SYSTEM AND METHOD OF FORMING PATTERNED TUFTED PRODUCTS

Abstract

A system, apparatus and methods for forming tufted products can include a tufting machine for forming patterned tufted products, such as carpets, rugs, and artificial grass or turf product with logos of other designs including multiple colors of yarns integrated therein. The tufting machine can include a series of hollow needles arranged along a needle bar at a gauge spacing and can receive a series of different color and/or types of yarns from a yarn feed system. A yarn selection system can be controlled to selectively hold back or retract yarns from the needles. The needles will be reciprocated into and out of a backing to deliver a series of yarns into the backing and can be engaged by corresponding knives to form tufts of yarns.

Description

INCORPORATED BY REFERENCE

The disclosures of U.S. Provisional Application No. 63/533,171 filed Aug. 17, 2023, U.S. Provisional Application No. 63/555,590, filed Feb. 20, 2024, and U.S. Provisional Application No. 63/683,097, filed Aug. 14, 2024, are incorporated by reference herein for all purposes as if set forth in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to tufted fabrics or products, and in particular to systems and methods for forming tufted fabrics or products having patterned designs formed therein, including formation of patterned artificial/synthetic sports grass or turf fabrics or products.

BACKGROUND OF THE DISCLOSURE

Tufted products such as carpets, rugs, turf, etc. having company branding, such as logos, script designs and other patterned graphics have become increasingly popular. In addition, as the installation of artificial or synthetic grass or turf products has expanded in both indoor and outdoor applications, demand has grown for the formation of such turf products with a greater variety of colors and/or patterns such as team or sponsor logos or various graphic patterns. In the past, to create large tufted product fields, such as turf or artificial grass fields, with graphic patterns or designs such as logos, numbers or other features, has involved installing sections of plain turf or artificial grass at a site and either having to paint a desired design or logo, etc. onto the turf or artificial grass or cutting and removing a portion of the installed turf or artificial grass and inserting and securing (e.g., gluing) a pre-cut logo, number or other design feature having the desired color or colors into place. Such a process is often very labor and time intensive and expensive, and can lead to increased material waste, as well as, in some cases, inaccuracies in terms of the alignment of such later applied logos or other intricate designs. In addition, as players have become larger and stronger, more force can be applied to turf or artificial grass fields during play, which can cause an increased incidence of separation of the turf or artificial grass along seams where the turf has been separated and logos or other designs have been applied.

Accordingly, it can be seen that a need exists for a system and method for forming patterned tufted products, including artificial/synthetic grass or sports turf products, that address the foregoing and other related and unrelated problems in the art.

SUMMARY OF THE DISCLOSURE

Briefly described, the present disclosure generally relates to systems and methods for forming patterned tufted products, including carpets for commercial, residential applications, carpets tiles, rugs, sport carpets, including but not limited to artificial grass or turf, landscape applications, and/or other tufted products. In embodiments, tufted products can include patterned designs including multiple different colors, varying pile heights, and/or loop pile and/or cut pile tufts. In one example embodiment, the patterned tufted products formed using the systems and methods of the present disclosure can be formed from various colors and/or types of yarns, including synthetic grass or turf type filaments or yarns, and/or other yarns, which can be inserted into a backing material to form patterned artificial/synthetic grass or turf products, as well as tufted products including carpets and rugs.

In embodiments, the yarns can include one or more yarns for forming carpets and rugs (e.g., shag carpets), or for forming sports carpets or turf products, which can include combinations of one or more of filaments and/or ribbon yarns for forming sports fields and landscape applications. In embodiments, the systems and methods of the present disclosure generally can include and/or can be adapted to be utilized in a tufting machine including at least one row of needles that can be reciprocated into and out of a backing material passing below the needles to insert a plurality of yarns into the backing material for forming tufts of such yarns therein. In embodiments, the tufting machine can comprise a hollow needle tufting machine having a plurality of hollow needles mounted in spaced series along a needle bar. In some embodiments, the tufting machine can include more than one needle bar having a plurality of needles spaced therealong (e.g. a pair of needle bars each carrying a plurality of needles could be provided).

In addition, in embodiments, the tufting machine can include a needle stroke support assembly configured to guide the push rods driving reciprocation of the needle bar(s). In embodiments, each needle stroke assembly can include a series of support plates, including an upper support plate through which the push rods are received and a lower support plate that can act as a brace or strut that can have a first guide mounted therealong. The push rods extend through the support plates and connect to a push foot coupled to the needle bar. The push rod foot can have a second guide that interacts with the first guide of the lower support plate to help guide the linear movement of the push rods and the needle bar during each needle stroke, and can help reduce pressure applied to the push rods and resist limit excessive vibratory and/or side-to-side movement of the push rods during the stroke of the needles into and out of the backing.

In embodiments, particular colors of yarns can be assigned to or associated with each of the needles, e.g., the needles can be provided with a selected color thread-up such as an ABC, ABCD, ABCDE, ABCDEF, etc. . . . , with yarns of a selected color or colors being fed directly to one needle. In some embodiments, two or more yarns can be fed directly into each needle. In embodiments, the yarns can be fed directly into their associated needles using air from at least one injector, and in some embodiments, two injectors can be provided, one on each side of the needle. One or more yarns of a selected color thus can be fed directly into an associated needle without having to feed multiple colors of yarns into funnels for each hollow needle and then selectively feeding one of those color yarns to the hollow needle.

In addition, in some embodiments, yarn tubes can be mounted along the needle bar, in communication with each of the needles to help maintain the yarns within the needles. In embodiments, the yarn tubes can extend at an angle into and through openings in the needle bar, for guiding the yarns to their corresponding needles. In some embodiments, the yarn tubes can be positioned adjacent the needle bar and can communicate with and feed into passages extending through the needle bar for feeding into the passages defined though associated ones of the needles. In other embodiments, the yarns are fed directly into passages formed along the needle bar and into the hollow needles.

In embodiments, the needle bar(s) can be coupled to a shift mechanism, such as a servo motor driven shift mechanism, a rack-and-pinion type shift mechanism, or other shift mechanism, for shifting the needles transversely with respect to the backing material. In some embodiments, a backing support or shuttle on which the backing material is supported during a tufting operation can be coupled to a shift mechanism, and can be shifted in conjunction with, or, in embodiments, independently of the shifting of the needles. In optional embodiments, the backing can be shifted or the needle bar(s) can be shifted transversely, or both the backing and needle bar(s) can be shifted transversely. In still other embodiments, only the shuttle supporting the backing may be connected to a shift mechanism such that the backing can be shifted with a lateral position of the needles being substantially consistent as the backing is moved transversely with respect to the needles, or with the needles being shifted in different increments and/or in a different direction.

