yarn is permitted to move with that needle in and out of the backing material. Additionally, in certain instances where a loop of yarn is formed, such as when a looper or hook is in a fully extended position and forms a low loop, the resulting loop of yarn formed can be further backlobbed or substantially pulled down or pulled out of the backing material by controlling the yarn feed to an extent that leaves an amount of yarn engaged with or "sewn" to the backing, while substantially removing such yarn to an extent that such unselected yarn ends generally do not interfere with the appearing face side or placement of the selected yarn at a particular stitch location within the color area being sewn.

[0106] The placement of non-emerging threads that are sewn or otherwise secured to the backing material can also be controlled to control the formation of such extended length ends that may later get caught or cause other defects in the finished tufted article. For example, the control system can be programmed / set to sew such non-emerging threads at desired intervals, e.g., every 1 inch to 1.5 inches, or to form low stitches, although larger or smaller intervals can also be used. Thread compensation can also be used to help ensure that a sufficient amount of thread is fed when it is necessary to prevent a thread from showing through another color or blowing out, i.e., a thread protruding through one of the stitch threads along with several threads that are placed together, while generally allowing the non-emerging threads to be sewn into the backing material. Additionally, where extended lengths or ends will be formed for multiple non-emerging threads, the spacing at which such different threads are sewn into the backing material can be varied (i.e., 1 inch on one, 1.5 inches on the other, etc.) to avoid such sewn threads interfering with each other and / or with the threads of the color area being formed.

[0107] Still further, the actuators 66 can also be controlled in conjunction with the control of the yarn feed mechanism to cause the formation of extended or stretched yarn loops, such as by engaging and retracting or lowering their respective loopers or hooks with the loops of yarn captured in the loopers or hooks. The captured yarn loops can thus be further pulled and / or stretched while the corresponding yarn feed can also be controlled for feeding additional amounts of such yarn. As a result, even longer or greater length yarn loops can be formed in the backing, such as for tip shear and / or other patterning features, to create higher pile tufts, and / or to produce other desired pattern effects. The selective control of the actuators 66 to selectively retract and extend those loopers or hooks 50 can further be used to provide additional variations or transition steps or pile heights within the pattern being controlled as needed, for example, to provide more gradual or subtle differences or changes in pile height, or to provide more dramatic or distinct separations between the pile heights of the yarn tufts being formed.

[0108] Thus, across the width of the tufting machine, the control system will control the shifting and feeding of the yarn of each color or desired pattern texture effect such that each color that can or may be sewn at a particular tuft location or pattern pixel will be presented within that pattern pixel space or tuft location for sewing, but only the selected yarn tuft for a particular color or pattern texture effect will remain at that tuft / stitch location or pattern pixel. As will be further described, additional or more colors may also be presented to each of the loopers or hooks during the tufting step, where two or more stitches or colors will be placed at a desired pattern pixel or tuft location, to form mixed color tufts, or to provide a tweed effect as desired. The result of the operation of the stitch distribution control system thus provides a multi-color visual or texture effect of pattern colors that are selectively placed to obtain a desired density and pattern appearance for the finished tufted article. This further enables the creation of a wide variety of geometric, flowing, and other pattern effects by control of the placement of tufts or yarns at selected pattern pixels or tuft locations.

[0109] Thus, the systems and methods for tufting engraved-like multiple pile height patterned articles of the present disclosure can enable an operator to develop and execute a variety of tuft patterns having different looks, textures, etc. on a tufting machine without necessarily having to utilize a design center to plan and create the patterns. Instead, the present disclosure allows an operator to scan an image (i.e., photo, drawing, jpeg, etc.) or upload a designed pattern file on the tufting machine in addition to and / or as an alternative to manually preparing a pattern or using a design center, and the stitch distribution control system can read the image, develop program steps or parameters, and thereafter control the tufting machine substantially without further operator input or control that would necessarily be required to form the desired tufted patterned article.

