Tufting machine and tufting method

Abstract

To provide suitable tufting machines and tufting methods.SOLUTION: There is provided a tufting machine for selectively forming tufts of yarns, including different color or type yarns, for forming patterned tufted articles such as carpets. A series of needles are reciprocated into and out of a backing material being fed through the tufting machine and are engaged by a series of gauge parts so as to pick-up loops of yarns from the needles. The gauge parts will be selectively controlled by activators to extend or retract the gauge parts to positions or elevations sufficient to pick-up or not pick-up loops of yarns from the needles. The feeding of the yams to the needles further will be controlled to back-rob yarns not picked-up by the gauge parts, while the backing feed will be controlled to enable formation of tufts at an increased rate over a pattern stitch rate for the pattern of the tufted article being formed.SELECTED DRAWING: Figure 1

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 Feb. 16, 2021.

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

[0003] (Field of Disclosure) This disclosure generally relates to tufting machines and methods of forming tufted fabrics. In particular, this disclosure relates to a tufting machine that includes a selectively controllable gauge part and a module or gauge block for carrying such a gauge part, and a method of forming a patterned tufted fabric.

Background Art

[0004] In the field of tufting, particularly with respect to commercial and hospitality carpets, there is an increasing demand for the production of carpets and rugs with new visual patterns that include the use of multiple different colors as an effort to keep up with changing consumer preferences and increasing competition in the market. Carpet designers and manufacturers are thus increasingly focusing on creating newer, different, and more eye - catching patterns for carpets, rugs, and other tufted fabrics, including patterns having a selective arrangement and display of specific colors or types of yarns within the pattern area, such that the resulting tufted fabric is formed with a substantially true pattern density of the visible tufts of the pattern. In particular, it is desirable to be able to create and form such patterned tufting carpets, rugs, and / or other fabrics on a wide - width tufting machine while closely replicating as precisely as possible the appearance and atmosphere of the patterned carpets, rugs, or other fabrics formed on a loom, in order to enable increased efficiency in the production of such patterned tufting carpets, rugs, and / or other fabrics.

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

[0006] Therefore, it can be seen that there is a need for systems and methods for forming tufted fabrics such as carpets and rugs to address these and other related and unrelated issues within the technical field. [Overview of the Initiative] [Means for solving the problem]

[0007] In short, the disclosure relates to a tufting machine and method for forming patterned tufted articles, such as carpets, which generally have a fluid, multi-color and / or multi-pile height pattern and have various pattern effects, including the formation of tufted articles having a substantially woven or loom-formed appearance, in which the arrangement of tufts of yarn or stitches formed on the backing material and the pile height can be selectively controlled.

[0008] In one aspect, a tufting machine would 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 may include various pattern effects, including having multiple diverse or different pile heights, different types of tufts in identical and / or fluctuating tuft rows, and other texture effects, and arrangements of various colors and / or types of yarn that are visible at selected locations and pile heights across the backing material, 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 a desired or specified pattern density or stitch per inch of the pattern being formed / tufted.

[0009] In embodiments, a tufting machine would include one or more needle bars having a series of needles mounted along it. The needles can be arranged in a straight line, alternating, or other configurations. As the backing material is fed through the tufting belt of the tufting machine, the thread will be introduced into it as the needles are reciprocated in and out of the backing material. Shifting mechanisms may be further provided to shift the needle bar laterally across the tufting belt, and multiple shifting mechanisms may be utilized as needed. The shifting mechanisms would generally be operable in response to commands or communications from a control system to stepwise move or shift the needle bar laterally across the backing material according to programmed and / or designed pattern shifting steps for the pattern being tufted, in order to present the thread carried thereby to the tuft or stitch location along / across the backing material.

[0010] Tufting machines will generally further include at least one yarn feeding mechanism or attachment for controlling the feeding of yarn to each of their needles. Such yarn feeding mechanisms or pattern attachments may include, but are not limited to, Yarntronics, such as those manufactured by Card-Monroe Corp. TM Or Infinity TM / Infinity IIE TM The yarn feeding attachment may include various rolls, scrolls, servo scrolls, single-ended, double, or multiple-ended yarn feeding attachments. Other types of yarn feeding control mechanisms may also be used. At least one yarn feeding mechanism or pattern attachment may be operated to selectively control the feeding of yarn to its needles for forming yarn tufts, which may include forming tufts with a selected pile height and / or not forming tufts, in order 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 such as that disclosed in U.S. Patent No. 8,359,989 (which is incorporated herein by reference as if its disclosure were fully described), through which control of backing material feeding and control of the operation of a shift mechanism for shifting at least some of the needles may be coordinated with the control of at least one thread feeding mechanism, such that various threads may be presented at various stitch locations or pixels, and threads to be shown on the front or surface of the tufted article may generally be fed in sufficient quantities to form a tuft of the desired height, while threads that should not be shown in the tufting area, that do not appear, may be backlobbed or otherwise sufficiently pulled down and / or pulled out from the backing material. With respect to each pixel or stitch location of the pattern, a set of threads may be presented, and threads that are not selected to be visible or appear at such stitch locations may be hidden and sufficiently pulled down so as not to interfere with selected threads that become visible. In some embodiments, this may include pulling non-appearing or unselected threads out of the backing material, or leaving a sufficient portion of non-appearing threads within the backing material, thereby retaining or sewing the unselected or non-appearing threads to the backing material, and substantially minimizing interference of the pattern threads to the front side or retained visible tufts. Thus, in embodiments, only desired or selected threads / colors placed at specific stitch locations may be retained at such stitch locations, while the remaining threads / colors may be hidden so as not to appear or be shown in the pattern area being sewn at that time. The control system may further control and adjust the operation of the gauge component assembly, at least using thread feeding, according to instructions for the pattern being formed, to control the selective formation of thread loops and / or tufts, and their length or pile height.

[0012] In addition, in embodiments, the gauge component assembly may generally include a series of gauge components, such as loopers, hooks, level-cut loop loopers, cut / loop clips, etc., which are provided below the tufting band and are movable in a first direction so as to be reciprocated to engage with the needle as the needle penetrates the backing material and then picks up loops of yarn. In some embodiments, each of the gauge components may be selectively further movable in a direction substantially perpendicular to the direction of its reciprocation, for example, being moved substantially perpendicular to the stroke or reciprocation of the needle on and off the backing material, i.e., in an up-and-down motion, and being moved in a reciprocating motion toward and away from the needle to selectively pick up and form loops of yarn in the backing material. In addition, the vertical movement of the gauge components may 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 the absence of loops of yarn in the backing material. In further embodiments, loop pile loopers, cut pile hooks, cut / loop hooks, level cut loopers or hooks, and / or other configurations and / or combinations of gauge components may also be used.

[0013] For example, in some embodiments, the gauge component may include a looper or hook, each slidably mounted within a gauge module or gauge block, and comprising a body having a first and a second portion, which may include an elongated throat terminating at a pointed proximal end or bill. The first portion of the body may extend through the gauge block or module and, at its distal end, may be connected to an actuator. In some embodiments, each of the gauge modules may include a module or block body having a first or rear section adapted to be coupled or mounted along a gauge rod, and a second or front section having at least one channel or passage formed through it, through which a gauge component will be received. The module may further include a replaceable insert that can be received in a passage or channel formed within the module body, the replaceable insert further including a slot or recess adapted to receive and guide the gauge component during its movement through / along the passage of the module block. Alternatively, the insert may be integrated with the module or gauge block body by being joined to or otherwise substantially permanently attached or fixed to it, and in some embodiments, it may still be substantially attached while allowing for at least useful removal if necessary.

[0014] In embodiments, interchangeable inserts may be formed from a hardened material which may include, but is not limited to, various metal carbides, metals, ceramics, and / or composite materials, while the module body may be manufactured from lighter materials such as aluminum and / or other metals and various composite or composite materials. The insert may further include an opening or slot configured to receive a guide pin or other positioning device, and one or more fasteners for securing the insert within the gauge module. The openings may 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 arrangement or positioning of gauge components across and / or along the gauge module. The inserts may further be interchangeable to allow easy removal of the insert, and therefore replacement of one or more of the gauge components received therein, for example, to replace a worn or damaged gauge component, or to change the spacing between gauge components.

[0015] As a further alternative, in some embodiments, the module or gauge block itself may be removable and interchangeable with other gauge blocks or modules, each containing a set or series of gauge components mounted therein, to provide for changing the gauge spacing between gauge components, changing the type or size of gauge components used, or replacing substantially all or at least most of worn or damaged gauge components as a unit. In addition, guide slots or recesses formed within the insert will generally be configured to receive the bodies of the gauge components, with a clearance that is generally sufficient to allow substantially free sliding movement of the gauge components through them, but not to allow excessive shifting or twisting of the gauge components such as creating misalignment of the bill or throat of the gauge components and their respective needles. The slots or recesses in the insert may further terminate at a rear end or portion that can be configured or adapted to allow the edges of the bodies of the gauge components to seat against and / or possess a base or engagement area along which they can slide, helping to maintain the desired alignment of the gauge components as they reciprocate or move through their module.

[0016] The gauge components can also be positioned to engage with the needle, including being positioned substantially in a straight line, offset or alternating, and / or other configurations as necessary to engage with a straight line, alternating, and / or double needle bar arrangement. In embodiments, each gauge component can be further positioned at a certain angle to the needle when the needle penetrates the backing material. For example, in some embodiments, the gauge components can be positioned and / or extendable / retractable along a travel path oriented at an angle that can range from about 1° to about 10° from perpendicular to the needle and / or its stroke or vertical movement, while in other arrangements, no offset, i.e., a 0° angle, can be provided. The offset of the gauge components relative to the needle can be further varied, depending on the spacing and / or arrangement of the needles, so that the gauge components can be extended and retracted along a travel path that forms an angle with or is offset from the needle as necessary to minimize potential engagement with the needle when the gauge components are moved.

[0017] In various embodiments, the actuators driving the movement of the gauge components may comprise hydraulic, electric, pneumatic, or pneumatic cylinders, motors, or other similar actuators. Each actuator of a gauge component may be selectively controlled, according to a pattern command, to move the gauge component to a desired perpendicular position relative to the associated needle for picking up a loop of yarn from the needle, including picking up a loop of yarn at different points in the needle stroke to form loops / tufts of different pile heights, and retracting to a “non-sewing” position where the loop of yarn will generally not be picked up. In further embodiments, the actuator may be controlled / triggered to move its gauge component together with such a captured loop of yarn to stretch or pull the loop captured thereon, to provide other pile heights and / or other effects for tip shear or other pattern or texture effects, etc.

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

[0019] For example, in some embodiments, the actuator can drive the gauge component in a direction substantially perpendicular to the directional reciprocating motion of the needle in and out of the backing material, such as to adjust the height of the gauge component relative to the needle when the gauge component is reciprocated toward and away from the needle. In other embodiments, the operation of the actuator and the movement of the connector may help to control the movement of the gauge component toward and away from the needle in a direction substantially aligned with the directional reciprocating motion of the gauge component toward and away from the needle.

[0020] In addition, in embodiments, the connector or gate coupling or arm may be further housed within a housing or support structure. In one exemplary embodiment, such a housing or support structure may include a body formed from a durable lightweight material such as carbon-filled nylon material or other similar composite or plastic material, selected to provide durability and support for the coupling or arm while allowing for weight reduction. Other materials, including various metals, synthetics, and / or composite materials, may also be used. The configuration of the support structure or housing may be further varied as needed to accommodate couplings of varying configurations and / or sizes, while in various embodiments, the connector coupling or arm may have further reduced thickness or structure to further help reduce weight, and in some embodiments, a skeletonized structure may be included. The connector coupling or arm is housed within a channel or passage formed within the connector housing and moves through the channel or passage when the actuator is engaged and disengaged, transferring this movement to their associated or corresponding gauge components.

[0021] In some aspects of the present disclosure, a tufting machine comprises at least one needle bar having a needle provided and mounted thereon; a backing material feed roll for feeding backing material; an insert having a series of slots, each of which one of gauge components is slidably received; at least one thread feed mechanism for feeding thread to the needle; and a gauge component assembly positioned below the backing material.