In some embodiments, the systems of the present disclosure further can comprise a tufting machine having a plurality of hollow needles, a yarn feed system, a yarn selection system, a yarn cutting system, and a control system. In embodiments, the yarn feed system can include a yarn feed mechanism or pattern attachment having a plurality of yarn feed devices each configured to feed one or more yarns to the hollow needles. For example, in embodiments, the yarn feed mechanism can include a single or double end yarn feed mechanism having a plurality of individual yarn feed devices that can be selectively controlled for feeding one or two yarns, or in some embodiments, more than two yarns to one or more associated needles. In addition, in some embodiments, the yarn feed devices of the yarn feed system can include yarn feed rolls driven by a servo motor, which can be sized or otherwise configured to control feeding of selected lengths of yarn per revolution of a yarn feed roll to form individual stitches or tufts and/or to form tufts of selected pile heights. For example in embodiments, at least some of the yarn feed devices can include one or more feed rollers that can be configured with a larger diameter to feed a prescribed amount of yarn(s) per revolution and to help feed yarns such as polymer yarns or filaments as generally used for artificial turf or grass, an a drive roll having a smaller diameter than the feed rollers to compensate for potential reduction in torque for feeding the yarns due to the increased size of the feed rollers.

In embodiments, the yarn selection system can be arranged along a path of travel or pathway of the yarns from the yarn feed system to the needles. In embodiments, the yarn selection system can include a series of yarn jerkers each coupled to an actuator and positioned along the path of travel of the yarns from the yarn feed system to the needles for selectively engaging the yarns being fed to the needles. The yarn jerkers can be selectively controlled to extend and retract along a selected length or travel, which can, in embodiments, be set or adjusted to a selected distance. The yarn jerkers can be moved between extended and retracted positions to enable feeding of selected yarns to the needles or to retract or hold non-selected yarns from being fed through the needles in accordance with a pattern being formed.

In addition, in embodiments, the yarn jerkers can be coupled to or can be incorporated with jerker modules that can comprise or include the actuators for controlling the movement of the yarn jerkers between their extended and retracted positions. For example, in embodiments, the jerker modules can include a plurality of bores each receiving a piston rod therein, though other types of actuators also can be provided. In some example embodiments, the jerker modules (and/or the actuators thereof) can comprise double acting air cylinders configured without a mechanical spring return, and which can, in embodiments, use air supplied to different portions of bores of the jerker modules (and/or actuators thereof) to cause selective movement of the pistons along the bores so as to control extension and retraction of the yarn jerkers.

In embodiments, the cutting system is positioned below the backing support and can be selectively actuated to cut yarns carried by the needles to form tufts of the yarns in the backing material. In embodiments, the cutting system can include a series of knives or one or more cutting blades. In some embodiments, the knives or one or more cutting blades can be individually mounted along a knife bar or can be received in modules that can be mounted along a knife bar.

In some embodiments, the knives or one or more cutting blades can be maintained in a substantially stationary position, with the cutting edges of the knives or one or more cutting blades arranged at a substantially fixed elevation or position with respect to the penetration depth or lower portion of the stroke of the needles penetrating into the backing. In embodiments, the knives or one or more cutting blades can be moved up and down, toward and away from the needles as the needles penetrate the backing, with the knives or one or more cutting blades being moved separately or together between a retracted, non-engaging or no-cut position, and one or more extended cutting positions for engaging and cutting the yarns carried by the needles into the backing.

In some embodiments, the cutting system can include a plurality of individually controllable knife modules or blocks each with a body in which a knife or at least one cutting blade is mounted, and a multi-position actuator, such as, for example, an air cylinder that can be selectively controlled or fired selectively to move its corresponding or associated knife or at least one cutting blade between a no-cut and at least first and second cutting positions (e.g., non-engaging and one or more engaging positions) in relation to a stroke of the needles as the needles are reciprocated into and out of the backing.

In embodiments, the knives can have a substantially flat cutting edge or surface adapted for cutting flat ribbon yarns or filaments such as used for artificial grass or turf.

In other embodiments, the cutting system can comprise at least one elongated cutting blade or plate that can take the place of at least a portion of the knives of the series of knives. In embodiments, the at least one cutting blade can have an elongated, substantially flattened cutting edge. In addition, the at least one cutting blade or plate can be moved between a non-engaging/no-cut position and an engaging/cutting position to cut a series of yarns.

In addition, in embodiments, the cutting system can include one or more multi-position actuators. In embodiments, controlled flows of pressurized air or other fluid can be supplied to the multi-position actuators from an air supply by the control system to move the knives or at least one cutting blade between various selected cutting positions to form cut pile tufts of selected pile heights, and a non-engaging or no-cut position to form loop pile tufts. For example, in embodiments, the multi-position actuator can include a 3-position actuator (such as a 3-position pneumatic or hydraulic cylinder), a servo or stepper motor, or other actuator. In embodiments, the multi-position actuator can include a 4-way fluid valve for selectively controlling a supply of fluid (e.g., air) to the multi-position actuator. In embodiments, at least two positions for each of the knives or at least one cutting blade can be provided, for example, a high cut position, low cut position, and a no-cut or loop position could be provided.

In some embodiments, other gauge parts (e.g., loopers, hooks, level cut loop loopers, clips, etc.) also can be provided, in addition to the knives or at least one cutting blade of the cutting system.

In embodiments, the control system can be linked to the yarn feed system, yarn selection system, cutting system, and to other operative components of the tufting machine (e.g., a main shaft and/or one or more drive motors therefor). The control system can be linked to one or more drive motors of a backing feed system, to an air supply (which, in some example embodiments, can include a compressor, blower or tank) for controlling flows of pressurized air to the jerker modules of the yarn selection system and/or actuators of the cutting system. In embodiments, the control system can comprise one or more processors and programming configured to cooperatively control the feeding of yarns to the hollow needles by the yarn feed system, control engagement of one or more yarn jerkers of the yarn selection system to pull back non-selected yarns, and/or control movement of one or more knives or one or more cutting blades of the yarn cutting system to form a selected pattern.