[0110] The foregoing description generally illustrates and describes various embodiments of the present disclosure. However, it will be understood by those skilled in the art that various changes and modifications may be made to the above-discussed structures of the present disclosure without departing from the spirit and scope of the present disclosure as disclosed herein, and it is intended that all matters contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not limiting. Furthermore, the scope of the present disclosure shall be interpreted to cover various modifications, combinations, additions, alterations, etc. to the above-described embodiments that shall be considered within the scope of the present disclosure. Thus, various features and characteristics of the present disclosure as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the present disclosure, and numerous variations, modifications, and additions may be made thereto without departing from the spirit and scope of the present disclosure as described in the appended claims. (Item A1) A tufting machine, comprising: at least one needle bar having a plurality of needles, the plurality of needles being mounted along the at least one needle bar; a backing feed roll for feeding the backing material; at least one yarn delivery mechanism for delivering yarn to the needles; a gauge component assembly positioned below the backing material, the gauge component assembly comprising: at least one module carrying a series of gauge parts in a reciprocating motion toward and away from engagement with the needle as the needle is reciprocated into the backing material, the at least one module comprising: a modular body formed from a metal, a polymer, a composite, or a synthetic material, or a combination thereof, and having a first hardness, the modular body adapted to be mounted along a gauge bar and having a passageway defined therethrough; inserts positioned along the module body on either side of the passage; Equipped with each of the inserts having a slot in which one of the gauge parts is slidably received, each of the slots configured to slidably receive at least a portion of one of the gauge parts therein; the insert comprises a metal or metal carbide material having a second hardness greater than the first hardness of the module body; at least one module, each of the gauge components including a body at least partially received in opposing slots of the insert, the body being movable through a passage of the module body in an additional direction relative to the stroke of the needle, the body of each gauge component having a first portion extending through the passage of the at least one module and a second portion having a throat configured to pick up a loop of thread from the needle; a series of actuators coupled to the gauge components for controlling movement of the gauge components through the module body; a gauge component assembly comprising: Control system including programming Equipped with The programming controls the at least one yarn feed mechanism to control the feeding of the yarn to the needles in coordination with controlling the actuation of one or more actuators to extend or retract selected ones of the gauge parts, whereby the throats of the selected ones of the gauge parts are moved between a non-sewing position and an engaged position relative to the stroke of the needle into the backing material to selectively form tufts of yarn in the backing material according to a pattern being formed. (Item A2) a shifting mechanism for shifting the at least one needle bar laterally across the backing material; The control system is adapted to present a series of threads at selected stitch locations along the backing material as the needles are shuttled in and out of the backing material and to withdraw unselected threads. shifting the at least one needle bar by the shift mechanism; feeding the backing material by the backing feed roll; Control of the actuator coupled to the gauge component; and Controlling the at least one yarn delivery mechanism that delivers the yarn to the needles; and further comprising programming for adjusting Such unselected loops of yarn are not picked up by one of said gauge components; The tufting machine of claim A1, wherein the backing material is moved through a tufting zone at an operating stitch rate, the operating stitch rate being greater than a pattern stitch rate for the pattern being formed to provide a number of tufts retained per inch of face yarn in the backing material approximately equal to the pattern stitch rate. (Item A3) The tufting machine of claim A1, wherein the gauge component comprises a level cut loop looper, a loop pile looper, or a cut pile hook. (Item A4) The tufting machine of claim A1, wherein the actuator comprises a hydraulic or pneumatic cylinder. (Item A5) The tufting machine of item A1, wherein the gauge component assembly further comprises a series of connectors extending between actuators associated with each gauge component, each of the connectors including a coupling portion received within a housing and movable through the housing. (Item A6) The tufting machine of claim A5, wherein the housing of each connector comprises a polymer, a composite, or a synthetic material, or a combination thereof, and further includes a channel extending through the housing, and each coupling comprises a metal, a composite material, or a combination thereof. (Item A7) the body of each housing further comprises a composite material