[0022] In some embodiments, a gauge component assembly may comprise at least one module that carries a series of gauge components in a reciprocating motion toward and toward engagement with the needle when the needle is reciprocating within the backing material, the at least one module comprising a module body which may be cast, molded or otherwise formed from a metal, polymer, composite or synthetic material or a combination thereof, and which will have a first hardness. The module body will be adapted to be mounted along a gauge rod and will consist of a passage defined through it. Inserts will be mounted on the module body on both sides of the passage, and each insert will have a series of spaced slots formed therein, each slot being configured to slidably receive therein at least one portion of a gauge component. In embodiments, the inserts may be cast, molded or otherwise formed from a metal or metal carbide or powdered metal material which has a hardness greater than that of the module body, and the slots will be formed or defined therein. In an embodiment, each gauge component may include a body that is at least partially received in opposing slots of an insert and is movable in an additional direction through a passage of the module body relative to the stroke of the needle, the body of each gauge component having a first portion extending through a 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 includes a series of actuators coupled to the gauge parts to control the movement of the gauge parts through the module body, and controls at least one yarn feeding mechanism and coordinates with the control of the operation of one or more of the actuators to control the feeding of yarn to the needles, thereby extending or retracting selected ones of the gauge parts, whereby the throat of the selected one of the gauge parts is moved between a non-sewing position and an engaging position relative to the stroke of the needles into the backing material to selectively form yarn tufts in the backing material according to the pattern being formed, and a control system including programming therefor.

[0024] In various embodiments of the tufting machine, the gauge parts 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 can further comprise a series of connectors extending between the actuators associated with each gauge part, each of the connectors including a connecting portion received within and movable therethrough a housing.

[0026] In some embodiments, the housing of each connector comprises a body formed from a polymer, composite, or synthetic material, or combinations thereof, and having a channel extending therethrough, and each connecting portion comprises a metal, or composite material, or combinations thereof.

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

[0028] In further embodiments, each of at least one module insert comprises a first insert and a second insert, each including a tab or flange portion that will cover and / or mount the upper or first or bottom or second surface of the module body. In other embodiments, the body of each insert may have an upper or proximal portion, a lower or distal portion, and an intermediate portion extending between them and along a passage defined through the module body, and the slot of the first or left insert is spaced apart from, opposite to, and substantially aligned with the corresponding slot of the second or right insert.

[0029] In addition, in embodiments, the tab or flange portions of each of the first and second inserts are configured to cover the upper surface of the module body and include slotted openings adapted to receive fasteners through them for adjustable mounting of each of the first and second inserts to the module body, and the inserts are positioned at selected locations relative to passages defined through the module body at selected intervals from each other. In addition, the inserts can be molded, enclosed, encapsulated, or otherwise substantially integrated within the module body. The inserts may also include tab or flange portions that can engage with the opposite surface of the module body, and a plate or intermediate section may be provided between them. The intermediate section may connect to the tab or flange of the insert, and slots of the insert are at least partially formed therein and extending along them. Alternatively, a bearing plate of a support can be received along the first and second side surfaces of the passage between the tabs or flanges of the inserts.

[0030] Accordingly, in some aspects of the present disclosure, a gauge component assembly for a tufting machine comprises at least one module having a module body with a passage defined therethrough, and a series of gauge components received within the passage of the module body, each gauge component comprising a body having a first part and a second part having a throat, the gauge components being carried together with their modules in a first direction toward and away from engagement with an associated needle of a tufting machine, picking up a loop of thread from the needle along the throat of the gauge component, and the gauge components being selectively movable in a second direction along the passage of the module body. The first and second module inserts are positioned along opposite sides of the passage of the main body, and each insert is formed of a material having a hardness exceeding the hardness of the metal or composite material of the module body, and has a series of spaced slots along it configured to receive at least a portion of one of the gauge parts, the slots of the first and second inserts are substantially aligned across the passage, and each actuator of the plurality of actuators is coupled to a first portion of an associated gauge part of a series of gauge parts and is adapted to move the associated gauge part in a second direction through the passage of at least one module, thereby extending or retracting through the module body so that the throat of the gauge part is moved between an extended position for engaging the loop of thread from the needle and picking it up and a retracted position for substantially avoiding picking up the loop of thread from the needle.

[0031] In some embodiments, the gauge component assembly described in the claims may further comprise connectors extending between each actuator and its associated gauge component, each connector having a housing formed from a polymer material, with the connecting portion enclosed 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 may include first and second inserts, each having a body molded or cast from a metal, carbide, or powdered metal material, and comprising tabs or flange portions in which slots are formed. Furthermore, each body of the first and second inserts may further comprise upper and lower tabs or flange portions that engage with the upper and lower surfaces of the module body, and the slots extend through the upper and lower tabs or flange portions.

[0033] In additional embodiments, the gauge component assembly may include first and second inserts, each having a body including a tab or flange portion, which is molded or cast from a metal, carbide, or powdered metal material and has slots formed therein, wherein the module body of at least one module comprises a metal or composite material molded or cast to form the module body together with the first and second inserts which are substantially integrated therewith.

[0034] In some aspects of this disclosure, methods for operating a tufting machine are disclosed, and according to an exemplary embodiment of this disclosure, as the needle of the tufting machine is reciprocated in and out of the backing material, actuators of a gauge component can be selectively engaged or disengaged to move the gauge component between a fully retracted or non-sewn position, where the gauge component does not engage with the associated or corresponding needle and therefore no loop of yarn is formed, and a variable extended or raised position, including a fully extended position. In the raised or extended position, the gauge component engages with the needle at its take-off portion as the needle passes in and out of the backing material, picking up a loop of yarn from the needle. The loop of yarn picked up from the needle may have a variable 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 material, including those substantially removed by the control of its yarn feeding. Longer yarn loops can be formed by the looper as it is moved to the lowered position and, if necessary, the yarn loops are picked up and pulled along with them, so that the yarn tufts in the backing material are higher or greater pile heights. In addition, the actuator can be further controlled to selectively lower or retract its corresponding gauge component, along with the yarn loops captured on it, to form even longer yarn loops, such as for tip shearing, and to enable additional patterning effects.

[0035] The needle can generally be further shifted laterally relative to the longitudinal movement of the backing material through the tufting strip to present different colored or different types of threads to each stitch location of the pattern formed in the backing material. For example, the needles of a 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 started at an actual or effective stitch rate substantially exceeding the prescribed or desired pattern stitch rate for the pattern being formed. As a result, as the needle is shifted, a desired number of different colored or typeed threads can be presented to each stitch location. By controlling the positioning and / or movement of the gauge component, loops of thread can be selectively formed in the backing material, and the formation of such loops of thread can, in some embodiments, be further controlled to form a fluctuating pile height of the resulting tuft. For example, in various aspects, a series of different colored or typed threads may be presented at each stitch location as the needle bar is shifted, and if a tuft of a particular colored or typed thread is not selected to be sewn at that stitch location, the corresponding gauge component may be held in a retracted or lowered position so that loops of such unselected threads are generally not formed.

[0036] In addition, as the needle is moved back and forth from the backing material, the thread feeding for this purpose can be controlled such that several thread loops are moved back, backlobbed, or pulled back so that unselected threads are moved back with the needle, backlobbed, or otherwise pulled back from the backing material, or pulled out, and so as to prevent such threads from being shown in their stitch locations in the finished patterned article. Higher control of the backing material in operation, effective, or actual stitch rate allows for the formation of a substantially increased number of stitches of thread presentation into the backing material so as to substantially avoid missing color or type of thread or gaps being created, shown, or otherwise appearing in the patterned areas of the patterned tufted article. The finished patterned tufted article can therefore be provided with a tuft density per inch that substantially matches the desired or specified pattern stitch rate, i.e., with respect to a pattern designed with a pattern stitch rate of 8, 10, or 12 stitches per inch, or any other number of stitches, the resulting finished patterned tufted article can be formed with a visible and / or retained facet yarn or tuft density per inch that substantially matches the pattern stitch rate.

[0037] The aforementioned and other advantages and aspects of the embodiments of this disclosure will become apparent and more readily understood from the following detailed description and claims, which will be considered in conjunction with the accompanying drawings. Furthermore, it should be understood that both the aforementioned summary of this disclosure and the following detailed description are illustrative and intended to provide further explanation without limiting the scope of this disclosure. This specification also provides, for example, the following items: (Item 1) A tufting machine, wherein the tufting machine is A needle bar having a plurality of needles, wherein the plurality of needles are mounted along the at least one needle bar, A backing material feeding roll for feeding backing material, A yarn feeding mechanism for feeding yarn to the needle, A gauge component assembly positioned below the backing material, wherein the gauge component assembly is When the needle is being reciprocated within the backing material, at least one module carries a series of gauge components in a reciprocating motion toward and toward engagement with the needle, wherein the at least one module is A module body formed from a metal, polymer, composite material, or synthetic material, or a combination thereof, having a first hardness, wherein the module body is mounted along a gauge rod and adapted to have a passage defined therethrough, Inserts positioned along the module body on both sides of the aforementioned passage Equipped with, Each of the inserts has a slot into which one of the gauge components is slidably received, and each of the slots is configured to slidably receive in thereat least a portion of one of the gauge components. The insert comprises a metal or metal carbide material having a second hardness exceeding the first hardness of the module body. Each of the gauge components includes a body that is at least partially received in the opposing slots of the insert, the body being movable in additional directions relative to the stroke of the needle through the passage of the module body, and the body of each gauge component includes at least one module 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, A series of actuators coupled to the gauge component to control the movement of the gauge component through the module body, A gauge component assembly, Control system including programming and Equipped with, Tufting machine, wherein the programming extends or retracts a selected gauge component by controlling the at least one thread feeding mechanism to control the feeding of the thread to the needle in coordination with the control of the operation of one or more actuators, thereby moving the throat of the selected gauge component between a non-sewing position and an engagement position with respect to the stroke of the needle into the backing material in order to selectively form a thread tuft in the backing material according to a formed pattern. (Item 2) The system further comprises a shift mechanism for shifting the at least one needle bar laterally across the backing material, The control system, when the needle is moving back and forth in and out of the backing material, presents a series of threads to selected stitch locations along the backing material and pulls out any unselected threads. The shift of the at least one needle bar by the shift mechanism, The feeding of the backing material by the backing material feeding roll, Control of the actuator coupled to the gauge component, Control of the at least one thread feeding mechanism that feeds the thread to the needle and It also includes programming to adjust, Such unselected thread loops are not picked up by one of the gauge components. The tufting machine according to item 1, wherein the backing material is moved through a tufting strip at a certain operational stitch rate, the operational stitch rate being greater than the pattern stitch rate for the pattern formed in the backing material, so as to provide a number of tufts held per inch of face yarn that is approximately equivalent to the pattern stitch rate. (Item 3) The tufting machine according to item 1, wherein the gauge component comprises a level cut loop looper, a loop pile looper, or a cut pile hook. (Item 4) The tufting machine according to item 1, wherein the actuator comprises a hydraulic or pneumatic cylinder. (Item 5) The tufting machine according to item 1, wherein the gauge component assembly further comprises a series of connectors extending between each gauge component and an actuator associated with it, each of the connectors including a coupling portion that is received within a housing and movable through the housing. (Item 6) The tufting machine according to item 5, wherein the housing of each connector comprises a polymer, composite material, or synthetic material, or a combination thereof, and further includes a channel extending through the housing, and each connecting portion comprises a metal, composite material, or a combination thereof. (Item 7) The body of each housing further comprises a composite material including a polymer or plastic together with a fiber-filled material, and having defined channels therein, The tufting machine according to item 5, wherein the connecting portion is movable along the channel, and the connecting portion of each connector comprises a hardened metal body coupled to the body of the housing, the hardened metal body having a proximal end configured to engage with a first portion of one of the gauge components, and a distal end configured to be engaged by an actuator associated with the gauge component to transfer movement by the actuator to the gauge component. (Item 8) Each of the at least one module inserts comprises a first pair of inserts mounted on the upper and lower surfaces of the module body along the first side of the passage of the module body, and a second pair of inserts mounted on the upper and lower surfaces of the module body along the second side of the passage of the module body, The second pair of inserts is spaced apart from and facing the first pair of inserts. The tufting machine according to item 1, wherein the slots of the first pair of inserts are arranged opposite and substantially aligned with the corresponding slots of the second pair of inserts. (Item 9) The tufting machine according to item 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, the slotted opening being adapted to receive fasteners through which each of the first and second pairs of inserts can be adjustably mounted on the module body, and the inserts are positioned at selected intervals from each other and at selected locations relative to the passage defined through the module body. (Item 10) The tufting machine according to item 1, wherein the at least one needle bar comprises a pair of needle bars, each of which has a series of needles mounted in series and spaced apart along it. (Item 11) A gauge component assembly for a tufting machine, wherein the gauge component assembly is A plurality of modules, each module including a module body and having a passage defined through it, A series of gauge components slidably received within each of the modules, each of which has a throat terminating at a bill, and the gauge components are carried together with the modules in a first direction toward and away from engagement with the needle of the tufting machine so as to selectively pick up a loop of thread from the needle, and each of the gauge components is selectively movable in a second direction toward the passage of the modules, First and second inserts mounted on the module body of each module on both sides of the passage defined through the module body, each insert being formed from a metal or metal carbide material having a hardness greater than that of the module body, and having a series of slots formed therein, wherein the slots of the first insert and the slots of the second insert are substantially aligned across the passage and configured to define a contact area along at least a portion of one of the slidably received gauge components, A plurality of actuators, each of which is coupled to an associated gauge component and is adapted to move those associated gauge components in the second direction through the passage of the module, thereby extending or retracting the throat of the gauge component between an extended position for engaging with 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, A connector extending between each actuator and the associated gauge component, each connector having a housing formed of a polymer material, the connecting portion enclosed therein, and A gauge component assembly equipped with the following features. (Item 12) The gauge component assembly according to item 11, wherein each housing further comprises a composite material including a polymer or plastic together with a fiber-filled material, having a defined channel therein, the connector being movable along the channel, and the connector of each connector having a hardened metal body extending through the housing, and having a proximal end configured to engage with a portion of one of the gauge components, the distal end being configured to be engaged by the actuator associated with each gauge component to transfer movement by the actuator to the gauge component. (Item 13) The upper 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, which is adapted to receive fasteners through which each of the first and second inserts can be adjustably mounted on the module body, and the inserts are positioned at selected intervals from each other and at selected locations relative to a passage defined through the module body, as described in item 11. (Item 14) The gauge component assembly according to item 11, wherein the insert comprises a metal carbide material having a hardness of at least 75+RC. (Item 15) The gauge component assembly according to item 11, wherein the insert comprises a metal carbide material and the module body comprises an aluminum material. (Item 16) A gauge component assembly for a tufting machine, wherein the gauge component assembly is A module having a module body, wherein the module body has a passage defined through it, A series of gauge components received into the passage of the module body, each gauge component comprising a body having a first portion and a second portion having a throat, the gauge components being carried together with the module in a first direction toward and away from engagement with the associated needle of the tufting machine, the gauge components picking up loops of thread from the needle along the throat of the gauge component, and the gauge components being selectively movable in a second direction along the passage of the module body, An insert disposed along both sides of the passage of the module body, each insert being formed from a material having a hardness exceeding that of the metal or composite material of the module body, and having a series of spaced slots configured to receive at least a portion of one of the gauge components, Multiple actuators and Equipped with, Each actuator is coupled to a first portion of an associated gauge portion of the series of gauge components and is adapted to move the associated gauge component in a second direction through the passage of the at least one module, thereby extending or retracting through the module body the gauge component moves the throat of the gauge component between an extended position for engaging with 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, in a gauge component assembly. (Item 17) The gauge component assembly according to item 16 further comprises connectors extending between each actuator and its associated gauge component, each connector having a housing formed of a polymer material, with the connecting portion enclosed therein. (Item 18) The gauge component assembly according to item 16, wherein the module body of at least one module is molded or cast from metal or composite material. (Item 19) 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 within the tab or flange portion, as described in item 18. (Item 20) The gauge component assembly according to item 19, wherein each of the inserts' bodies further comprises upper and lower tabs or flange portions that engage with the upper and lower surfaces of the module body, and the slots extend through the upper and lower tabs or flange portions. (Item 21) 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 within the tab or flange portion, and the module body of at least one module comprising a metal or composite material, the metal or composite material being molded or cast to be substantially integrated with the module body to form the module body, as described in item 16. [Brief explanation of the drawing]