In embodiments, the control system can include instructions or programming that can be executed to control the various operative systems or components of the tufting machine in a cooperative manner to form patterns using an increased number of colors or types of yarns that can be formed without having to expand the gauge spacing between the needles. For example, and without limitation, in embodiments, patterned articles including 4, 8, 16, and possibly more colors of yarns can be formed, with the hollow needles of the tufting machine arranged at a selected gauge spacing. For example, a gauge spacing of approximately 1″, and with a substantially consistent feeding of yarns to each of the needles. Other needle spacings also can be provided.

In some embodiments, the needles can be arranged at spacings that can be selected based on a tufting gauge for the tufted products. For example, in embodiments, the needles can be arranged at gauge spacings of approximately ¼″ to 1″, and in some embodiments, gauge spacings of approximately ¼″, ⅜″, ½″, ⅝″, ¾″, ⅞″, 1″, 1¼″, 1⅜″, 1½″, 1⅝″, 1¾″, 1⅞″, and/or 2″ can be used. Thus, in embodiments, the needle bar can be configured with the needles arranged at a true gauge spacing that generally matches the gauge of the tufting machine, which further generally can match the desired or selected gauge of the tufted product being produced.

In addition, it is contemplated that, in some embodiments, other desired gauge fabrics based on a multiple or a fraction of the gauge spacing of the needles can be created by shifting the backing, shifting the needles or both, enabling a variety of different colors to be presented and tufted at a variety of gauge spacings. The needles also can be mounted at a closer spacing. The backing, the needles, or both can be shifted transversely as needed to form selected patterns. For example, in some embodiments, the backing can be shifted transversely while the needles are not shifted, with the needles being maintained in a substantially fixed lateral position as they are reciprocated into and out of the backing. Thus, patterns having a construction with tufts or groups of yarns arranged at different spacings in a gauge direction (e.g., in a direction along the needle bar or transversely across the backing) and in a longitudinal direction (e.g., in the direction in which the backing is fed), can be produced.

According to aspects of the present disclosure, a tufting machine is provided, including at least one needle bar having a plurality of needles spaced therealong, a yarn feed system including a pattern attachment (e.g., a single end yarn feed mechanism), a needle bar shift mechanism (e.g., a servo motor or rack and pinion driven shift mechanism) coupled to the at least one needle bar and configured to control shifting of the needles across a backing, and an air induced yarn selection system, with a yarn feed pathway defined therethrough for the yarns.

In addition, or alternatively, a backing shift mechanism can be provided, which, in various embodiments, can be used in conjunction with a needle bar shift mechanism (being controlled independently of the needle bar shift mechanism or independently controlled) and/or as a replacement for a needle bar shift mechanism.

In embodiments, the needles and/or the backing can be shifted and the yarn feed system and the yarn selection system controlled to present a measured feed length of yarn per tuft in the backing per revolution of the main drive shaft. In embodiments, there may be one yarn fed per individual yarn feed devices of the yarn feed system to each of the needles. In embodiments, the yarn selection system can be positioned between the yarn feed system and the needles, and can include a series of yarn jerkers. In embodiments, the yarn jerkers that can be selectively controlled to retract or pull a non-sewing end of a non-selected yarn back (e.g., extension and retraction of the yarn jerkers can be controlled by controlling a supply of pressurized air to an actuator associated with each yarn jerker), and allow only selected yarns (e.g., desired colors or types of yarns) to be fed to the needles.

In embodiments, the yarn feed system of the tufting machine can include a single or double end yarn feed mechanism that, in some embodiments, further can be provided with enlarged feed roll systems configured to feed tuft lengths of yarns to be consumed by turf or shag carpets, fields, rugs, or other tufted products, with a pile height of a selected height, such as, for example, based on an industry standard height for artificial grass or turf fields. In some embodiments, yarn or tuft lengths for forming pile heights exceeding three inches can be provided.

In embodiments, the tufting machine is controlled by a control system that can include one or more processors and programming to control the yarn feed, yarn jerker actuation, backing feed rolls, yarn feed puller rolls, a needle bar shift mechanism, and/or a backing shifter.

According to other aspects of the present disclosure, a method is provided for operating a tufting system to form tufted turf or artificial products with logos or other designs integrated therein. In embodiments, the tufting system can comprise a hollow needle tufting machine having a plurality of spaced hollow needles that can be threaded with or directly fed by a series of different color or types of yarns based on a desired thread-up. For example, in an embodiment, if 3-4 colors are used in the pattern, the needles can have a yarns thread-up sequence of ABC or ABCD, with at least two of the yarns being different color or type yarns (e.g., yarns A and B, C and/or D, or any combination thereof, can be one color, while the other yarn or yarns of the thread-up sequence can be different color or type yarns; or each of yarns A, B, C and D can be of different colors and/or types).

In some embodiments, such as for forming sports carpets such as sports turf fields, a larger number of colors can be used. For example, in some applications, such as for forming a sports turf field 6 colors can be used, including at least one green yarn and a white yarn for the bulk of the field, with the remaining yarns being accent colors for forming logos, etc.

In some embodiments, the needles can be grouped in sets of needles, and can include different thread-ups. For example, in embodiments, for a tufted turf product, for areas where mostly green yarns are to be tufted, a set of needles can be provided with an ABCD, ABCDE, ABCDEF, or other thread-up sequence, with, in embodiments, multiple ones, or all, of the yarns of the thread-up sequence being one color (e.g., green), while for other areas where different colors or types or yarns are to be tufted, another set of needles can have a thread-up sequence with several different color or types of yarns.

In embodiments, the needle bar shift mechanism can be controlled to shift the needles across the backing to displace the colors and/or types of yarns as needed, resulting in the ability to present and mix different colors and/or types of yarns in the face of the tufted product, which can allow for enhanced color control in the finished carpet design. For example, in some embodiments, the needles can be shifted one or more gauge steps or portions to enable multiple colors and/or types of yarns to be presented to one or more stitch locations of the pattern being formed; and when a particular color or type yarn is not desired in the face, one or more yarn feed devices of the yarn feed system that are feeding such a non-selected color or type yarn can be controlled to stop the color or type yarn from being fed. Corresponding yarn jerkers for such non-selected yarns can be actuated to hold or otherwise maintain the non-selected yarns with their needles.