including a polymer or plastic with a fiber-filled material and has a channel defined therein; The tufting machine described in item A5, wherein the coupling portion is movable along the channel, and the coupling portion of each connector comprises a hardened metal body coupled to a body of the housing, the hardened metal body having a proximal end configured to engage a first portion of one of the gauge parts and a distal end configured to be engaged by an actuator associated with the gauge part to transfer movement by the actuator to the gauge part. (Item A8) each of the at least one modular insert comprises a first pair of inserts mounted to upper and lower surfaces of the modular body along a first side of the passage of the modular body and a second pair of inserts mounted to the upper and lower surfaces of the modular body along a second side of the passage of the modular body; the second pair of inserts are spaced apart from and face the first pair of inserts; The tufting machine of claim A1, wherein the slots of the inserts of the first pair of inserts are disposed in opposing and substantially aligned relationship with the corresponding slots of the inserts of the second pair of inserts. (Item A9) The tufting machine described in item A8, wherein the inserts of the first and second pairs of inserts are configured to cover the upper and lower surfaces of the modular body, each including a slotted opening adapted to receive a fastener therethrough for adjustably mounting each of the first and second pairs of inserts to the modular body, and the inserts are positioned at selected intervals from one another and at selected locations relative to the passage defined through the modular body. (Item A10) The tufting machine of claim A1, wherein the at least one needle bar comprises a pair of needle bars, each of the pair of needle bars having a series of needles mounted in series and spaced apart relation therealong. (Item A11) 1. A gauge component assembly for a tufting machine, said gauge component assembly comprising: a plurality of modules, each module including a module body and having a passageway defined therethrough; a series of gauge parts slidably received within each of said modules, each of said gauge parts having a throat terminating in a bill, said gauge parts being carried with their modules in a first direction toward and away from engagement with needles of the tufting machine along their throats to selectively pick up loops of yarn from needles, each of said gauge parts being selectively movable in a second direction along the paths of their modules; first and second inserts mounted to the module body of each module on either side of the passage defined through the module body, each insert formed from a metal or metal carbide material having a hardness greater than a hardness of the module body and having a series of slots formed therein, the slots of the first insert and the slots of the second insert being substantially aligned across the passage and configured to define a contact area along at least a portion of one of the gauge components slidably received therein; a plurality of actuators, each of the plurality of actuators coupled to an associated one of the gauge parts and adapted to move its associated one of the gauge parts in the second direction through the passageway of the module, whereby the gauge parts are extended or retracted to move the throat of the gauge part between an extended position for engaging and picking up a loop of thread from the needle and a retracted position for substantially avoiding picking up the loop of thread from the needle; a connector extending between each actuator and its associated one of the gauge components, each connector having a housing formed from a polymeric material with a coupling portion encased therein; and The gauge component assembly comprises: (Item A12) The gauge component assembly of item A11, wherein each housing further comprises a composite material including a polymer or plastic with interdigitated fiber filling material and has a channel defined therein along which the coupling portion is movable, and the coupling portion of each connector comprises a hardened metal body extending through the housing and has a proximal end configured to engage a portion of one of the gauge components and a distal end, the distal end configured to be engaged by the actuator associated with each gauge component to transfer movement by the actuator to the gauge component. (Item A13) The gauge component assembly of item A11, wherein an upper portion of each of the first and second inserts is configured to cover an upper surface of the modular body and includes a slotted opening adapted to receive a fastener therethrough for adjustably mounting each of the first and second inserts to the modular body, the inserts being positioned at a selected spacing from one another and at a selected location relative to a passage defined through the modular body. (Item A14) The gauge component assembly of claim A11, wherein the insert comprises a metal carbide material having a hardness of at least 75+RC. (Item A15) The gauge component assembly of claim A11, wherein the insert comprises a metal carbide material and the module body comprises an aluminum material. (Item A16) 1. A gauge component assembly for a tufting machine, said gauge component assembly comprising: at least one module having a module body having a passageway defined therethrough; a series of gauge parts received within the passage of the