[0038] The accompanying drawings incorporated herein, which are part of this specification and included to provide a further understanding of the embodiments of the disclosure, illustrate the embodiments of the disclosure and, together with the detailed descriptions, illustrate the principles of the embodiments discussed herein. No attempt is made to show the structural details of the 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, in accordance with general practice, that various features of the drawings discussed below are not necessarily drawn to exact scale, and that the dimensions of various features and elements of the drawings may be enlarged or reduced in order to more clearly illustrate the embodiments of the disclosure described herein.

[0039] [Figure 1] Figure 1 is a side elevation view of an exemplary embodiment of a tufting machine with a selectively controllable looper assembly according to the principles of the present disclosure.

[0040] [Figure 2] Figure 2 is a side elevation view of the tufting strip of the tufting machine shown in Figure 1.

[0041] [Figure 3] Figure 3 is a perspective view of the tufting machine shown in Figure 1-2.

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

[0043] [Figure 5] Figure 5 is a cross-sectional view of the gauge module or gauge block and gauge components shown in Figure 4.

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

[0045] [Figure 7] Figures 7A-7B illustrate embodiments of a connector for connecting a gauge component to its actuator according to the principle of this disclosure.

[0046] [Figure 8] Figures 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] Figures 9A-9B illustrate further embodiments of connectors for connecting gauge components to their actuators according to the principles of the present disclosure.

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

[0049] [Figure 11] Figures 11A-11C are side elevation views illustrating embodiments of the operation of a selectively operable gauge component according to the principles of this disclosure. [Modes for carrying out the invention]

[0050] Herein, referring to drawings where similar figures show similar parts throughout several figures, Figure 1-11C generally illustrates embodiments of a tufting machine 10 and method for forming patterned tufted articles according to the principles of the present disclosure, where the placement of stitches or tufts 5 of yarn Y can be in desired locations on a controllable backing material B. Such tufts or stitches can be formed with a carved-like multi-pile height tufted appearance and can be placed with improved selectivity and / or control for the formation of further variation or fluidity pattern effects. For example, a tufted article can be formed using tufts of yarn formed with varying pile heights to provide a carved-like appearance, and using different colors or types of yarn for the formation of multi-color patterns of various geometric and / or fluidity designs. In addition, it will be understood that various numbers of different types and / or colors of yarn (i.e., 2 colors, 3 colors, 5 colors, 6 colors, etc.) can be used to form multi-pile height patterned tufted articles according to the principles of the present disclosure.

[0051] As generally illustrated in Figure 1, in one embodiment, the tufting machine 10 includes a frame 11, which may include a head or upper portion 12 that houses the needle bar drive unit 13 and defines the tufting strip 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 unit 16 (gearbox / assembly, etc.) or similar mechanism shown in Figure 1, which is then 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, and the main drive shaft 18 itself is driven by a motor such as a servo motor. Alternatively, the push rods 14 of the needle bar drive mechanism 13 may be directly connected to the main drive shaft 18 via connector rods 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 also be provided to monitor the rotation of the main drive shaft and report its position to a control system 25 (Figure 1) that controls the operation of the tufting machine 10. The control system 25 may generally include tufting machine control, including a computer / processor or system controller 26 with an operator interface 26A such as a touchscreen, keyboard, or mouse, which allows the operator to input patterns, make adjustments, etc. In some embodiments, the control system 25 may include, or be incorporated herein by reference as if its disclosure were fully described, a stitch distribution control system such as that disclosed in U.S. Patent No. 8,359,989, 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 distribution control patterns such as those disclosed in U.S. Patent No. 8,359,989.

[0053] The control system 25 will generally include programming that enables monitoring and control of the operating elements of the tufting machine 10, such as the needle bar drive mechanism 13, the thread feeding attachment 27, the backing material feeding roll 28, the main drive shaft 18, the needle bar shift mechanism 40 (Figure 3), and the gauge component assembly 30 mounted under the tufting strip T of the tufting machine, in accordance with the calculated / determined pattern instructions, as will be discussed in more detail below. The control system 25 (Figure 1) can further receive, execute, or store pattern information in the 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 on the backing material B as the backing material is fed through the tufting strip T in the direction of arrow 33 by the backing material feeding roll 28, as shown in Figure 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 tuft articles, the steps of which can be created or calculated manually or through the use of a design center or design software as 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 via a network connection. Alternatively, the controller 26 may include image recognition software, which enables scanned and / or designed pattern images (such as designed patterns including pile height and other features such as the arrangement of loop pile and cut pile tufts in the pattern indicated by different colors or similar markers or indicators), and 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 (Figure 1)). The control system can recognize and identify various pattern features (including color and / or differences) in the texture of a designed pattern image that exhibits texture effects such as the arrangement or location of loops and / or cut pile tufts, and can assign selected yarns to them.

[0055] In addition, in embodiments, the control system 25 may operate with, be equipped with, or include a stitch distribution control system, as disclosed in U.S. Patent No. 8,359,989 (which is incorporated herein by reference as fully described). For example, but not limited to, 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 color reading and recognition of an input scanned pattern, and the control system may assign supply positions for threads being supplied from a supply creel to various needles based on a thread-up sequence of needles of a needle bar to optimize their supply for best use of various colored threads in a creel to form a recognized pattern region from the pattern image. The control system may further include programming to enable it to create a pattern region or pattern mapping, which includes a mapping of a series of pattern pixels or tuft / stitch placement locations that identify spaces or locations where various colored threads and / or cut / loop pile tufts will be selectively placed to form a pictured pattern. The desired pattern density (i.e., the desired number of stitches per inch that should appear on the front 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 to calculate proposed 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 in the tufting machine or via a network connection, and the control system may read, recognize, and calculate pattern steps / parameters (including control of thread feeding, control of backing material movement and / or needle reciprocation to form tufts on the backing material at an effective stitch rate to achieve a desired pattern density, cam / shift profiles, and thread placement to match scanned and / or designed pattern images), and then control the operation of the tufting machine to form this selected pattern. The operator can also select or modify the stitch rate, thread feed, selected cam profile, or calculated shift profile, etc., by indicating whether the pattern should have 2, 3, 4, 5, 6, or more colors, or by indicating the desired number of pattern repetitions, and / or, the operator can manually calculate, input, and / or adjust or modify 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 Figure 1-3, the tufting machine 10 may further include one or more needle bars 35 attached to and driven by a 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 material. In some embodiments, the needles may be arranged in a single straight row along one or two needle bars. In other embodiments, the needles 36 may be mounted in an alternating arrangement along a single needle bar or along a pair of needle bars, with the offset rows of needles spaced laterally along the length of each needle bar and alternating across the tufting strip of the tufting machine. The needle bars 35 may be further shiftable laterally across the width of the backing material to shift the needles 36 in a direction traversing (or substantially perpendicular to) the longitudinal path through the tufting machine, or to move them in steps. Therefore, an exemplary embodiment including a single needle bar 35 (with a straight row of needles 36 arranged along it) may be shown in the figures, but the disclosure is not limited to the use of a single needle bar or a particular configuration of needles. Instead, additional arrangements of double needle bars and single needle bars (both of which can be further shifted) having spaced rows of needles 36 which can be arranged in a straight line, or in alternating or offset configurations may also be utilized in the tufting machine 10 incorporating the system according to the disclosure.

[0058] Each needle generally includes a shank or body 38, which terminates at a pointed end 38A and includes a take-off point or area 39 where a gauge component 32 can engage with the thread Y from the needle and pick it up, as shown in Figures 10A-11A. When the needle is reciprocated in 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 a stroke to a desired or predetermined penetration depth, carrying the thread Y with it, which will be selectively engaged by the gauge component 32 of the gauge component assembly 30 for picking up the loop L of thread L from the needle, as shown in Figures 11A-11C. In addition, a shift mechanism 40 may also be connected to the needle bar 35 (or multiple needle bars) if used to shift the needle bar laterally across the tufting strip in the direction of arrows 41 and 41' according to a calculated or calculated pattern instruction, as shown in Figure 3. The shift mechanism 40 is a Smart Step, such as those manufactured by Card-Monroe Corp. TM The system may include a type of shifter, or alternatively, various other types of shifting mechanisms, including conventionally used servo-motor or hydraulically controlled shifters and / or pattern cam shifters. Additional shifting mechanisms, including a backing material or jute shifter that can operate separately or in conjunction with the needle bar shifter, may also be used to shift the backing material laterally relative to the needle.

[0059] As further illustrated in Figure 1, one or more thread feeding mechanisms or attachments 27 may be mounted on the frame 11 of the tufting machine 10 to control the feeding of thread Y to each of the needles 36 during the operation of the tufting machine. For example, as shown in Figure 3, a series of different types or colors of thread (Y1-Y4) may be fed to each of the needles in a selected thread-up sequence or order (e.g., A, B, C, D), the thread-up sequence being determined or selected generally based on the pattern being executed. In addition, although one thread feeding unit 27 is shown along one side of the tufting machine 10 (for illustrative purposes), in other embodiments, multiple thread feeding units may be mounted on one or both sides of the tufting machine to feed thread to the needles 36 of one or more needle bars 35.