In some embodiments, the non-selected yarns can be retracted with the reciprocation of their needles out of the backing and can be retained within the needles, or within yarn tubes connected thereto, to help maintain the non-selected yarns with their needles when the non-selected yarns are held back by the yarn jerkers.

In embodiments, where a yarn is selected to be retained for forming a tuft or stitch of the pattern, the yarn feed system can be controlled to feed a desired length or amount of each selected yarn for forming a tuft or stitch of a desired length or pile height while the yarn jerkers are moved to a position to allow passage of a length of each of the selected yarns sufficient to form a tuft of a selected pile height to be blown and/or flow through their associated needles. In embodiments, the yarn feed rollers of the yarn feed devices of the yarn feed system that control feeding of such selected yarns can be configured with a diameter/size configured to feed a desired or selected amount or length of yarn per revolution that is sufficient to substantially form a tuft of a predetermined length for forming a tuft or stitch of a desired or selected pile height. In embodiments, the selected yarns exit the yarn tubes and are directed into the passages of their associated needles as the needles are reciprocated into and out of the backing, such that the selected yarns are presented/inserted into the backing and can be engaged with corresponding gauge parts (e.g. being engaged and cut by knives or a cutting blade, or being engaged by other gauge parts, such as loopers, hooks, level cut loop loopers, clips, etc.) for forming stitches or tufts in the backing.

In embodiments, the backing can be moved incrementally, while in other embodiments, the backing can be fed substantially continuously through the tufting zone or region. In some embodiments, such as where the backing is shifted transversely while the needles are maintained in a substantially set position, the backing can be shifted to generally align stitch locations of a pattern being tufted with a selected color of yarns being carried by the needles. The backing can be shifted transversely in various increments or steps, which can include shifting the backing by a distance based on the gauge spacing of the needles, and which, in some embodiments, may not be tied to the gauge spacing of the needles (e.g., the backing can be shifted across distances or lengths that are less than or greater than the gauge spacing between the needles). The backing can be shifted multiple times in both directions across the tufting zone to enable presentation of the selected color yarns to corresponding stitch locations of the pattern, and moved along its path of travel per the pattern steps.

In embodiments, the feeding of the backing can be controlled such that the actual stitch rate at which the backing is fed can comprise an effective process stitch rate that is greater than a desired pattern stitch rate for the pattern being formed. In embodiments, the control of the feeding of the yarns by the yarn feed system and the yarn selection system can be controlled by the control system in conjunction with control of the backing material at a higher effective or actual stitch rate to enable a substantially increased number of penetrations of the needles per inch into the backing material, (e.g., each needle in the thread-up sequence can be inserted at each stitch location of the pattern). Non-selected colors or types of yarns may not be placed in the backing and selected colors or types of yarns can be placed into the backing to form the desired tufts in order to substantially avoid a missing color or type of yarn or a gap being created and shown or otherwise appearing in the pattern fields of the patterned tufted article. The finished patterned tufted article thus can be provided with a number of tufts per inch that substantially matches a desired or prescribed pattern stitch rate, or other numbers of stitches per inch, such that the resultant finished patterned tufted article can be formed with a density of visible and/or retained face yarns or tufts that can approximately match a desired density of the pattern.

In certain scenarios, the ends of the needles maybe configured with a flattened and/or extended cutting surface configured to better cut flat ribbon yarns. For example, in embodiments, the distal ends of the needles can be formed with an altered cutting angle and an increased cutting surface configured to increase a shear angle and shearing surface of the needle for more consistent cutting of flat ribbon yarns used in typical turf applications. In addition, in embodiments, the cutting system can include a series of generally flat knives; or in some embodiments, one or more cutting blades can be used in place of a series of knives.

In embodiments, the knives or cutting blade(s) can moveable between various cutting positions, including a first, retracted position and at least a second, extended cutting position where the cutting edges of the knives or cutting blade(s) contact the cutting surfaces of the needles when the needles penetrate the backing. In embodiments, the knives or cutting blade(s) can be positioned in modules that can be mounted in series along a knife bar and can be selectively moved to their cutting positions by the control system together as a set, in groups, or moved individually when a selected yarn is presented to each stitch location. The knives or cutting blade(s) and can be maintained in a lowered, non-engaging or no-cut position when needles of the non-selected yarns penetrate the backing at such stitch locations.

In some embodiments, the knives or cutting blade(s) can be mounted in a substantially fixed position with respect to the stroke or depth of penetration of the needles into the backing. In embodiments, the knives or cutting blade(s) can be positioned to engage with an associated or corresponding needle. In embodiments, as the needles penetrate the backing, the cutting surfaces of the needles can engage the cutting edges of the knives.

In addition, in embodiments, the feeding of the yarns from the yarn feed system and actuation of the yarn jerkers can be controlled by the control system to be actuated in accordance with a position or sequence of the rotation of the main shaft. In embodiments, a position or sequence of the rotation of the main shaft can be related to a stitch or tuft of the pattern being formed to actuate the yarn jerkers in first and second directions, for example, between retracted and extended positions. For example, in some embodiments, different stitch lengths or amounts of yarn making up a total stitch length of each selected yarn to be fed for forming a tuft or stitch of a desired pile height can be fed at an increased or decreased rate during different portions of the tufting cycle, or at different times based on the rotation or position of the main shaft (e.g., in embodiments, the yarn feed devices of the yarn feed system can be operated to feed different percentages or amounts of yarns in view of where the main shaft is in a revolution thereof, as opposed to feeding a substantially consistent amount of yarn during a revolution of the main drive shaft). In embodiments, such control of the feeding or of different amounts or lengths of the yarns during different portions of the rotation of the main shaft can allow for enhanced color control in the finished patterns/designs.

Various aspects of the present disclosure can include a tufting machine for forming artificial grass or turf products with patterned designs, comprising: at least one needle bar having a plurality of needles positioned therealong, wherein the needles comprise hollow needles; a yarn feed system configured to feed a plurality of yarns to the needles, wherein the needles are moved in a reciprocating movement toward and away from a backing moving along a path of travel through the tufting machine so as to introduce selected yarns into the backing as the needles penetrate the backing to form tufts; at least one shift mechanism for shifting at least some of the needles or for shifting the backing transversely with respect to the path of travel of the backing; and a yarn selection system arranged along a path of travel of the yarns between the yarn feed system and the needles, the yarn selection system configured to retract and/or hold back non-selected yarns supplied by the yarn feed system to one or more of the needles.