module body, each gauge part including a body with a first portion and a second portion having a throat, the gauge parts being carried with their modules in a first direction toward and away from engagement with an associated needle of the tufting machine to pick up loops of yarn from a needle along the throat of the gauge part, the gauge parts being selectively movable in a second direction along the passage of the module body; inserts disposed along opposite sides of the passageway in the modular body, each insert being formed from a material having a hardness greater than a hardness of the metal or composite material of the modular body and having a series of spaced apart slots configured to receive at least a portion of one of the gauge parts; Multiple actuators and Equipped with a gauge component assembly, wherein each actuator is coupled to a first portion of an associated gauge section of the series of gauge components and adapted to move its associated gauge component in the second direction through the passage of the at least one module, whereby the gauge component is extended or retracted through the module body to move the throat of the gauge component between an extended position for engaging and picking up a loop of thread from the needle and a retracted position for substantially avoiding picking up a loop of thread from the needle. (Item A17) The gauge component assembly of item A16, further comprising a connector extending between each actuator and its associated gauge component, each connector having a housing formed from a polymeric material and in which the coupling portion is encased. (Item A18) The gauge component assembly of item A16, wherein the module body of the at least one module is molded or cast from metal or composite material. (Item A19) The gauge component assembly of item A18, wherein each of the inserts is molded or cast from a metal, carbide, or powdered metal material and includes a body with a tab or flange portion, and the slot is formed in the tab or flange portion. (Item A20) The gauge component assembly of item A19, wherein the body of each of the inserts further includes upper and lower tabs or flange portions that engage upper and lower surfaces of the module body, and the slots extend through the upper and lower tabs or flange portions. (Item A21) The gauge component assembly of item A16, wherein each of the inserts comprises a body molded or cast from a metal, carbide, or powdered metal material, the body comprising a tab or flange portion, the slot being formed in the tab or flange portion, and the module body of the at least one module comprises a metal or composite material, the metal or composite material being molded or cast so as to be substantially integral with the module body to form the module body. (Item B1) A tufting machine, comprising: at least one needle bar having a plurality of needles, the plurality of needles being mounted along the at least one needle bar; a backing feed roll for feeding the backing material; at least one yarn delivery mechanism for delivering yarn to the needles; a gauge component assembly positioned below the backing material, the gauge component assembly comprising: a plurality of gauge parts, each of the plurality of gauge parts including a first portion and a second portion configured to pick up a loop of thread from the needle; at least one module having a module body having a first hardness formed from a metal, a polymer, a composite, or a synthetic material, or combinations thereof, said module body having at least one passageway defined therethrough and inserts positioned along opposite sides of said at least one passageway, each of said inserts having a slot into which one of said gauge components is received; the insert comprises a metal, metal carbide, ceramic, powdered metal material, including a metal powder including tungsten, titanium, or a combination thereof, having a second hardness greater than the first hardness; at least one module, the gauge component being movable in a first direction relative to the stroke of the needle into and out of the backing material, into and out of engagement with the needle, and movable in a second direction relative to the stroke of the needle along the at least one passageway of the module body; a series of actuators coupled to the gauge components for controlling movement of the gauge components in the second direction through the modular body; and a gauge component assembly comprising: Control system including programming Equipped with the programming controls actuation of one or more of the actuators to move the selected ones of the gauge components in the second direction between a lowered position that substantially prevents the selected ones of the gauge components from picking up loops of yarn from corresponding needles and one or more raised positions relative to the stroke of the needle into the backing material to pick up loops of yarn from the corresponding needles, to selectively form tufts of yarn in the backing material according to a pattern being formed, and controls the at least one yarn feed mechanism to control the feed of yarn to the needles. (Item B2) a shifting mechanism for shifting the at least one needle bar laterally across the backing material; the control system further comprising programming for presenting a series of yarns at selected stitch locations along the backing material and withdrawing unselected yarns by coordinating shifting of the at least one needle bar by the shift mechanism