[0060] There are various thread feeding attachments that can be used with the stitch distribution control system of the present disclosure to control the feeding of different threads Y to various of the needles 36. The pattern thread feeding attachment or mechanism 27 (Figure 1) may comprise a conventional thread feeding / driving mechanism such as a scroll pattern attachment having a roll or a series of rolls that extends at least partially along the tufting machine and is motor-driven under the direction of a control system 25, the control system 25 controlling the feeding of thread across the tufting machine to form pattern repetitions and / or multiple pile heights and / or other texture effects across the width of the backing material. Such thread feeding mechanisms or attachments include Quick Thread, such as those manufactured by Card-Monroe Corp. TM Enhanced Graphics TM , and / or may include multi-pile height scroll yarn feeding control / attachment.

[0061] In some embodiments, such as Infinity manufactured by Card-Monroe Corp. TM and Infinity IIE TMOther types of pattern yarn feeding attachments can be used to control the feeding of a particular set of yarn iterations to a selected needle, including the use of individual yarn feeding rolls or drives 45 to control the feeding of a single yarn (or end) or multiple ends of yarn (i.e., 2 to 4 or more yarns) to a needle 36, such as single and multi-end / servo scroll attachments including a system, each having multiple yarn feeding drives 45, such as those shown in Figure 1, each having a motor 46 and a feeding roll 47. Thus, although Figure 1 shows yarn feeding such as a single or multiple-end type yarn feeding mechanism 27, it will be understood by those skilled in the art that the pattern yarn feeding mechanism used to control yarn feeding may include single or double-end yarn feeding controls, scrolls, rolls, and / or similar attachments, and / or various combinations thereof, and may be mounted along one or both sides of a tufting machine. Furthermore, in the embodiment, the control system 25 can perform yarn feeding compensation and / or yarn feeding modeling to help control, reduce, or minimize the amount of yarn that is not retained / not present being fed, to avoid overfeeding of yarn, and thus minimize waste during the tufting operation.

[0062] The yarn feeding attachment allows for the presentation of several different colors or types of yarn into the backing material, and the control of selectively picking up and holding loops of selected or desired yarns from among 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 yarn to their respective needles in coordination with other operating systems of the tufting machine (including the operation of backing material feeding, needle bar shifting, and gauge component assembly 30) to form a tuft of such yarn with a selected or desired pile height. In addition, surface or surface yarns or tufts that are to be visible on the surface of a tufted article can be controlled to be fed in sufficient quantities to form such tufts of selected color or type yarns at a desired or specified pile height, while non-visible yarns that are to be hidden in certain color and / or texture areas of the pattern will be backlobbed to a sufficient degree and / or pulled substantially low or out of the backing material to avoid such yarns interfering with the surface yarns or retained tufts that are visible in the pattern area, and to avoid creating undesirable spaces or gaps between the retained yarns or surface yarns.

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

[0064] As further shown in Figure 1-3, the gauge component assembly 30 is generally mounted below the base 34 and tufting strip 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 (Figure 2-3) of yarn Y for forming a tuft 5 of selected color or type yarn with a selected length or pile height. The gauge components 32 of the gauge component assembly 30 may, in various embodiments, include a series of loopers or hooks 50, each of which may be slidably mounted within a gauge module, gauge block, or other holder, the gauge module, gauge block, or other holder may be mounted along a gauge rod 52 or similar mount or attachment for coupling with a drive mechanism 53, the drive mechanism 53 driving the reciprocating motion of the gauge in a first direction such as toward and away from the needles 36, as indicated by arrows 54 and 54' as shown in Figure 1-3. It will be further understood by those skilled in the art that various other types of gauge components, including cut pile hooks, loop pile loopers, level-out loop loopers, cut / loop clips, or other gauge components, may also be used.

[0065] As shown in Figure 4-5, in one embodiment, the gauge component 32 may include a looper or a hook 50, each of which has an elongated body 55, the elongated body 55 may be slidably mounted within and movable through its gauge module 51. Each looper or hook 50 body 55 includes a first portion 60 and a second portion 61 including an elongated throat 62, which in one embodiment may extend at a certain angle to the middle portion 56 of the body 55, as shown in Figure 4-5, and may terminate at 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 the gauge component may also be used. As further shown in Figure 4-5, each looper or hook 50 body first portion 60 may generally have a slot or recess 64 that protrudes through and is formed therein through a gauge module or block 51, so that the looper or hook can be engaged and / or coupled to an actuator 66 by a gate or connector 67 (Figure 2), etc.

[0066] Figure 4-5 illustrates 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, but other configurations may also be used, in 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, but various composite materials, synthetic materials, and / or other materials may also be used. For example, but not limited to, the body of a gauge module may be made from lightweight steel, e.g., mild steel or tool steel, or aluminum, or other similar lightweight but substantially hard and durable materials. In embodiments, the module body may be cast, molded, or otherwise formed. The material from which the body of the gauge module is formed can then be further selected to provide weight reduction to the gauge module, but still provide sufficient durability and rigidity to hold and / or substantially maintain the gauge component in its aligned state, or in the position for engaging with the needle's take-off portion during the reciprocating motion of the gauge component engaging and disengaging during the operation of the tufting machine.

[0067] Generally, as illustrated in Figures 4-6B, the module body 75 of each gauge module 51 will include a first front section 76 and a second rear section 77. The rear section 77 of the body 75 of each gauge module 51 will generally be further configured to engage with and mount on a gauge rod, as illustrated in Figure 3. For example, the rear section of the body may include a tab or other positioning device 77A (Figure 5) for aligning the gauge module along the gauge rod, and along it further include at least one fastening opening, as shown in 78 in Figures 6A-6B. A removable fastener, such as a socket, hex screw, or other similar removable fastener or mounting device, will be inserted through the fastening opening 78 into a corresponding opening 79 (Figure 6B) in the gauge rod to releasably mount the gauge module 51 on the gauge rod. As a result, in some embodiments, the gauge module containing the gauge components can be removed and replaced as a unit, for example, to facilitate the replacement of a broken or damaged gauge component, or to change the gauge spacing or arrangement of the gauge components of a tufting machine, without necessarily having to replace the individual gauge components.

[0068] As further shown in Figure 4-6B, the passage 80 is generally formed through the body 75 of each gauge module 51, and the passage 80 is generally positioned along the intermediate portion 81 of the body between the first and second sections 76 / 77 of the body. The passage 80 will be sized and / or configured to receive a plurality of gauge components, such as loopers or hooks 50, in it. In an embodiment as illustrated in Figure 4-5, each body 55 of the looper or hook 50 is generally received into and extends through the passage 80, and each first portion 60 of the looper or hook generally projects downward over the lower or bottom surface 82 of the module body 75, while each second portion 61 of the looper or hook may extend / project upward from the upper or upper surface 83 of the module body 75.

[0069] In addition, one or more inserts 85 may be mounted on both side surfaces of each module body, e.g., the upper and lower surfaces, at positions or locations aligned along a passage 80 defined through the entire body of each gauge module, as generally shown in Figures 4-5. The inserts will be configured to engage with and guide the gauge component as the gauge component is moved through and along the passage of the gauge module body. For example, in some embodiments as illustrated in Figure 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 the first left or front side 80 of the passage 80, while the insert (e.g., a second insert 85B) is mounted along the second right or rear side 80B of the passage 80, and each of the inserts 85A and 85B is generally positioned substantially facing, opposite, and parallel to the movable gauge component 32 that engages between them. In some embodiments, as shown in Figure 4-5, a pair of first inserts can be mounted along the upper and bottom surfaces of the module body along the first or left side of the passage, and a pair of second inserts 85B can be mounted along the upper and bottom surfaces of the module body along the second or right side of the passage.

[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 containing tungsten, titanium, or other materials having a hardness greater than that of the gauge module body material. For example, in some embodiments, the inserts may be formed from metal carbide materials having a hardness of about 74+RC or greater, while the module body may be formed from mild steel. In other embodiments, the inserts may be formed from powdered metal materials, metal carbides, or other materials having a hardness of about 74+RC to about 85+RC or greater, including ceramics, tungsten, titanium, or similar hardened metal components.

[0071] Each insert 85 may further include an insert body 86 having a tab or flange portion 87, the tab or flange portion 87 extending either forward or rearward from the passage of the gauge module body, as shown in Figure 5, and generally located on and engaging with the upper and lower surfaces 83 / 82 of the module body. In addition, as shown in Figures 4 and 6A-6B, each insert 85 also includes at least one opening or slot 89 formed along its tab or flange portion, through which fasteners such as set screws 90 or other similar removable fasteners can be received. The slots or openings 89 formed within the tab or flange portion of the insert can generally be aligned with corresponding slots or positioning openings 91 formed along the upper and / or lower surfaces 83 / 82 of the module body, which helps to position and mount each insert on the body of its module and along the passage of its gauge module. As also shown in Figure 6B, the insert can be shifted laterally across the module body, substantially parallel to the passage 80, and the insert can be further adjustable across the passage of the gauge module body toward and away from each other, and then fasteners can be inserted therein and tightened securely to fix the insert 85 to its module body. Additional positioning guide pins 92 can be further received in slots on positioning openings 93 formed along each flange or tab portion 87 of the insert, and may further assist in positioning the insert along and across the passage of the module body as needed.

[0072] In additional embodiments, the inserts 85 can be substantially integrated with those modules. The inserts can be bonded, molded, encapsulated, and / or otherwise attached to the bodies of those modules, and the inserts can be substantially integrated with the module bodies to form a substantially integrated structure of the module bodies, and the inserts can form or define a portion of the passages of the module bodies. For example, in one embodiment, the inserts can be positioned or received within the passages of the module bodies and substantially permanently mounted therein, while in other embodiments, the inserts can be molded or cast as part of the module bodies themselves, defining passages and slots for loopers or hooks, and can be coated or treated with a hard metal coating such as carbide or other substantially wear-resistant coatings. In such cases, the gauge components can be supplied in tandem with those gauge modules and can be replaced as a tandem 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 those modules with limited ability to remove (or detach) one or more of the inserts as needed for maintenance.

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

[0074] In addition, for example, as shown in Figure 6A, the end 96 of the slot 95 may be further formed with a substantially flattened (or slightly curved or arc-shaped) configuration to define a seat 97, against which the respective first and second edges of the looper or hook to be received in each slot may be positioned and supported against it for mounting the looper or hook into the insert, and then fixing the insert to each gauge module together with the looper or hook received therein. The slots in the insert will help guide the looper or hook as the looper or hook is extended, retracted or otherwise moved through the passages of those gauge modules, and will help maintain the alignment of the looper or hook (and thus its throat and bill) with respect to the needle so that the needle is reciprocated in and out of the backing material and engaged by the looper or hook.

[0075] In another embodiment, each insert 85 may have a first upper or upper portion and a second lower or bottom portion, and may include an insert body 86 with an intermediate section extending between the first and second portions of the body of each insert and connecting thereto. 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, the tab or flange extending forward or backward from the intermediate section and passage of the gauge module body, generally covering and engaging with the upper and lower surfaces 83 / 82 of the module body, and helping to position and secure each insert within the passage of the gauge module. The first and second inserts 85A / 85B may thus have a substantially integrated structure including the upper and lower portions, with their slots extending through their upper and lower sections and along the intermediate body section, allowing for further engagement and guidance of at least some of the first and second edges of a looper or hook. In embodiments, the inserts of such structures can be molded or cast to have a substantially integrated 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 opposite sides of its passage, while increasing the contact points / area between the insert and the looper or hook 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 module body. For example, in yet further embodiments, an intermediate guide or bearing plate can also be used to help guide the movement of the looper or hook, the guide or bearing plate extending along the passage between the inserts positioned along the upper and lower surfaces of the module body. Such a guide or bearing plate can provide a body or surface, and the first and second or front and rear edges of the looper or hook can straddle / slide along it when they are moved along the passage of the module body. The guide or bearing plate can also function as a connecting member or section between the inserts or between 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) and may provide a hardened surface to which one or both edges of the looper or hook can slide; or, in some cases, may be easily replaceable and may function as a sacrificial plate that can protect the module body along the side of the passage.