In embodiments, the tufting machine can further comprise a cutting system arranged below the backing and including at least one knife or cutting blade configured to cut the selected yarns as selected yarns are carried into the backing with the reciprocation of the needles into and out of the backing.

In embodiments, the tufting machine can further comprise a control system including programming configured to control operation of the yarn feed system for feeding a length of each of the selected yarns to the needles sufficient to form a tuft of predetermined pile height, operation of the yarn selection system, and operation of the at least one shift mechanism to enable presentation of different colors or types of yarns to each of a plurality of stitch locations of a pattern being formed.

In embodiments of the tufting machine, the yarn selection system further comprises a plurality of yarn jerkers adapted to engage the yarns being fed to the needles and a plurality of actuators each linked to at least one yarn jerker and adapted to move the yarn jerkers between their extended and retracted positions; wherein each of the yarn jerkers is moveable between an extended position to allow passage of the selected yarns from the yarn feed system through the needles, and a retracted position to retract and/or hold the non-selected yarns supplied by the yarn feed system within the one or more needles.

In embodiments of the tufting machine, the control system includes programing configured to dynamically advance operation of the yarn feed system and the yarn jerkers or the yarn selection system in advance of a next stitch placement step of a pattern being formed.

In embodiments of the tufting machine, the at least one needle bar can comprise a series of openings spaced therealong and in communication with a passage extending through a corresponding needle; wherein the yarns are directed through the openings in the at least one needle bar and into the passages of the needles.

In some embodiments of the tufting machine, the needles are arranged along the at least one needle bar at a selected gauge spacing based on a gauge of an artificial grass or turf product of the tufting machine.

In some embodiments, the tufting machine can further comprise a series of yarn tubes mounted along an upper surface of the at least one needle bar, each of the yarn tubes in communication with a corresponding needle positioned along the at least one needle bar; and an air induced yarn feed apparatus coupled to an air supply and configured to direct flows of air through the yarn tubes to assist feeding of the yarns through the yarn tubes and the needles. In other embodiments, yarn tubes may not be used.

In embodiments of the tufting machine, the shift mechanism comprises a rack and pinion shift mechanism.

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

In embodiments of the tufting machine, the needles each comprise a body having an internal passage defined therein, a first end received within a needle bar, and a second end terminating at a tip and having a flattened cutting surface configured for cutting flat ribbon yarns or filaments.

In embodiments of the tufting machine, as the needles are reciprocated into and out of the backing, the feeding of the selected and non-selected yarns is controlled by the yarn feed system and the yarn jerkers are moved between the retracted and extended positions to enable insertion of the selected yarns into the backing to form loop pile or cut pile tufts of the selected yarns in accordance with a pattern being tufted.

In other aspects, a tufting machine comprises: a plurality of needles configured to penetrate a backing; a yarn feed system configured to selectively feed a plurality of yarns to the needles; a yarn selection system including a plurality of yarn jerkers adapted to be moveable between an extended position to allow passage of selected yarns from the yarn feed system to the needles, and a retracted position to retract and/or hold back non-selected yarns supplied by the yarn feed system to one or more of the needles; and at least one shift mechanism for shifting the needles across the backing or shifting the backing with respect to the needles; wherein the needles comprise hollow needles, each having a first end and a second end, with a passage defined between the first and second ends through which one or more yarns are fed; and wherein as the needles are reciprocated into and out of the backing, the feeding of the selected and non-selected yarns is controlled by the yarn feed system and the yarn jerkers are moved between the retracted and extended positions to enable insertion of the selected yarns into the backing to form loop pile or cut pile tufts of the selected yarns in accordance with a pattern being tufted.

In embodiments, the tufting machine can further comprise a cutting system including at least one knife or cutting blade configured to cut the selected yarns to form the tufts of yarns in the backing.

In embodiments, the tufting machine can further comprise a control system having programming configured to control operation of the yarn feed system for feeding the selected yarns to the needles, and programing configured to dynamically advance feeding of the yarns by the yarn feed system and movement of the yarn jerkers between the extended and retracted positions in advance of a next stitch placement step of a pattern being formed.

In embodiments, the tufting machine can further comprise at least one needle bar along which the needles are mounted; wherein the needles are arranged along the at least one needle bar at a selected gauge spacing based on a gauge of an artificial grass or turf product produced by the tufting machine.

In embodiments, the tufting machine can further comprise an air supply and an air induced yarn feed apparatus coupled to an air supply for directing the yarns through the needles.

In embodiments of the tufting machine, the at least one shift mechanism can comprise a rack and pinion shift mechanism.

In embodiments of the tufting machine, the second end of each of the needles includes a tip and having an opening through which the one or more yarns exit the needle and a flattened cutting surface configured for cutting flat ribbon yarns or filaments.

In embodiments of the tufting machine, the tufting machine is configured to produce tufted turf or artificial grass products with integrated designs (e.g., logos) or panels of tufted turf or artificial grass products that include portions of larger designs and that can be attached together to form a sports carpet or an artificial grass or turf field.

According to other aspects, a method is provided, comprising: moving a backing along a path of travel; feeding a plurality of yarns from a plurality of yarn feed devices along a path of travel to each of a plurality of needles; reciprocating the needles into and out of the backing; shifting the backing or shifting the needles in a direction transverse to movement of the path of travel of the backing; selectively controlling the yarn feed devices to substantially stop or slow feeding of non-selected yarns to the needles; actuating one or more yarn jerkers to engage and hold or pull back the non-selected yarns such that the non-selected yarns are substantially maintained within the needles; selectively controlling the yarn feed devices and yarn jerkers as movement of the backing along its path of travel is controlled to enable presentation of different yarns to each of a plurality of stitch locations; and forming a plurality of tufts of selected yarns in the backing; wherein the yarns comprise artificial grass or turf yarns including one or more colors so as to form a tufted artificial grass or turf product having one or more of a design, accent feature, logo, or portions thereof integrated therein.

In embodiments, shifting the backing or shifting the needles comprises shifting a backing support over which the backing is moved.

In embodiments, the method can comprise moving at least one cutting blade into engagement with a cutting surface of each needle as the needles penetrate the backing and cutting the selected yarns to form the tufts of the selected yarns in the backing.