with control of the actuator coupled to the gauge component and control of the at least one yarn feed mechanism that feeds the yarns to the needles; The tufting machine of claim B1, wherein such unselected yarn loops are not picked up by one of the gauge components. (Item B3) The tufting machine of claim B2, further comprising programming for controlling the feeding of the backing material by the backing feed rolls such that the backing material is moved through the tufting zone at an actual stitch rate that is greater than a pattern stitch rate such that the pattern is formed to provide a number of retained tufts per inch of face yarn in the backing material approximately equal to the pattern stitch rate. (Item B4) The tufting machine of claim B1, wherein the gauge component assembly further comprises a series of connectors extending between actuators associated with each gauge component, each of the connectors including a coupling portion received within and movable through a housing. (Item B5) The tufting machine of claim B4, wherein the housing of each connector comprises a polymeric material, a composite material, a synthetic material, or a combination thereof, and each link comprises a metal, a composite material, or a combination thereof. (Item B6) The tufting machine described in item B4, wherein the housing of each connector further comprises a composite material including a polymer or plastic with a continuous fiber filling material and has a channel defined therein, the coupling portion being movable along the channel, and the coupling portion of each connector comprises a hardened metal body extending through the housing and having a proximal end configured to engage a portion of one of the gauge parts and a distal end configured to be engaged by an associated actuator for the gauge part to transfer movement by the actuator to the gauge part. (Item B7) The tufting machine of claim B1, wherein each of the inserts of the at least one module comprises opposing inserts mounted on upper and lower surfaces of the module body along opposite sides of the passage, the slots of the inserts being disposed in opposing, substantially aligned relationship. (Item B8) The tufting machine of claim B1, wherein each of the inserts comprises a molded or cast body having a tab or flange portion, the slot being formed in the tab or flange portion. (Item B9) The tufting machine of claim B1, wherein the module body comprises steel, aluminum, an aluminum alloy, a steel alloy, mild steel, tool steel, or a combination thereof. (Item B10) The tufting machine of claim B1, wherein the first hardness is at least 60+RC and the second hardness is at least 75+RC. (Item B11) 1. A gauge component assembly for a tufting machine, said gauge component assembly comprising: a plurality of modules, each module including a module body having a passageway defined therethrough; opposing inserts positioned on either side of the passage defined through the module body, each insert being formed from a metal, metal carbide, ceramic, or powdered metal material, including metal powders including tungsten, titanium, or combinations thereof, having a hardness greater than that of the module body, and having a series of slots formed therein, the slots of the opposing inserts being substantially aligned across the passage; a series of gauge parts slidably received within the slots of the opposing inserts, each of the gauge parts having a first portion and a second portion having a throat; the slots of the opposing inserts are configured to define a contact area along which at least a portion of one of the gauge parts is received; a series of gauge parts carried with the module in a first direction toward and away from engagement with the needles of the tufting machine to selectively pick up loops of yarn from needles along the throats of the gauge parts, each of the gauge parts being selectively movable in a second direction along the slots of the opposing inserts in which the gauge parts are received; Multiple actuators and Equipped with a gauge component assembly, each of the plurality of actuators coupled to the gauge component, each of the actuators selectively operable to move the gauge component coupled thereto in the second direction, whereby the throat of the gauge component is moved between one or more extended positions for engaging and picking up a loop of thread from the needle and a retracted position for substantially avoiding picking up the loop of thread from the needle. (Item B12) The gauge component assembly of claim B11, further comprising a connector extending between each gauge component and an actuator associated with each gauge component, each connector having a housing formed from a polymeric material, the coupling portion being encased within the housing. (Item B13) The gauge component assembly of item B12, wherein each housing further comprises a composite material including a polymer or plastic with interdigitated fiber filling material and has a channel defined therein, the coupling portion being movable along the channel, and the coupling portion of each connector comprises a hardened metal body extending through the housing and having a proximal end configured to engage a portion of one of the gauge components and a distal end configured to engage an associated actuator for the gauge component to transfer movement by the actuator to the gauge component. (Item B14) The gauge component assembly of claim B11, wherein an upper portion of each of the opposing inserts