[0077] During operation of a tufting machine as disclosed in embodiments of this disclosure, loopers, hooks, or other gauge components are moved in multiple directions, reciprocating to engage with and disengage from a needle, while also being moved in a second direction through their gauge module or gauge block (e.g., being moved vertically between an elevated and lowered position for engaging with a needle (including being moved to a sewing position), and in some operations, being moved after a loop of yarn has been picked up from a needle to form an extended or longer loop). This tufting machine thus enables the formation of highly detailed tuft patterns, which may include varying pile heights and other carved and multi-color pattern effects. However, such repeated periodic movement of the gauge component causes fairly rapid wear of the gauge component, particularly its gauge module, as the looper, hook, or other gauge component slides and its edges frictionally engage with the body of its module. As these components wear down, their ability to engage with the needle with virtually high precision, form thread loops, and create tuft patterns may be reduced. For example, gauge components may become misaligned and / or fail to engage with the needle properly or with the desired level of precision, which may require more frequent replacement of gauge components / gauge modules.

[0078] The use of metals containing powdered metals (such as high-hardness heat-treated steel), metal carbides, ceramics, and / or other hardened metal materials that provide the insert with a hardness of at least 75+RC or greater, and the configuration of the insert that defines the 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 when the looper or hook is circulated through it, while the reduced size of the contact area 98 defined by the insert is configured to guide and maintain the alignment of the looper or hook substantially consistently during such movement, while reducing frictional engagement between the insert and the looper or hook. Loopers or hooks are also generally pre-hardened or heat-treated to stiffen the looper or hook body, and in some embodiments, the surface of the looper or hook body is coated, treated or bonded with a low-friction material, which helps reduce friction between their edges 55A / 55B that engage and slide along the slot of the insert, and thus can help increase their wear life. For example, in some applications, the wear life of loopers or hooks has been found to well exceed 50 million to 100 million machine cycles, and in some embodiments, at least about 100 million to 500 million cycles or more.

[0079] The increased hardness of the insert protects the gauge module and allows the gauge module to be formed from a substantially lighter and lower-hardness material such as mild steel, aluminum, or an alloy thereof. For example, instead of requiring the gauge module to be formed from a substantially high-hardness material such as tungsten and / or 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 (for example, the body of the gauge module can be formed from mild steel or an aluminum alloy with a hardness of less than about 60 RC), which helps to reduce the weight and cost of the overall gauge component assembly without reducing operational cycle performance. Such a reduction in the weight of the gauge module or block can further provide improved control of the movement of the looper through the passage of that gauge module, and the reciprocating motion of the looper or hook toward and away from the needle, by reducing the inertia that may need to be overcome during the reciprocating motion of the looper or hook toward and away from the needle.

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

[0081] Generally, as illustrated in Figures 7A-9B, each of the connectors or gates 67 will generally include a housing or support structure 101 that substantially includes, encloses, or houses a coupling portion or connector arm 102. 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 passage or channel 107 defined through it, through which the coupling portion or connector arm 102 can be received and moved. The housing 101 of each connector 67 may generally be formed from a lightweight and durable material such as composite material, plastic, or synthetic material, or a combination thereof. For example, composite or polymer materials such as nylon, polyamide, polyamide nylon, or other similar polymer materials may be used, mixed with or comprised of, or otherwise included with, carbon fiber, glass fiber, or other supporting fibers that can provide reinforcement to the housing body material. The material of the housing body may be further adapted or selected to provide elastic and shock-reducing or damping or cushioning effects during starting / stopping and moving, for example, during the extension and / or retraction of gauge components by their associated actuators, as well as to help reduce inertia.

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

[0083] In some embodiments, the coupling or connector arm 102 may further include a skeletonized metal body configured to allow for a reduction in its weight. In such embodiments, each connector or gate housing 101 can provide additional support and rigidity to the coupling or connector arm 102, helping to guide and maintain its consistent reciprocating movement or motion during operation. As a result, the connector or gate 67 can be applied over the coupling or connector arm and / or used together with the additional support and impact resilience and damping effects provided by the housing 101 that surrounds or encapsulates it, providing a more economical connector or gate design, and allowing the coupling 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 intermediate section of each connector housing can have shorter or longer spans depending on the gauge, distance, progression length, or length of the coupling or connector arm, and thus can be varied for different tufting machines and / or tufting applications. For example, as shown in Figures 7B, 8B, and 9B, the connectors or gates can have varying configurations for use with different gauge tufting machines, such as 1 / 8 gauge or 1 / 10 gauge machines, but 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 intermediate section of the housing through each connector can be further oriented at an angle, in some cases oriented at an angle extending downwards, while in other cases oriented at an angle extending upwards, so that adjacent connectors in opposite angle orientations or configurations minimize the space or area they occupy.

[0085] Each connector or gate 67 coupling portion or connector arm 102 (Figures 7A, 8A, 9A) can be further formed to a variable length as needed or desired. Each coupling portion generally has a first or proximal end 110 which can be fitted or configured to engage or connect to one or more actuator shafts or drive rods 68 of an associated actuator or a plurality of actuators, and a substantially angled body section or portion 111 extends through the housing of the connector along a passage or channel of the housing and terminates with a distal flanged or hooked end 112. The body portion 111 of each coupling portion will be further positioned and / or aligned within the passage of its housing, enclosed within the passage, which will help provide stability and / or help guide the movement of the coupling portion along the channel of its connector housing.

[0086] For example, in some cases, pins or other inserts are used during the formation of a housing around (or covering) the couplings to align and support the couplings in place, and the pins can then be removed. Alternatively, several guide pins can be provided along one or more portions of the coupling or connector arm that include or act as bearings to help maintain and guide movement. Furthermore, 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 the movement of the couplings, further helping to provide additional impact resilience.

[0087] In additional embodiments, a guide pin or fastener 114A can be inserted through the housing into the body of the coupling and can engage with a slot or guide path or similar means to help guide and control or maintain the movement of the coupling along the passage or channel 107 (Figures 7B, 8B, and 9B) of the connector housing without twisting, rotating, or otherwise becoming misaligned. In yet another embodiment, the guide pin 114A can function as a pivot point, and the coupling or connector arm can be moved or pivoted around the pivot point rather than being moved in substantially linear motion.

[0088] As further shown in Figures 7A, 8A, and 8B, each distal hooked end 112 of the coupling or connector arm 102 may 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 the sliding movement of the coupling. The hooked end of the coupling or connector arm engages with a corresponding hooked portion, recess, or slot of the corresponding gauge component, for example, in an embodiment it would engage with a slot or recess 64 (Figure 5) formed in the first portion 60 or distal end of the corresponding (or associated) one of the looper or hook 50. In other embodiments, the hooked end of the coupling may engage with 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 gauge component via the coupling or connector arm of its corresponding connector or gate. The connector or gate can therefore provide an economical, rigid, and high-strength connection between each actuator and its associated gauge component, and the gauge component can be removed or changed as needed without the need to replace the actuator associated with it.

[0089] In one embodiment, as generally illustrated in Figures 2 and 11A-11C, the actuator may comprise a hydraulic, pneumatic, electric, or pneumatic cylinder 68, each of which includes a cylindrical rod or shaft 69, which will generally be connected by a connector or gate 67 to the associated (or corresponding) looper or hook. In some embodiments, the actuator may further be used to control the movement of two or more loopers or hooks 50. In addition, other types of actuators, including solenoids, motors, or other similar operating mechanisms as will be understood by those skilled in the art, may also be used.

[0090] Each actuator will generally be connected to a control system 25, which will selectively control its operation to control the firing and / or movement of each looper relative to the needle. The actuators will be controlled to selectively extend and retract their loopers or hooks, thereby causing their throat / bille positions to vary in a second direction relative to the reciprocating motion of the needle in and out of the substrate material and the movement of the looper or hook in the direction of arrows 54 / 54'. For example, in an embodiment, when the looper or hook is reciprocated in the direction of arrows 54 and 54' so that the looper or hook is toward and away from the needle 36, it will be moved in a substantially perpendicular (i.e., roughly up and down) movement relative to the needle, as illustrated by arrows 71 and 71' in Figures 2, 4A, and 5A-5C. The actuator can be controlled to extend and retract the looper or hook between extended and / or non-sewn positions, and can be further selectively controlled to extend and / or retract the looper or hook to a series of varying positions or heights with respect to the needle stroke or penetration depth. Thus, the position or location of the throat of the looper or hook relative to the needle can be controlled and varied, as shown in Figures 11A-11C, to cause or prevent the pickup and / or formation of a yarn loop from a selected needle at a varying pile height or length.

[0091] For example, in the fully extended position, selected loopers or hooks 50 can pick up loops of thread from the needles they engage with, and these loops can generally be formed with a first selection or desired pile height, while other loopers or hooks can be extended or retracted to a position or location between the fully extended position and the retracted position to pick up and form loops of thread 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 position them in a non-sewing position, thereby so that the throats / billes of such loopers or hooks are below the full penetration depth or end of the stroke of the needle and therefore will not pick up loops of thread from their corresponding (or respective) needles. In other operations, actuators can be selectively controlled or triggered to retract or lower each of those loopers or hooks after a loop of yarn has been captured by a looper or hook, to pull down such captured loops of yarn, to stretch them, or to create higher pile or increased yarn length for additional patterning effects such as tip shearing and / or other texture effects.

[0092] As shown in Figures 10A-10B, each of the gauge components 32, such as loopers or hooks 50, can generally be arranged in sets or groups, each contained within a module 51, which provides a plurality of gauge components mounted in series along a gauge bar and arranged at specified intervals (e.g., gauge intervals of 1 / 10, 1 / 8, 5 / 16, etc.) across a tufting strip. The gauge components 32 will be positioned to engage with the needle (including being arranged in substantially linear, offset, alternating, and / or other configurations as needed, depending on the configuration of the needles in a needle bar or multiple needle bars; for example, when the needles are arranged in linear, alternating, and / or other configurations along a single or double needle bar). Each of the loopers or hooks 50 can be further positioned at an angle or offset to the needle penetrating the backing material so as to move along a travel path 71 / 71' that forms an angle with respect to the needle and / or its take-off point, or to be extendable / retractable. Such offset movement of the looper or hook can also be varied as needed, depending on the spacing and / or arrangement of the needles, to minimize the potential engagement of the looper or hook with the needles as the looper is retracted.

[0093] For example, in some embodiments, the looper or hook may be positioned and / or moved along the path of travel at an angle / offset shown by θ in Figure 10B, which can be about 1° to about 10° or more from the vertical and / or with respect to the stroke of the needle, when the looper or hook is retracted, and at an angle of about 4° to 6° with respect 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 material, while in other embodiments, there may be substantially no offset, i.e., an angle of about 0° with respect to the needle, between the looper or hook and the needle. Thus, when the looper or hook is extended to a position / height sufficient to engage with the needle's take-off area 39 (Figures 10A-11A), its throat / bill will generally be properly aligned (or positioned) to engage with and pick up the loop of thread from its corresponding needle. When loopers or hooks are retracted, they can generally be moved further along the offset path of travel, thereby positioning, or may position, their throats / bills outside the needle's path of travel to minimize potential accidental thread pickup when the looper or hook is moved to and / or in the retracted non-sewing position.

[0094] During operation, according to some embodiments, a tufted article can be formed according to the systems and methods of the present disclosure, which may include the use of multiple different colors and / or types of yarn to form various patterns and pattern effects, and which may include engraved or multi-pile height effects. For example, the systems and methods of the present disclosure may be operated in conjunction with stitch distribution control systems or yarn color arrangement systems, such as those disclosed and illustrated in U.S. Patents 8,141,505, 8,359,989, and 8,776,703, which are incorporated herein by reference as if the disclosure were fully described.

[0095] In such embodiments, the thread stitches or tufts formed in the backing material may be further formed at an increased or higher actual operation or effective process stitch rate compared to the desired or specified fabric or pattern stitch rate for the formed tuft pattern. If the pattern or fabric stitch rate or density of the formed pattern requires the tufted article to have the appearance of stitches such as 8, 10, or 12 stitches per inch formed therein and / or to be shown on its surface, the actual operation or effective stitch count per inch formed during the operation of the tufting machine will be substantially greater than the desired or specified pattern or fabric stitch rate. Therefore, the actual formation of thread stitches or tufts in the backing material is achieved with an increased actual operation or effective process stitch rate, thereby effectively resulting in a greater number of stitches per inch being formed in the backing material than would be required to be shown in the finished pattern. Those stitches or front threads that are not desired to be shown or left on the front side of the pattern area or area being sewn are back-lobbed, pulled out from the backing material, or pulled down sufficiently to the extent that such threads are retained in the backing or sewn in, while substantially avoiding the creation of undesirable or unnecessary gaps or spaces between the retained threads or front threads of the pattern (i.e., thread tufts that should remain visible or appear in the finished pattern of the tufted article).