In another aspect, a tufted artificial grass or turf product can be provided, comprising a backing; and a plurality of spaced tufts of artificial grass or turf yarns formed in the backing so as to define patterned areas or a pattern being formed along the backing; wherein the artificial grass or turf yarns include a plurality of different colors; wherein only selected colors of the artificial grass or turf yarns to be shown at each stitch location of the pattern being formed are presented for cutting and are retained in the backing; and wherein the artificial grass or turf yarns are arranged in a thread-up sequence having at least two artificial grass or turf yarns of different colors and two artificial grass or turf yarns of a same color.

Accordingly, embodiments of tufting machines or systems and methods forming patterned tufted products (such as carpets, rugs, artificial grass or turf, and/or other tufted products) in which patterned designs (such as, for example, logos, pictures, fields of varying colors, and combinations thereof) that are directed to the above discussed and other needs are disclosed. The foregoing and other advantages and aspects of the embodiments of the present disclosure will become apparent and more readily appreciated from the following detailed description, taken in conjunction with the accompanying drawings. Moreover, it is to be understood that both the foregoing summary of the disclosure and the following description are exemplary and intended to provide further explanation without limiting the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of this disclosure, and together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the exemplary embodiments discussed herein and the various ways in which they may be practiced.

FIG. 1A is a perspective view of an embodiment of a tufting system or apparatus according to the principles of the present disclosure.

FIG. 1B is a perspective view of an embodiment of a tufting system or apparatus according to the principles of the present disclosure.

FIG. 1C is a perspective view of a portion of the tufting zone of an embodiment of a tufting system or apparatus schematically illustrating the use of a backing shift mechanism according to the principles of the present disclosure.

FIGS. 2A-2H illustrate embodiments of a tufting zone or region of a tufting system or apparatus according to the principles of the present disclosure.

FIGS. 3A-3B illustrate an embodiment of hollow needles of a tufting system or apparatus according to the principles of the present disclosure.

FIG. 3C is a perspective view schematically illustrating a needle stroke support assembly of a tufting system or apparatus according to the principles of the present disclosure.

FIG. 3D is a cross-sectional view of the needle stroke assembly of FIG. 3CFIG. 3E is an exploded perspective view of the needle stroke assembly of FIGS. 3C-3D.

FIGS. 4A-4D illustrate embodiments of a yarn feed system for a tufting system or apparatus according to the principles of the present disclosure.

FIGS. 5A-5C illustrate an embodiment of a yarn selection system for a tufting system or apparatus according to the principles of the present disclosure.

FIGS. 6A-6B illustrate an embodiment of a cutting system for a tufting system or apparatus according to the principles of the present disclosure.

FIG. 6C is an exploded perspective view of a cutting system including individually actuatable knives for a tufting system or apparatus according to the principles of the present disclosure.

FIGS. 7A-7C illustrate an embodiment of knife modules for a cutting system tufting system or apparatus according to the principles of the present disclosure.

FIGS. 8A-8C illustrate examples of a multi-color tufted fabric and back stitches formed by a tufting system or apparatus and method according to the principles of the present disclosure.

FIGS. 9A-9B illustrate an example of a portion of a sport carpet, in particular showing an example embodiment of a tufted turf or artificial grass field with a plurality of colors and designs integrally formed as part of the tufted or artificial grass field and back stitching thereof, using a tufting system or apparatus and method according to principles of the disclosure.

FIGS. 10A-10B illustrate an example of a multi-color tufted fabric and back stitching thereof, in particular showing an example of a sports carpet using flat yarns and/or filaments, formed by a tufting system or apparatus and method of tufting according to the principles of the present disclosure.

FIGS. 11A-11B illustrate an example of a multi-color tufted fabric and back stitching thereof, in particular showing an example of a shag style carpet or rug, formed by a tufting system or apparatus and method of tufting according to the principles of the present disclosure.

FIG. 12 illustrates an example of a multi-color tufted artificial turf or grass product with a seamless design formed by a tufting system or apparatus and method of tufting according to the principles of the present disclosure.

DESCRIPTION

The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, it is to be understood that this disclosure is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, and as such can, of course, vary. It is also to be understood that unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs, and that the terminology used herein is for the purpose of describing particular aspects of the systems, features, elements, methods, and example embodiments discussed herein only, and is not intended to be limiting. Accordingly, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.

By way of example, and used throughout, the singular forms “a” and “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a processor” can include two or more such processors unless the context indicates otherwise. The terms “or” and “and/or” as used herein are to be interpreted as inclusive or meaning any one or any combination.

In addition, as used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” or any other variation thereof, and are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive condition.

Spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper,” and the like may be used herein for case of description to describe one element's or feature's relationship to other element(s) or feature(s) as illustrated in the figures. It will be understood that spatially relative terms are intended to encompass different orientations of a device, system, or component in use or operation in addition to the orientation depicted in the figures.

Dimensional information in the following description further should be understood as intended to encompass variations in dimensions that normally occur in production; and terms such as “approximately,” “about,” and “substantially” may be used to qualify dimensional information in the following description. It will be recognized that some variations in dimensions provided with respect to various features can occur without affecting their function or usability. Ranges further can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect.

The terms “tuft” and “stitch,” as used herein, encompasses both cut pile tufts or stitches and loop pile tufts or stitches of yarns, and the term “tufting” encompasses both the act of forming a cut yarn or cut pile stitch or tuft of yarn and the act of forming a loop of yarn or loop pile stitch or tuft of yarn.

The term “yarn” as used herein, encompasses yarns, threads, filaments, fibers, and/or combinations thereof for use in forming tufted products, which can include, without limitation, carpets (e.g., including cut pile, loop pile, cut and loop pile, shag, etc.), rugs, artificial grass or turf, and other, similar tufted products. By way of example, and not limitation, such yarns could include yarns of natural fibers such as cotton, wool or other similar fibers, as well as synthetic fibers or filaments such as nylon, polypropylene, acrylic, and/or other polymer materials, or combinations thereof; and can include two or more yarns that are fed to each needle. For example, in the production of sports carpets, such as artificial turf or grass, the yarns can include a combination of at least one filament (e.g., a polymer monofilament) and a ribbon yarn having a flattened construction.