is configured to cover an upper surface of the modular body and includes a slotted opening adapted to receive a fastener therethrough for adjustably mounting the opposing insert to the modular body at a location selected relative to the passage defined through the modular body. (Item B15) The gauge component assembly of claim B11, wherein the opposing inserts have a hardness of at least 75+RC. (Item B16) The gauge component assembly of claim B11, wherein the modular body comprises steel, aluminum, an aluminum alloy, a steel alloy, mild steel, a tool steel, or a combination thereof. (Item B17) A tufting machine, comprising: one or more needle bars, the one or more needle bars having a plurality of needles mounted therealong; a backing feed roll configured to feed a backing material through the tufting machine; at least one yarn delivery mechanism for delivering yarn to the needles; a gauge component assembly positioned below the backing material, the gauge component assembly comprising: at least one module having a module body formed from a metal, polymer, composite, or synthetic material, or combinations thereof, said module body with a passageway defined therethrough; a plurality of gauge parts received within the passage of the modular body, each of the plurality of gauge parts including a body having a first portion and a second portion configured to pick up a loop of thread from a needle; a plurality of gauges, the gauge components being carried with the modules in a first direction toward and away from engagement with needles of the tufting machine to pick up loops of yarn from needles and selectively movable in a second direction along the passages of the module body; an insert received within the passage of the modular body, the insert having a series of opposing slots disposed along opposite sides of the passage and configured to receive the gauge parts; an insert, the insert comprising a material having a hardness greater than a hardness of a material of the module body; a series of actuators coupled to the gauge component, the series of actuators configured to control movement of the gauge component in the second direction along the passage of the modular body; and a gauge component assembly comprising: Control system including programming Equipped with the programming controls the at least one yarn feed mechanism and, in coordination with controlling the actuation of one or more actuators, controls the feed of the yarn to the needles to move selected ones of the gauge parts in the second direction, whereby the second portions of the selected ones of the gauge parts are moved between a lowered position and one or more raised positions relative to a stroke of a needle into the backing material to selectively form tufts of yarn in the backing material according to a pattern being formed. (Item B18) The tufting machine of claim B17, wherein the insert comprises a metal carbide, ceramic, powdered metal material, including metal powders including tungsten, titanium, or combinations thereof. (Item B19) The tufting machine of claim B17, wherein each of the inserts is molded or cast from a metal, carbide, or powdered metal material and includes a body with a tab or flange portion, and the slot is formed in the tab or flange portion. (Item B20) The tufting machine of claim B17, further comprising a connector extending between an actuator associated with each gauge component, each connector having a housing formed from a polymeric material, the coupling portion being encased within the housing. (Item B21) The tufting machine of claim B20, wherein the housing of each connector further comprises a composite material including a polymer or plastic with interdigitated fiber filling material and has a channel defined therein along which the coupling is movable, and the coupling of each connector comprises a hardened metal body extending through the housing and having a proximal end configured to engage a portion of one of the gauge parts and a distal end configured to be engaged by an associated actuator for the gauge part to transfer movement by the actuator to the gauge part. (Item B22) The tufting machine of claim B19, wherein the body of each of the inserts further comprises upper and lower tab or flange portions that engage upper and lower surfaces of the module body, the slot extending through the upper and lower tab or flange portions. (Item B23) a shifting mechanism for shifting the one or more needle bars laterally across the backing material, the control system further comprising: to present a series of yarns at selected stitch locations along said backing material and to withdraw unselected yarns; shifting the at least one needle bar by the shift mechanism; Control of the actuator coupled to the gauge component; and controlling the at least one yarn feeding mechanism to feed the yarn to the needles as the needles are shuttled in and out of the backing material; programming adapted to adjust The tufting machine of claim B17, wherein such unselected yarn loops are not picked up by one of the gauge components. (Item B24) The tufting machine of claim B23, further comprising programming for controlling the feeding of the backing material by the backing feed rolls so that the backing material is moved through the tufting zone at an actual stitch rate that exceeds the pattern stitch rate so that the pattern is formed to provide a number of retained tufts per inch of face yarn in the backing material approximately equal to the pattern stitch rate.