[0096] For illustrative purposes, in one exemplary embodiment, the effective process stitch rate can be based on or determined by increasing the weave or pattern stitch rate of the pattern to be tufted in the pattern, which is largely formed by several selected colors. With respect to 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 working process stitch rate (i.e., the rate at which stitches are actually formed in the backing material) can be from about 18–20 stitches per inch to up to about 40 stitches per inch or more. However, it will be understood by those skilled in the art that additional variations or adjustments of such working or effective process stitch rates can be made for a particular pattern depending on the type and / or size and / or other factors of the yarn. For example, if thicker, larger size, or heavier yarn is used, the effective process stitch rate may undergo additional variations as needed to account for the use of such larger yarns (for example, with respect to a 4-color pattern, the effective process stitch rate may vary further, such as being performed at about 25–38 stitches per inch, but further variations may be used as needed). Therefore, if the selected or programmed pattern being executed is designed or desired to have 10 to 12 stitches per inch as the desired pattern density or stitch rate, the system may actually operate to form approximately 20 to 48 stitches per inch or more, depending on the number of thread colors and / or types, but visually from the front side of the finished tufted article, generally only the desired / selected 10 to 12 stitches will be visible.

[0097] In addition, when a series of different colors are tufted, the needles 36 of the needle bar 35 are generally provided with the desired thread-up sequence, for example, with respect to a four-color pattern, A, B, C, and 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., the A / C threads are on the front needle bar and the rear needle bar is threaded using the B / D color thread-up. In addition, the needles of such front and rear needle bars can be arranged in alternating or offset alignment. One or more needle bars will generally be further shifted by the control of the needle bar shifter 40 (Figure 2) according to a shift profile for the pattern being formed, in conjunction with the control of the backing material and the thread feeding, so as the backing material is fed through the tufting band, the needle bar will be shifted laterally relative to the backing material, thereby effectively presenting to the looper or hook one or each of the thread colors (i.e., 2, 3, 4, 5 colors, etc.) that can be sewn at the selected pattern pixels or tuft / stitch locations to the looper or hook.

[0098] For example, with respect to a four-color pattern, each of the 1 to 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 gradually moved approximately 1 / 8 to 1 / 40 inch per shift movement or cam movement cycle, i.e., one, two, three, or four colored threads can be presented at the selected pixel or stitch location, or no threads can be presented. The looper or hook engages to form a loop of thread, and one or more desired threads are held to form the selected tuft, while the remaining threads can generally be pulled down or backlobbed (pulled out from the backing material to float along the backing material, including pulling these unheld threads) by the control of the thread feeding mechanism. Therefore, each looper or hook is given the ability to tuft any one of the pattern colors, or potentially two or more colors (i.e., two, three, four, five, six, etc.) for each pattern pixel or tuft / stitch location associated with it, during each shift sequence of the backing material and the corresponding incremental movement, or perhaps none of the colors are presented to it. If, as described, none of the different types or colors of thread should be tufted or placed at a particular tuft or stitch location or pixel, the thread feed can be controlled to limit or otherwise control the needle thread that may be presented at such stitch location or pixel in order to substantially pull back all of the thread or otherwise prevent such thread from being placed or appearing at that stitch location, and / or, the needle bar can also be controlled to skip, or otherwise avoid or omit, the presentation of needle / thread to that stitch location or pixel.

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

[0100] Each different thread / color that can be tufted at a specific stitch location or pixel can therefore be presented at such stitch locations or pixels as the pattern is formed on 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, depending on the calculation or selected cam profile or shift profile of the pattern to be executed / formed, and based on, for example, the number of colors being executed in the pattern and the area of ​​the pattern region formed by each specific color, as needed / desired. Such combinations of single and double shift jumps or steps can be used to avoid overlapping or engaging with already sewn tufts as the needle bar is shifted laterally and the backing material is advanced at its effective or working stitch rate. The backing material can also be shifted by the backing material or jute shifter, etc., in conjunction with or separately from the needle bar shifting mechanism.

[0101] As the needle penetrates the backing material B, as shown in Figures 1 and 2, the loopers or hooks 50 of the gauge component assembly 30 will be reciprocated toward the needle in the direction of arrow 54 to engage with the loops of thread from their associated or corresponding needles and to pick them up or pull them. In addition, actuators 66 for the loopers or hooks can be selectively controlled and engaged to extend or retract a selected looper or hook, thereby positioning the bill 63 of the looper or hook and its throat portion 62 in a desired position relative to the needle as the needle 36 penetrates and completes its stroke in and out of the backing material. As shown in Figures 10A-11C, the location or positioning of the bill and / or throat portion of the looper or hook can be varied between a fully extended position or height and a lowered or retracted “non-sewn” position, in which the thread loops can generally be substantially prevented from being picked up and / or formed by such looper or hook, providing selective pickup of thread loops (including no thread loops being picked up) and control over the length of the thread loops selectively picked up from the threads presented at each stitch location or pixel in accordance with the instructions for the pattern being formed. As a result, the location where selected or desired front-side thread loops are picked up from the needle by the looper or hook, as shown in the “finished” pattern, can be controlled, and the formation of tufts resulting from such picked-up thread loops remaining in the backing material can be further controlled to be formed at various different pile heights.

[0102] The type / color of threads in each series of threads presented at each pixel or stitch location that should be held or shown on the front side of the backing material at a particular stitch location will generally be determined by pattern instructions or programming for forming the tuft pattern. Controlling the activation and / or positioning of the looper or hook 50 corresponding to (or associated with) the needle that carries such threads can allow the tufting machine to selectively pick up and hold the loops of such threads at each stitch location where such threads remain according to the pattern, so as to form a tuft resulting from such threads at a selected pile height. For example, if a presented thread is not shown or appears, the corresponding looper or hook can be retracted to a non-sewing position so that the loops of threads are not picked up, and the thread feeding therefor can be controlled so that the threads are not held at the pixel or stitch location. With respect to the retained yarns / colors, i.e., the yarns that appear on the front side of the patterned tufted article, the position or height of the loopers or hooks and the yarn feeding mechanism that feeds these yarns can generally be controlled in a coordinated manner to allow for the pickup and formation of loops of such yarns that are sufficient to form a tuft of the desired type and pile height.

[0103] Further control of backing feed in an increased effective or operational process stitch rate (e.g., the actual rate at which stitches are formed in the backing) according to the principles of this disclosure provides further areas of denser or more compressed stitches or tufts per inch, such that back-lobbed threads are removed or pulled down to a sufficient extent to avoid creating undesirable spaces or gaps between retained front threads (those that appear on the front side of the tufted article according to the pattern), or interfering with or being visible through such retained front threads formed in the backing material. In addition, the control system can perform thread feed compensation and / or thread feed modeling to help control and reduce the amount of unretained or unexposed threads that may "float" on the back of the backing material, and to further help reduce / minimize excessive thread feed and / or waste.

[0104] In addition, the thread feeding mechanism, which controls the feeding of each thread to each needle, can be selectively controlled to backlob or pull the thread carried substantially out of the backing material by the needle or by the reciprocating motion of the needle, and in general, several thread loops can be retracted or pulled back / down to a substantially lower position to avoid such unselected thread ends occupying selected stitch locations or interfering with the arrangement of threads shown in certain color areas formed according to separately selected front threads or patterns.

[0105] For example, in some embodiments, when a selected or particular looper or hook is retracted to a fully retracted or “non-sewn” position, the loop will generally not be picked up from the needle associated with such a fully retracted looper or hook, while the thread feed is controlled accordingly to allow the thread to move in and out of the backing material with its needle. In addition, in certain cases where a loop of thread is formed, such as when a looper or hook is in a fully extended position and forms a low loop, the resulting formed loop of thread can be further backlobbed, substantially pulled down, or pulled out from the backing material by the control of the thread feed, leaving an amount of thread that engages with or “sews” to the backing material, while substantially removing such unselected thread ends so as not to interfere with the outward appearance or the arrangement of selected threads at a particular stitch location within the color area being sewn.

[0106] The placement of non-visible threads sewn or otherwise secured to the backing material can also be controlled to prevent the formation of extended ends that could later snag or cause other defects in the finished tufted article. For example, the control system can be programmed / set to sew such non-visible threads or form low stitches at desired intervals, e.g., every 1 to 1.5 inches, although larger or smaller intervals can also be used. Thread compensation can also be used to ensure that a sufficient amount of thread is fed when it is necessary to prevent the thread from showing through another color or bleeding out, i.e., the thread protruding through one of the stitching threads along with several threads placed together, while generally allowing the non-visible threads to be sewn into the backing material. In addition, if the extended length or end would be formed for multiple non-existent threads, the spacing at which such different threads are sewn into the backing material can be varied (i.e., one inch and the other 1.5 inches, etc.) so as to avoid interference between such sewn threads and / or between the threads of the formed color area.

[0107] Furthermore, the actuators 66 can also be controlled in conjunction with the control of the yarn feeding mechanism to engage with each of the loopers or hooks, along with the yarn loops captured in the loopers or hooks, and cause the formation of extended or stretched yarn loops, etc., by retracting or lowering them. The captured yarn loops can therefore be further pulled and / or stretched, while the corresponding yarn feeding can also be controlled for the feeding of additional amounts of such yarn. As a result, longer or greater yarn loops can be formed in the backing material to create higher pile tufts, etc., for tip shear and / or other patterning features, and / or to produce other desired patterning effects. The selective control of the actuators 66 for selectively retracting and extending those loopers or hooks 50 can be further used to provide additional variations or transition steps or pile heights in the pattern, which are 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 formed yarn tufts.

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

[0109] Accordingly, the systems and methods for tufting multi-pile height patterned articles, such as engraved articles, according to the present disclosure can enable operators to develop and execute various tuft patterns having various appearances, textures, etc., in a tufting machine without necessarily having to utilize a design center to plan and create patterns. Alternatively, in addition to and / or as an alternative to manually preparing patterns or using a design center, the present disclosure allows operators to scan images (i.e., photographs, drawings, JPEGs, etc.) or upload designed pattern files in a tufting machine, and a stitch distribution control system can read the images, develop program steps or parameters, and then control the tufting machine with substantially no further operator input or control required to form the desired tufted article.