Referring to the drawings, in which like numerals indicate like parts throughout the several views, FIGS. 1-6D illustrate exemplary embodiments of a tufting system or apparatus, and various operative components and/or features thereof, constructed in accordance with the principles of the present disclosure. FIGS. 8A-12 illustrate examples or tufted products, and examples of back stitches thereof, produced using the tufting systems or apparatus and methods of the present disclosure. In various embodiments, such tufted products can include carpets and rugs (for example, shag carpets and loop or cut pile tufted carpets or rugs of selected pile heights), sports carpets including, but not limited to artificial turf or grass for fields and/or for various landscaping applications, as well as other types of tufted products.

In some example embodiments, such as shown in FIGS. 1A-2H, the tufting system or apparatus can comprise a tufting machine 10 that generally can include a plurality of needles 12 that can be mounted in series along a needle bar 11 The plurality of needles, in embodiments, can comprise hollow needles. The tufting machine 10 (FIGS. 1A-1B) further can include other operative components such as a needle bar drive assembly or system 20, a backing feed system 25, yarn feed system 60, yarn selection system 70, and a cutting system 80, as well as a control system 15 for controlling the operations thereof. In embodiments, the needles 12 can comprise hollow needles configured for penetrating a backing material B to deliver and/or implant a series of yarns Y fed through each needle into the backing B as the backing B moves along a path of travel P (FIGS. 1A-1B) through the tufting machine 10 for forming a plurality of stitches or tufts of yarns therein. In addition, in embodiments, the tufting machine can include or can be connected to an air supply such as a compressor or blower that supplies pressurized air to blow the yarns into and through the needles, and in embodiments, for driving operation of other components of the tufting machine.

In embodiments, the tufting machine 10 can feed a series of different colors and/or types of yarns to each of the needles, which yarns can then be selectively implanted or tufted into the backing materials to form tufted patterned articles. In embodiments, the tufts of yarns generally can comprise cut pile tufts (though in other embodiments, loop pile tufts also could be formed). In some embodiments, the tufts can be formed with different or varying pile heights, to provide texturing or other pattern effects. In some embodiments, various color and/or type yarns can be selectively presented by the needles to one or more of a plurality of stitch locations of a pattern being tufted for forming tufted articles such as carpets, rugs, artificial turf or grass, and other tufted products with a tufted patterned design.

In embodiments, such tufted products can be formed with selected designs (e.g., a logo or a portion of a logo, text, markings, or other designs), which, in embodiments, can include, without limitation, fields or portions of a designed pattern having yarns of different colors or types, texturing, and/or other pattern effects. Such selected designs can be integrated as part of the tufted product during tufting, rather than having to separately form the design from the rest of the field and thereafter attach the design to the field (e.g., cutting and sewing the separately created design into the tufted turf field).

For purposes of illustration, and not limitation, exemplary embodiments of the systems and methods of the present disclosure are shown and discussed with regard to the formation of tufted products such as sports carpets, including, in embodiments, patterned artificial grass or turf products, in which patterned designs, such as, for example, text, logos, pictures, fields of varying colors, and combinations thereof, which can be produced within a tufting zone or space defined with a tufting machine frame. In addition, in the present example embodiments illustrated and discussed herein, the yarns are shown as artificial grass filaments, which generally can be formed from a polymer or plastic material and can have a substantially flat configuration that can mimic the look and feel of grass or turf after installation. It will, however, be understood by those skilled in the art that other types of yarns also can be used.

For example, in embodiments, such as illustrated in FIGS. 9A and 12, such tufted products can be formed as panels having a pattern or designs integrated therein, and which can be attached together as part of a larger tufted product. Examples could include forming sections or strips of artificial grass or turf for an athletic field using a base color grass filament or yarn (typically green though other colors can be used), and additional colors of yarns for a design or portion of a design, such as a team or sponsor logo, hash or yard markings, sideline markers, etc. The panels can be easily matched and connected (seamed together) to form a completed tuft installation with the design or pattern features integrated therein.

It will, be understood that the patterned tufted artificial turf or grass products shown in, for example, FIG. 12, can be formed in much larger sections or fields that can incorporate substantially the entire multi-color patterned design, such as the eagle and flag design shown incorporated within the green artificial turf or grass field, by utilizing a large/full size tufting machine configured and operated to perform embodiments of the method of forming a tufted product according to the principles of the present disclosure. Thus, substantially pattern designs can be tufted within an artificial turf or grass field or sections thereof with a transition or transitions between the designs and the remainder of the artificial turf or grass field being substantially seamless, and without having to separately form the design and then cut the turf field and sew the design into the field to create the finished patterned artificial turf or grass field.

It also will be understood that other tufted products, including carpets, rugs, etc. also can be formed using the tufting system or apparatus and methods of the present disclosure. For example, shag carpets or other types of carpets or rugs with increased pile heights can be formed with a variety of designs, images, logos, etc. including multiple colors or types of yarns.

In embodiments, such as illustrated FIGS. 2A-2C, 2E and 3A, the needles 12 can be mounted along the needle bar 11 in an in-line arrangement with the needles arranged at a desired or selected spacing, (e.g., a spacing of about ½″ to about 1″ or other spacing). In some embodiments, the needles can be arranged according to a desired gauge or spacing (e.g., in some embodiments, a gauge spacing of about ⅜″ or greater), including various half-gauge or other spacings. In addition, in other embodiments, the needles can be arranged in other configurations, such as being staggered along one or two needle bars. Also, while a single needle bar is illustrated in some embodiments where the needles generally can be arranged in inline arrangements along the needle bar, the disclosure is not limited to tufting machines with only one needle bar, or to needle arrangements including only a single, inline row of needles.

In embodiments, the needles can be arranged at spacings that can be selected based on a tufting gauge for the tufted products. For example, in embodiments, the needles can be arranged at gauge spacings that match the selected gauge of the tufting machine, such that for producing for tufted products with, e.g., a desired or selected gauge of ⅜″, the needles can be arranged at a gauge spacing of approximately ⅜″, for tufted products with a desired or selected gauge of ½″, the needles can be arranged at a gauge spacing of approximately ½″, for tufted products with a desired or selected gauge of ¾″, the needles can be arranged at a gauge spacing of approximately ¾″, and for tufted products with a desired or selected gauge of 1″, the needles can be arranged at a gauge spacing of approximately 1″. In other embodiments, gauge spacings of approximately ¼,″ ⅜″, ½″, ⅝″, ¾″, ⅞″, 1″, 1¼″, 1⅜″, 1½″, 1⅝″, 1¾″, 1⅞″, and/or 2″ can be used. Thus, in embodiments, the needle bar can be configured with the needles arranged at a substantially true gauge spacing that generally matches the desired or selected gauge of the tufting machine.