Claims

1. A tufting machine, comprising: at least one needle bar having a plurality of needles, the plurality of needles being mounted along the at least one needle bar; a backing feed roll for feeding the backing material; at least one yarn feeding mechanism for feeding yarn to the needles; a gauge component assembly positioned below the backing material, the gauge component assembly comprising: at least one module carrying a series of gauge parts in a reciprocating motion toward and away from engagement with the needle as the needle is reciprocated into the backing material, the at least one module comprising: a modular body formed from a metal, a polymer, or a combination thereof and having a first hardness, the modular body adapted to be mounted along a gauge bar and having a passageway defined therethrough; inserts positioned along the module body on either side of the passage; Equipped with each of the inserts having a slot in which one of the gauge parts is slidably received, each of the slots configured to slidably receive at least a portion of one of the gauge parts therein; the insert comprises a metal or metal carbide material having a second hardness greater than the first hardness of the module body; at least one module, each of the gauge components including a body at least partially received in opposing slots of the insert, the body being movable through a passage of the module body in an additional direction relative to the stroke of the needle, the body of each gauge component having a first portion extending through the passage of the at least one module and a second portion having a throat configured to pick up a loop of thread from the needle; a series of actuators coupled to the gauge components for controlling movement of the gauge components through the module body; a gauge component assembly comprising: Control system including programming Equipped with the programming controls the at least one yarn feeding mechanism to control the feeding of the yarn to the needles in coordination with controlling the actuation of one or more actuators to extend or retract selected ones of the gauge parts, whereby the throats of the selected ones of the gauge parts are moved between a non-sewing position and an engaged position relative to the stroke of the needle into the backing material to selectively form tufts of yarn in the backing material according to a pattern being formed.

2. a shifting mechanism for shifting the at least one needle bar laterally across the backing material; The control system is adapted to present a series of threads at selected stitch locations along the backing material as the needles are shuttled in and out of the backing material and to withdraw unselected threads. shifting the at least one needle bar by the shift mechanism; feeding the backing material by the backing feed roll; Control of the actuator coupled to the gauge component; and Controlling the at least one yarn delivery mechanism that delivers the yarn to the needles; and further comprising programming for adjusting Such unselected loops of yarn are not picked up by one of said gauge components; 10. The tufting machine of claim 1, wherein the backing material is moved through the tufting zone at an operating stitch rate, the operating stitch rate being greater than the pattern stitch rate to provide a number of retained tufts per inch of face yarn in the backing material equivalent to the pattern stitch rate for the pattern being formed.

3. The tufting machine of claim 1 , wherein the gauge components comprise a level cut loop looper, a loop pile looper, or a cut pile hook.

4. The tufting machine of claim 1 , wherein the actuator comprises a hydraulic or pneumatic cylinder.

5. 2. The tufting machine of claim 1, wherein the gauge component assembly further comprises a series of connectors extending between actuators associated with each gauge component, each of the connectors including a linkage received within a housing and movable through the housing.

6. The tufting machine of claim 5 , wherein the housing of each connector comprises a polymer and further includes a channel extending therethrough, and each link comprises a metal.

7. the body of each housing further comprises a composite material including a polymer or plastic with a fiber-filled material and has a channel defined therein; 6. The tufting machine of claim 5, wherein the couplings are movable along the channel, the couplings of each connector comprising a hardened metal body coupled to a body of the housing, the hardened metal body having a proximal end configured to engage a first portion of one of the gauge parts and a distal end configured to be engaged by an actuator associated with the gauge part to transfer movement by the actuator to the gauge part.

8. each of the at least one modular inserts comprises a first pair of inserts mounted to upper and lower surfaces of the module body along a first side of the module body passage and a second pair of inserts mounted to the upper and lower surfaces of the module body along a second side of the module body passage; the second pair of inserts are spaced apart from and face the first pair of inserts; 2. The tufting machine of claim 1, wherein the slots of said inserts of said first pair of inserts are disposed in opposing and substantially aligned relationship with corresponding slots of said inserts of said second pair of inserts.

9. 9. The tufting machine of claim 8, wherein the inserts of the first and second pairs of inserts are configured to cover the upper and lower surfaces of the module body, each including a slotted opening adapted to receive a fastener therethrough for adjustably mounting each of the first and second pairs of inserts to the module body, and the inserts are positioned at selected intervals from one another and at selected locations relative to the passage defined through the module body.

10. 2. The tufting machine of claim 1, wherein said at least one needle bar comprises a pair of needle bars, each of said pair of needle bars having a series of needles mounted in serially spaced relation therealong.