[0110] The foregoing description illustrates and illustrates various embodiments of the Disclosure. However, it will be understood by those skilled in the art that various changes and modifications may be made to the structures discussed above in the Disclosure without departing from the spirit and scope of the Disclosure as disclosed herein, and that all matters included in or shown in the drawings accompanying the foregoing description are intended to be interpreted as illustrative, not restrictively. Furthermore, the scope of the Disclosure shall be interpreted to encompass various modifications, combinations, additions, alterations, etc., to the embodiments described above that shall be considered within the scope of the Disclosure. Thus, various features and characteristics of the Disclosure as discussed herein may be selectively interchangeable and applied to other illustrated and unillustrated embodiments of the Disclosure, and numerous variations, modifications, and additions may be made thereto without departing from the spirit and scope of the Disclosure as described in the appended claims. (Item A1) A tufting machine, wherein the tufting machine is A needle bar having a plurality of needles, wherein the plurality of needles are mounted along the at least one needle bar, A backing material feeding roll for feeding backing material, A yarn feeding mechanism for feeding yarn to the needle, A gauge component assembly positioned below the backing material, wherein the gauge component assembly is When the needle is being reciprocated within the backing material, at least one module carries a series of gauge components in a reciprocating motion toward and toward engagement with the needle, wherein the at least one module is A module body formed from a metal, polymer, composite material, or synthetic material, or a combination thereof, having a first hardness, wherein the module body is mounted along a gauge rod and adapted to have a passage defined therethrough, Inserts positioned along the module body on both sides of the aforementioned passage Equipped with, Each of the inserts has a slot into which one of the gauge components is slidably received, and each of the slots is configured to slidably receive in thereat least a portion of one of the gauge components. The insert comprises a metal or metal carbide material having a second hardness exceeding the first hardness of the module body. Each of the gauge components includes a body that is at least partially received in the opposing slots of the insert, the body being movable in additional directions relative to the stroke of the needle through the passage of the module body, and the body of each gauge component includes at least one module 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, A series of actuators coupled to the gauge component to control the movement of the gauge component through the module body, A gauge component assembly, Control system including programming and Equipped with, Tufting machine, wherein the programming extends or retracts a selected gauge component by controlling the at least one thread feeding mechanism to control the feeding of the thread to the needle in coordination with the control of the operation of one or more actuators, thereby moving the throat of the selected gauge component between a non-sewing position and an engagement position with respect to the stroke of the needle into the backing material in order to selectively form a thread tuft in the backing material according to a formed pattern. (Item A2) The system further comprises a shift mechanism for shifting the at least one needle bar laterally across the backing material, The control system, when the needle is moving back and forth in and out of the backing material, presents a series of threads to selected stitch locations along the backing material and pulls out any unselected threads. The shift of the at least one needle bar by the shift mechanism, The feeding of the backing material by the backing material feeding roll, Control of the actuator coupled to the gauge component, Control of the at least one thread feeding mechanism that feeds the thread to the needle and It also includes programming to adjust, Such unselected thread loops are not picked up by one of the gauge components. The tufting machine according to item A1, wherein the backing material is moved through a tufting strip at a certain operational stitch rate, the operational stitch rate being greater than the pattern stitch rate for the pattern formed in the backing material, so as to provide a number of tufts held per inch of face yarn that is approximately equivalent to the pattern stitch rate. (Item A3) The tufting machine described in item A1 comprises a level cut loop looper, a loop pile looper, or a cut pile hook. (Item A4) The tufting machine according to item A1, wherein the actuator comprises a hydraulic or pneumatic cylinder. (Item A5) The tufting machine according to item A1, wherein the gauge component assembly further comprises a series of connectors extending between each gauge component and an actuator associated with it, each of the connectors including a coupling portion that is received within a housing and movable through the housing. (Item A6) The housing of each connector comprises a polymer, composite material, or synthetic material, or a combination thereof, and further includes a channel extending through the housing, and each connecting portion is made of metal, A tufting machine as described in item A5, which is equipped with composite materials or a combination thereof. (Item A7) The body of each housing further comprises a composite material including a polymer or plastic together with a fiber-filled material, and having defined channels therein, The tufting machine according to item A5, wherein the connecting portion is movable along the channel, and the connecting portion of each connector comprises a hardened metal body coupled to the body of the housing, the hardened metal body having a proximal end configured to engage with a first portion of one of the gauge components, and a distal end configured to be engaged by an actuator associated with the gauge component to transfer movement by the actuator to the gauge component. (Item A8) Each of the at least one module inserts comprises a first pair of inserts mounted on the upper and lower surfaces of the module body along the first side of the passage of the module body, and a second pair of inserts mounted on the upper and lower surfaces of the module body along the second side of the passage of the module body, The second pair of inserts is spaced apart from and facing the first pair of inserts. The tufting machine according to item A1, wherein the slots of the first pair of inserts are arranged opposite and substantially aligned with the corresponding slots of the second pair of inserts. (Item A9) The tufting machine according to item A8, 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, the slotted opening being adapted to receive fasteners through which each of the first and second pairs of inserts can be adjustably mounted on the module body, and the inserts are positioned at selected intervals from each other and at selected locations relative to the passage defined through the module body. (Item A10) The tufting machine according to item A1, wherein the at least one needle bar comprises a pair of needle bars, each of which has a series of needles mounted in series and spaced apart along it. (Item A11) A gauge component assembly for a tufting machine, wherein the gauge component assembly is A plurality of modules, each module including a module body and having a passage defined through it, A series of gauge components slidably received within each of the modules, each of which has a throat terminating at a bill, and the gauge components are carried together with the modules in a first direction toward and away from engagement with the needle of the tufting machine so as to selectively pick up a loop of thread from the needle, and each of the gauge components is selectively movable in a second direction toward the passage of the modules, First and second inserts mounted on the module body of each module on both sides of the passage defined through the module body, each insert being formed from a metal or metal carbide material having a hardness greater than that of the module body, and having a series of slots formed therein, wherein the slots of the first insert and the slots of the second insert are substantially aligned across the passage and configured to define a contact area along at least a portion of one of the slidably received gauge components, A plurality of actuators, each of which is coupled to an associated gauge component and is adapted to move those associated gauge components in the second direction through the passage of the module, thereby extending or retracting the throat of the gauge component between an extended position for engaging with 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, A connector extending between each actuator and the associated gauge component, each connector having a housing formed of a polymer material, the connecting portion enclosed therein, and A gauge component assembly equipped with the following features. (Item A12) The gauge component assembly according to item A11, wherein each housing further comprises a composite material including a polymer or plastic together with a fiber-filled material, having a defined channel therein, the connector being movable along the channel, and the connector of each connector having a hardened metal body extending through the housing, a proximal end configured to engage with 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 upper 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, which is adapted to receive fasteners through which each of the first and second inserts can be adjustably mounted on the module body, and the inserts are positioned at selected intervals from each other and at selected locations relative to a passage defined through the module body, as described in item A11. (Item A14) The gauge component assembly according to item A11, wherein the insert comprises a metal carbide material having a hardness of at least 75+RC. (Item A15) The gauge component assembly according to item A11, wherein the insert comprises a metal carbide material and the module body comprises an aluminum material. (Item A16) A gauge component assembly for a tufting machine, wherein the gauge component assembly is A module having a module body, wherein the module body has a passage defined through it, A series of gauge components received into the passage of the module body, each gauge component comprising a body having a first portion and a second portion having a throat, the gauge components being carried together with the module in a first direction toward and away from engagement with the associated needle of the tufting machine, the gauge components picking up loops of thread from the needle along the throat of the gauge component, and the gauge components being selectively movable in a second direction along the passage of the module body, An insert disposed along both sides of the passage of the module body, each insert being formed from a material having a hardness exceeding that of the metal or composite material of the module body, and having a series of spaced slots configured to receive at least a portion of one of the gauge components, Multiple actuators and Equipped with, Each actuator is a first part of the associated gauge portion of the series of gauge components. A gauge component assembly coupled to and adapted to move its associated gauge component in the second direction through the passage of the at least one module, thereby extending or retracting through the module body to move the throat of the gauge component between an extended position for engaging with 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 described in item A16 further comprises connectors extending between each actuator and its associated gauge component, each connector having a housing formed of a polymer material, with the connecting portion enclosed therein. (Item A18) The gauge component assembly according to item A16, wherein the module body of at least one module is molded or cast from metal or composite material. (Item A19) 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 within the tab or flange portion, as described in item A18, the gauge component assembly. (Item A20) The gauge component assembly described in item A19, wherein each of the inserts' bodies further comprises upper and lower tabs or flange portions that engage with the 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 according to 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 within the tab or flange portion, and the module body of at least one module comprising a metal or composite material, the metal or composite material being molded or cast to be substantially integrated with the module body to form the module body. (Item B1) A tufting machine, wherein the tufting machine is A needle bar having a plurality of needles, wherein the plurality of needles are mounted along the at least one needle bar, A backing material feeding roll for feeding backing material, A yarn feeding mechanism for feeding yarn to the needle, A gauge component assembly positioned below the backing material, wherein the gauge component assembly is A plurality of gauge components, each of which includes 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, polymer, composite material, or synthetic material or a combination thereof, wherein the module body has at least one passage defined through it and inserts positioned along both sides of the at least one passage, each of the inserts having a slot into which one of the gauge components is received. The insert comprises a metal, metal carbide, ceramic, or powdered metal material, including a metal powder containing tungsten, titanium, or a combination thereof having a second hardness exceeding the first hardness. The gauge component is moved in and out of the backing material in a first direction with respect to the stroke of the needle, moving toward and away from engagement with the needle, and the module A module that is movable in a second direction relative to the stroke of the needle along the at least one passage of the rule body, A series of actuators coupled to the gauge component to control the movement of the gauge component in the second direction through the module body, A gauge component assembly, Control system including programming and Equipped with, Tufting machine, the programming involves controlling the operation of one or more actuators to move the selected gauge component in a second direction between a lowered position where the pickup of the yarn loop from the corresponding needle by a selected gauge component is substantially avoided, and one or more raised positions relative to the stroke of the needle into the backing material for picking up the yarn loop from the corresponding needle, in order to selectively form a yarn tuft in the backing material according to a formed pattern, and controlling the at least one yarn feeding mechanism to control the feeding of yarn to the needle. (Item B2) The system further comprises a shift mechanism for shifting the at least one needle bar laterally across the backing material, The control system further comprises programming for presenting a series of threads to selected stitch locations along the backing material and for pulling out unselected threads by coordinating the shifting of the at least one needle bar by the shift mechanism, which involves controlling the actuator coupled to the gauge component, and the control of the at least one thread feeding mechanism for feeding the thread to the needle, Such unselected thread loops are not picked up by one of the gauge components in the tufting machine described in item B1. (Item B3) The tufting machine according to item B2, wherein the control system further comprises programming for controlling the feeding of the backing material by the backing material feeding rolls so that the backing material is moved through the tufting strip at an actual stitch rate exceeding a certain pattern stitch rate, so that the pattern is formed to provide several retained tufts per inch of front threads in the backing material at a rate approximately equal to the pattern stitch rate. (Item B4) The tufting machine according to item B1, wherein the gauge component assembly further comprises a series of connectors extending between each gauge component and an actuator associated therewith, each of the connectors including a coupling portion that is received within a housing and movable therethrough. (Item B5) The tufting machine described in item B4, wherein the housing of each connector comprises a polymer material, composite material, synthetic material, or a combination thereof, and each connecting portion comprises a metal, composite material, or a combination thereof. (Item B6) The tufting machine according to item B4, wherein the housing of each connector further comprises a composite material including a polymer or plastic together with a fiber-filled material and having a defined channel therein, the connecting portion being movable along the channel, and the connecting portion of each connector comprising a hardened metal body extending through the housing and having a proximal end configured to engage with 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 the movement by the actuator to the gauge part. (Item B7) Each of the inserts of the at least one module comprises opposing inserts mounted on the upper and lower surfaces of the module body along both sides of the passage, and the inserts The tufting machine described in item B1, wherein the aforementioned slots are arranged in a relationship of facing each other and substantially aligned. (Item B8) The tufting machine according to item B1, wherein each of the inserts comprises a molded or cast body having a tab or flange portion, and the slot is formed within the tab or flange portion. (Item B9) The tufting machine described in item B1, wherein the module body is made of steel, aluminum, aluminum alloy, steel alloy, mild steel, tool steel, or a combination thereof. (Item B10) The tufting machine according to item B1, wherein the first hardness is at least 60+RC and the second hardness is at least 75+RC. (Item B11) A gauge component assembly for a tufting machine, wherein the gauge component assembly is A plurality of modules, each module including a module body, the module body having a passage defined through it, Opposing inserts positioned on both sides of the passage defined through the module body, each insert being formed from a metal, metal carbide, ceramic, or powdered metal material, including metal powder containing tungsten, titanium, or a combination thereof, having a hardness exceeding 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 components slidably received into the slots of the opposing inserts, each of the gauge components 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 components is received. The gauge component is carried together with the module in a first direction toward and away from engagement with the needle of the tufting machine, along the throat of the gauge component, to selectively pick up a loop of thread from the needle, and each of the gauge components is selectively movable in a second direction toward the slot of the opposing insert into which the gauge component is received, with respect to a series of gauge components, Multiple actuators and Equipped with, A gauge component assembly in which each of the plurality of actuators is coupled to the gauge component, and each of the actuators is selectively actuated to move the gauge component coupled thereto in the second direction, thereby moving the throat of the gauge component between one or more extended positions for engaging with 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 according to item B11, further comprising connectors extending between each gauge component and an actuator associated therewith, each connector having a housing formed of a polymer material, the connecting portion being enclosed within the housing. (Item B13) Each housing further comprises a composite material including a polymer or plastic together with a fiber-filled material, having a defined channel therein, the connecting portion being movable along the channel, and the connecting portion of each connector comprising a hardened metal body extending through the housing, with a proximal end configured to engage with a portion of one of the gauge components, and the act A gauge component assembly according to item B12, having a distal end configured to engage with an associated actuator for the gauge component in order to transfer movement by a tuner to the gauge component. (Item B14) The gauge component assembly according to item B11, wherein the upper portion of each of the opposing inserts is configured to cover the upper surface of the module body and includes a slotted opening, the slotted opening being adapted to receive fasteners through which the opposing inserts are adjustably mounted on the module body at a location selected with respect to the passage defined through the module body. (Item B15) The opposing inserts have a hardness of at least 75+RC, as described in item B11 of the gauge component assembly. (Item B16) The module body comprises steel, aluminum, aluminum alloy, steel alloy, mild steel, tool steel, or a combination thereof, as described in item B11. (Item B17) A tufting machine, wherein the tufting machine is One or more needle bars, each having a plurality of needles mounted along it, A backing material feeding roll configured to feed backing material through the tufting machine, A yarn feeding mechanism for feeding yarn to the needle, A gauge component assembly positioned below the backing material, wherein the gauge component assembly is A module having a module body formed from a metal, polymer, composite material, or synthetic material, or a combination thereof, wherein the module body has a passage defined through it, and at least one module A plurality of gauge components received within the passage of the module body, each of the plurality of gauge components includes a body having a first part and a second part configured to pick up a loop of thread from a needle, The gauge components are transported together with their modules in a first direction toward and away from engagement with the needle of the tufting machine, picking up loops of thread from the needle, and are selectively movable in a second direction along the passage of the module body, comprising a plurality of gauges. An insert received within the passage of the module body, the insert having a series of opposing slots arranged along both sides of the passage and configured to receive the gauge component, The insert comprises a material having a hardness exceeding that of the module body, A series of actuators coupled to the gauge component, wherein the series of actuators are configured to control the movement of the gauge component in a second direction along the passage of the module body, and A gauge component assembly, Control system including programming and Equipped with, The programming controls the at least one thread feeding mechanism and, in coordination with the control of the operation of one or more actuators, controls the feeding of the thread to the needle, thereby moving a selected part of the gauge component in the second direction, thereby moving the second part of the selected part of the gauge component according to the formed pattern. A tufting machine, wherein a needle is moved between a descending position and one or more ascending positions with respect to the stroke of the needle into the backing material in order to selectively form a tuft of thread within the backing material. (Item B18) The tufting machine according to item B17, wherein the insert comprises a metal carbide, ceramic, or powdered metal material, including metal powder containing tungsten, titanium, or a combination thereof. (Item B19) 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 within the tab or flange portion, the tufting machine as described in item B17. (Item B20) The tufting machine according to item B17, further comprising connectors extending between each gauge component and an associated actuator, each connector having a housing formed of a polymer material, the connecting portion being enclosed within the housing. (Item B21) The tufting machine according to item B20, wherein the housing of each connector further comprises a composite material including a polymer or plastic together with a fiber-filled material, having a defined channel therein, the coupling portion being movable along the channel, and the coupling portion of each connector comprising a hardened metal body extending through the housing, having a proximal end configured to engage with 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 according to item B19, wherein each of the inserts' bodies further comprises upper and lower tabs or flange portions that engage with the upper and lower surfaces of the module body, and the slots extend through the upper and lower tabs or flange portions. (Item B23) The control system further comprises a shift mechanism for shifting one or more needle bars laterally across the backing material, and the control system further comprises To present a series of threads to the selected stitch locations along the backing material and to pull out the unselected threads, The shift of the at least one needle bar by the shift mechanism, Control of the actuator coupled to the gauge component, Control of the at least one thread feeding mechanism that supplies the thread to the needle when the needle is moved back and forth in and out of the backing material, and With programming adapted to adjust, Such unselected thread loops are not picked up by one of the gauge components in the tufting machine described in item B17. (Item B24) The tufting machine according to item B23, further comprising programming for controlling the feeding of the backing material by the backing material feeding roll so that the backing material is moved through the tufting strip at an actual stitch rate exceeding the pattern stitch rate, so that the pattern is formed to provide several retained tufts per inch of front threads in the backing material, approximately equal to the pattern stitch rate.

