Patterned Sports Turf Tufting for Precise Yarn Retention
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Solution Overview
Problem
Current methods for forming patterned tufted fabrics, such as synthetic sports turf, are labor-intensive, lead to material waste, and result in inaccuracies in design alignment and retention, while also requiring excessive fill material that can cause player discomfort and injuries.
Innovation Solution
A system and method using a tufting machine with needles arranged in-line or staggered configuration, equipped with gauging element assemblies and yarn feed mechanisms, allows for precise control of yarn pickup and formation of cut and loop pile tufts, enabling the creation of complex patterns directly during the tufting process without the need for post-installation templates or excessive fill material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If post-installation template and shearing method is used to create patterns, then design flexibility is improved, but labor intensity and time consumption increase significantly
Solution Approach 1:
The patent applies preliminary action by integrating pattern formation into the turf manufacturing process itself. The tufting machine forms different height tufts (first height and second height) directly during production, creating patterns before the turf is installed. This eliminates the need for post-installation template work and shearing, significantly reducing labor intensity and installation time while maintaining design flexibility.
2Manufacturing precision
If post-installation shearing is used to create patterns, then design accuracy can be achieved, but material waste increases due to sheared and removed yarns
Solution Approach 1:
The patent forms the desired pattern by creating tufts of different heights during the manufacturing process itself. The tufting machine selectively forms first height tufts and second height tufts in specific patterns based on design requirements. This preliminary formation of patterns during manufacturing eliminates the need for post-installation shearing and removal of yarns, thereby preventing material waste while maintaining design accuracy.
3Strength
If excessive fill material is used to support synthetic turf filaments, then structural support and cushioning are improved, but player comfort decreases due to fill material getting in players' eyes
Solution Approach 1:
The patent applies local quality by creating tufts of different heights in specific patterned locations. The first height tufts provide structural support and cushioning where needed, while the second height tufts create patterns and visual interest. This localized variation in tuft height allows the turf to meet structural support requirements with reduced overall fill material, minimizing the amount of fill that can disturb players during play.
Data Source
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AI summary
A system and method for forming synthetic/artificial grass or turf products in which a series of tufts of artificial/synthetic grass filaments or yarns are formed in a backing material with various graphic pattern effects being formed therewith. The system generally will include at least one needle bar having at least one row of needles mounted along a tufting zone and reciprocated through the backing to a desired penetration depth, and will present a desired set or group of yarns to a series of pattern pixels or stitch areas. A series of level cut loop loopers or hooks will be aligned with and will engage the needles in order to form tufts of yarns in the backing material. Clips of the level cut loop loopers will be selectively controlled to control the retention of selected ones of the yarns presented at each pattern pixel. The remaining, non-selected yarns generally are not retained at the pattern pixels, and can be formed as lower pile tufts or removed from the backing material.