11. 1. A gauge component assembly for a tufting machine, said gauge component assembly comprising: a plurality of modules, each module including a module body, the module body having a first hardness and having a passageway defined therethrough; a series of gauge parts slidably received within each of said modules, each of said gauge parts having a throat terminating in a bill, said gauge parts being carried with their modules in a first direction toward and away from engagement with needles of the tufting machine along said throats of said gauge parts to selectively pick up loops of yarn from needles, each of said gauge parts being selectively movable in a second direction along said paths of their modules; first and second inserts mounted to the module body of each module on either side of the passage defined through the module body, each insert formed from a metal or metal carbide material having a second hardness greater than the first hardness of the module body and having a series of slots formed therein, the slots of the first and second inserts being substantially aligned across the passage and configured to define a contact area along at least a portion of one of the gauge components slidably received therein; a plurality of actuators, each of the plurality of actuators coupled to an associated one of the gauge parts and adapted to move its associated one of the gauge parts in the second direction through the passageway of the module, whereby the gauge parts are extended or retracted to move the throat of the gauge part between an extended position for engaging and picking up a loop of thread from the needle and a retracted position for substantially avoiding picking up the loop of thread from the needle; a connector extending between each actuator and its associated one of the gauge components, each connector having a housing formed from a polymeric material with a coupling portion encased therein; and The gauge component assembly comprises:

12. 12. The gauge component assembly of claim 11, wherein each housing further comprises a composite material including a polymer or plastic with a fiber-filled material and has a channel defined therein along which the coupling is movable, and wherein the coupling of each connector comprises a hardened metal body extending through the housing and has a proximal end configured to engage a portion of one of the gauge components and a distal end configured to be engaged by the actuator associated with each gauge component to translate movement by the actuator to the gauge component.

13. 12. The gauge component assembly of claim 11, wherein an upper portion of each of the first and second inserts is configured to cover an upper surface of the modular body and includes a slotted opening adapted to receive a fastener therethrough for adjustably mounting each of the first and second inserts to the modular body, the inserts being disposed at a selected spacing from one another and at a selected location relative to a passage defined through the modular body.

14. The gauge component assembly of claim 11 , wherein the insert comprises a metal carbide material having a hardness of at least 75 RC.

15. The gauge component assembly of claim 11 , wherein the insert comprises a metal carbide material and the module body comprises an aluminum material.

16. 1. A gauge component assembly for a tufting machine, said gauge component assembly comprising: at least one module comprising a module body having a passageway defined therethrough, the module body having a first hardness; a series of gauge parts received within the passage of the module body, each gauge part including a body with a first portion and a second portion having a throat, the gauge parts being carried with their modules in a first direction toward and away from engagement with an associated needle of the tufting machine to pick up loops of yarn from a needle along the throat of the gauge part, the gauge parts being selectively movable in a second direction along the passage of the module body; inserts disposed along opposite sides of the passageway of the modular body, each insert being formed from a material having a second hardness greater than the first hardness of the modular body and having a series of spaced apart slots configured to receive at least a portion of one of the gauge parts; Multiple actuators and Equipped with a gauge component assembly, wherein each actuator is coupled to a first portion of an associated gauge section of the series of gauge components and adapted to move its associated gauge component in the second direction through the passage of the at least one module, whereby the gauge component is extended or retracted through the module body to move the throat of the gauge component between an extended position for engaging and picking up a loop of thread from the needle and a retracted position for substantially avoiding picking up a loop of thread from the needle.

17. 17. The gauge component assembly of claim 16, further comprising a connector extending between each actuator and its associated gauge component, each connector having a housing formed from a polymeric material with the coupling encased therein.

18. 17. The gauge component assembly of claim 16, wherein the module body of the at least one module is molded or cast from metal.

19. 20. The gauge component assembly of claim 18, wherein each of the inserts is molded or cast from a metal, carbide, or powdered metal material and comprises a body with a tab or flange portion, the slot being formed in the tab or flange portion.

20. 20. The gauge component assembly of claim 19, wherein the body of each of the inserts further comprises upper and lower tabs or flange portions that engage upper and lower surfaces of the module body, the slots extending through the upper and lower tabs or flange portions.

21. 17. The gauge component assembly of claim 16, wherein each of the inserts comprises a body molded or cast from a metal, carbide, or powdered metal material, the body comprising a tab or flange portion, the slot being formed in the tab or flange portion, and the module body of the at least one module comprises a metal, the metal being molded or cast to form the module body.

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