Claims

1. A tufting machine, wherein the tufting machine is A needle bar having multiple needles, wherein the multiple needles are mounted along the at least one needle bar, A backing material feeding roll for feeding backing material, A yarn feeding mechanism for feeding yarn to the needle, A gauge component assembly positioned below the backing material, wherein the gauge component assembly is A plurality of gauge components, each of which includes 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 formed from a metal, polymer, or a combination thereof, having a first hardness, wherein the module body has at least one passage defined through the module body and inserts positioned along both sides of the at least one passage, each of the inserts having a slot into which one of the gauge components is received, The insert comprises a metal, metal carbide, ceramic, or powdered metal material, including a metal powder containing tungsten, titanium, or a combination thereof having a second hardness exceeding the first hardness. The gauge component is movable in and out of the backing material in a first direction relative to the stroke of the needle, moving toward and away from the needle, and is movable in a second direction relative to the stroke of the needle along the at least one passage of the module body, and comprises at least one module, A series of actuators coupled to the gauge component to control the movement of the gauge component in the second direction through the module body, A gauge component assembly, Control system including programming and Equipped with, Tufting machine, the programming involves controlling the operation of one or more actuators to move the selected gauge component in a second direction between a lowered position where the pickup of the yarn loop from the corresponding needle by a selected gauge component is substantially avoided, and one or more raised positions relative to the stroke of the needle into the backing material for picking up the yarn loop from the corresponding needle; and controlling the at least one yarn feeding mechanism to control the feeding of yarn to the needle.

2. The system further comprises a shift mechanism for shifting the at least one needle bar laterally across the backing material, The control system further comprises programming adapted to present a series of threads to selected stitch locations along the backing material and pull out unselected threads by coordinating the shifting of the at least one needle bar by the shift mechanism, which involves controlling the actuator coupled to the gauge component, and the control of the at least one thread feeding mechanism that feeds the thread to the needle, The tufting machine according to claim 1, wherein such unselected thread loops are not picked up by the gauge component.

3. The control system further comprises programming for controlling the feeding of the backing material by the backing material feeding roll so that the backing material is moved through the tufting strip at an actual stitch rate, wherein the actual stitch rate is greater than the pattern stitch rate in the backing material to provide a number of tufts held per inch of face yarn equivalent to the pattern stitch rate for the pattern formed therein, according to claim 2.

4. The tufting machine according to claim 1, wherein the gauge component assembly further comprises a series of connectors extending between each gauge component and an actuator associated with it, each of the connectors including a coupling portion that is received within a housing and movable through the housing.

5. The tufting machine according to claim 4, wherein the housing of each connector is made of a polymer material and each connecting portion is made of metal.

6. The tufting machine according to claim 4, wherein the housing of each connector further comprises a composite material including a polymer or plastic material together with a fiber-filled material, and has a defined channel within the housing, the connecting portion being movable along the channel, and the connecting portion of each connector comprising a hardened metal body extending through the housing, having a proximal end configured to engage with a portion of one of the gauge components, and a distal end configured to be engaged by the actuator to transfer movement by the associated actuator for the gauge component to the gauge component.

7. The tufting machine according to claim 1, wherein each of the inserts of the at least one module comprises opposing inserts mounted on the upper and lower surfaces of the module body along both sides of the passage, and the slots of the inserts are arranged in a relationship of opposing and substantially aligned relations.

8. The tufting machine according to claim 1, wherein each of the inserts comprises a molded or cast body having a tab or flange portion, and the slot is formed within the tab or flange portion.

9. The tufting machine according to claim 1, wherein the module body is made of steel, aluminum, aluminum alloy, steel alloy, mild steel, tool steel, or a combination thereof.

10. The tufting machine according to claim 1, wherein the first hardness is at least 60 RC and the second hardness is at least 75 RC.

11. A gauge component assembly for a tufting machine, wherein the gauge component assembly is A plurality of modules, each module including a module body, the module body having a passage defined through the module body, 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 powder containing tungsten, titanium, or a combination thereof, having a hardness exceeding that of the module body, and having a series of slots formed within each insert, the slots of the opposing inserts being substantially aligned across the passage, A series of gauge components slidably received into the slots of the opposing inserts, each of the gauge components having a first portion and a second portion having a throat, The slots of the opposing inserts are configured to define a contact area, and along the slots, at least a portion of one of the gauge components is received. The gauge component is carried together with the module in a first direction toward engagement with the needle and away from the needle, along the throat of the gauge component, to selectively pick up a loop of thread from the needle of the tufting machine, and each of the gauge components is selectively movable in a second direction along the slot of the opposing insert into which the gauge component is received, Multiple actuators and Equipped with, A gauge component assembly in which each of the plurality of actuators is coupled to the gauge component, and each of the actuators is selectively actuated to move the gauge component coupled to each actuator in the second direction, so that the throat of the gauge component engages with a loop of thread from the needle and is moved between one or more extended positions for picking up the loop of thread and a retracted position for substantially avoiding picking up the loop of thread from the needle.

12. The gauge component assembly according to claim 11, further comprising connectors extending between each gauge component and an actuator associated therewith, each connector having a housing formed of a polymer material, the connecting portion being enclosed within the housing.

13. The gauge component assembly according to claim 12, each housing further comprises a composite material including a polymer or plastic together with a fiber-filled material, having a defined channel within each housing, the connecting portion being movable along the channel, and the connecting portion of each connector comprising a hardened metal body extending through the housing, having a proximal end configured to engage with a portion of one of the gauge components, and a distal end configured to engage with the actuator to transfer movement by the associated actuator for the gauge component to the gauge component.

14. The gauge component assembly according to claim 11, wherein the upper portion of each of the opposing inserts is configured to cover the upper surface of the module body and includes a slotted opening, the slotted opening being adapted to receive fasteners through the slotted opening for adjustably mounting the opposing inserts onto the module body at a location selected with respect to the passage defined through the module body.

15. The gauge component assembly according to claim 11, wherein the opposing inserts have a hardness of at least 75RC.

16. The gauge component assembly according to claim 11, wherein the module body comprises steel, aluminum, aluminum alloy, steel alloy, mild steel, tool steel, or a combination thereof.

17. A tufting machine, wherein the tufting machine is One or more needle bars, each having a plurality of needles mounted along the needle bar, A backing material feeding roll configured to feed backing material through the tufting machine, A yarn feeding mechanism for feeding yarn to the needle, A gauge component assembly positioned below the backing material, wherein the gauge component assembly is A module having a module body formed from a metal, polymer, or a combination thereof, wherein the module body has a passage defined through the module body, and A plurality of gauge components received within the passage of the module body, each of the plurality of gauge components includes a body having a first portion and a second portion configured to pick up a loop of thread from the needle, The gauge components are transported together with their modules in a first direction toward and toward engagement with the needle of the tufting machine, picking up loops of thread from the needle, and selectively movable in a second direction along the passage of the module body, An insert received within the passage of the module body, the insert having a series of opposing slots arranged along both sides of the passage and configured to receive the gauge component, The insert comprises a material having a hardness exceeding that of the module body, A series of actuators coupled to the gauge component, wherein the series of actuators are configured to control the movement of the gauge component in the second direction along the passage of the module body, and A gauge component assembly, Control system including programming and Equipped with, Tufting machine, wherein the programming controls the feeding of the yarn to the needle in coordination with the control of the operation of one or more actuators, thereby moving a selected portion of the gauge components in the second direction, the second portion of the selected portion of the gauge components is moved between a lowered position and one or more raised positions with respect to the stroke of the needle into the backing material in order to selectively form a yarn tuft in the backing material according to a formed pattern.

18. The tufting machine according to claim 17, wherein the insert comprises a metal carbide, ceramic, or powdered metal material, including a metal powder containing tungsten, titanium, or a combination thereof.

19. The tufting machine according to claim 17, 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, and the slot is formed in the tab or flange portion.

20. The tufting machine according to claim 17, further comprising connectors extending between each gauge component and an actuator associated therewith, each connector having a housing formed of a polymer material, the connecting portion being enclosed within the housing.

21. The tufting machine according to claim 20, wherein the housing of each connector further comprises a composite material including a polymer or plastic material together with a fiber-filled material, and has a defined channel within the housing, and the connecting portion is movable along the channel, and the connecting portion of each connector comprises a hardened metal body extending through the housing, having a proximal end configured to engage with a portion of one of the gauge components, and a distal end configured to be engaged by the actuator to transfer movement by the associated actuator for the gauge component to the gauge component.

22. The tufting machine according to claim 17, wherein each insert is molded or cast from a metal, carbide, or powdered metal material and comprises a body with a tab or flange portion, and the slot is formed within the tab or flange portion.

23. The control system further comprises a shift mechanism for shifting one or more needle bars laterally across the backing material, and the control system further comprises To present a series of threads to the selected stitch locations along the backing material and to pull out the unselected threads, The shifting of one or more needle bars by the shift mechanism, Control of the actuator coupled to the gauge component, Control of the at least one thread feeding mechanism that supplies the thread to the needle when the needle is moved back and forth in and out of the backing material, and With programming adapted to adjust, The tufting machine according to claim 17, wherein such unselected thread loops are not picked up by one of the gauge components.

24. The control system further comprises programming for controlling the feeding of the backing material by the backing material feeding roll so that the backing material is moved through the tufting strip at an actual stitch rate, wherein the actual stitch rate is greater than the pattern stitch rate in the backing material to provide a number of tufts held per inch of face yarn equivalent to the pattern stitch rate for the pattern formed therein, according to claim 23.

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