As shown in FIGS. 1A-1B, in embodiments, the tufting machine 10 generally includes frame 16 having an upper portion 17A and a lower portion 17B, a tufting zone or area T defined therethrough, and backing support or shuttle 18 over which the backing B is moved, and which can be located along the tufting zone. The tufting machine 10 further will include a main drive shaft 19 (FIG. 1A) located along the frame 16, typically extending laterally thereacross. In embodiments, the main drive shaft 19 can be linked to a needle bar drive assembly or system 20 for driving reciprocation of the needles 12 mounted therealong in a reciprocating (up and down) motion to cause the needles 12 to penetrate into and out of the backing B for inserting tufts of yarns into the backing as the backing moves through the tufting zone or region.

In embodiments, the main drive shaft 19 can be driven by one or more electric motors M operatively connected to opposite ends of the main drive shaft and mounted to opposite ends of the frame of the tufting machine for driving rotation of the main drive shaft. The one or more motors can be controlled by a control system 15 for the tufting machine, with the speed of rotation and position of the main drive shaft being monitored by the control system 15, e.g., by a sensor such as an encoder. In operation, each rotation of the main drive shaft can cause the needles to penetrate and then withdraw from the backing. In other words, each rotation of the main drive shaft can cause one needle reciprocation cycle, also referred to as a tufting cycle, which includes a downstroke and an upstroke of the needles. In embodiments, the control of various operational systems or components further can be tied to the rotation or position of the main drive shaft.

As indicated in FIGS. 2C and 2G, in embodiments, at least one presser foot 22 can be provided along the tufting zone adjacent the needles. The presser foot can comprise a substantially flat plate 23 with a forward edge 24 that, in embodiments, can have a ridged or corrugated configuration with a plurality of recesses 21 defined therealong, as indicated in FIGS. 2C, 2D, 2G, and 3A-3B. As the needles 12 are reciprocated into and out of the backing B, they can be received within the recesses 21, and can be guided into and through the backing along a substantially straight path of travel. In embodiments, the recesses 21 can have an open end and can be further configured to help direct or guide the needles therethrough when the needles are shifted and reciprocated.

In other embodiments, the presser foot 22 can have a substantially straight or flat forward edge 24 (e.g., without recesses or ridges therealong). The needles 12 can be reciprocated into and out of the backing without having to be received in recesses 21.

As illustrated in FIGS. 1A-1B, the backing B may be advanced longitudinally past the reciprocating needles by the backing feed system 25 along its path of travel or feed direction P. In embodiments, the backing feed system 25 can comprise feed rollers 26, which can comprise spike rolls, and which can be driven by motors 27 (e.g., servo or stepper motors, or other drives). In addition, in some embodiments, the backing feed system also can include gear reducers coupled to the backing feed rolls to help control the rotation thereof, and thus the feeding of the backing B along its path of travel P. The backing feed system 25 generally can be controlled (e.g., by the control system 100) and can, in embodiments, be provided with a backing feed controller programmed and configured to feed the backing B (FIG. 2A) under tension beneath the needles 12 and through the tufting zone T of the tufting machine 10.

Alternatively, in embodiments, the backing feed rolls can be driven off of the main drive shaft, such as through the use of timing belts or other linkages connecting the backing feed rolls to the main drive shaft and/or its motor, so as to drive the backing feed rolls substantially directly off of or by the operation of the main drives shaft.

The backing feed system 25 can be controlled to move the backing B in a controlled movement, e.g., in embodiments, in a stepping motion. As the needles 12 are reciprocated into and out of the backing, a series of yarns Y can be placed or inserted into the backing by the needles to form the tufts of yarns therein. Optionally, the backing can be fed substantially continuously through the tufting zone.

In embodiments, the needle bar drive assembly or system 20 for reciprocating the needles 12 can include a series of bearing assemblies 31 and a series of push rods 32 coupled to the main shaft so as to be driven in a reciprocating, substantially up and down motion or cycle, in a first or vertical direction indicated by arrows 33/33′, as the main drive shaft 19 is rotated by operation of its one or more drive motors. As further indicated in FIGS. 2B and 2G and 3C, in embodiments, the needle bar 11 can be coupled or connected to each of the series of push rods 32 by push rod feet 32A such that the needle bar will carried or moved in vertically reciprocating motion or cycle with the movement of the push rods 32 by operation of the main drive shaft 19 of the tufting machine 10. In addition, as indicated in FIG. 3D, the push rod can be connected to the push rod foot by a bearing assembly 30. As a result, the needles 12 mounted along the needle bar 11 will be carried in a reciprocating motion or stroke into and out of the backing B, between a raised or top position, and a lowered or bottom position penetrating through the backing B.

In embodiments, the needle bar 11 can be reciprocated along its stroke to carry the needles 12 into and out of the backing B, while remaining generally fixed against movement in a transverse direction. For example, in some applications, the needles can be arranged at a spacing based on a gauge of the tufting machine, and, in embodiments, the tufted product being produced, and the lateral position of the needles with respect to the movement of the backing B along its path of travel P being substantially fixed. The backing B can be shifted beneath the needles as the needles are reciprocated and maintained in their lateral position, to form patterned tufted fabrics.

As further indicated in FIGS. 2B-2E, 2G, and 3C, in other embodiments, the needle bar 11 generally can be slidably coupled or connected to the push rods 32 of the needle bar drive assembly or system 20, such as by a series of sliding brackets 34 of the bearing assemblies 31. In embodiments, the needle bar 11 can be coupled to guide rails 36 by brackets or linkages 36A, which can be slidably received within the brackets 34 that can be formed with or as a part of the push rod feet 32A (FIG. 2H) to which the ends of the push rods are mounted. The guide rails 36 can guide a transverse or lateral shifting movement of the needle bar 11 as indicated by arrows 37 and 37′ (FIG. 2E), in instances where the needles are shifted or moved transversely across the backing B under control of a shift mechanism.

In one example embodiment, the needle bar 11 can be mounted to or slidably supported in engagement with the push rods 32 of the needle bar drive assembly or system 20 by a series of linear bearing assemblies that can include a series of linear bearings. The needles 12 thus can be reciprocated vertically in a first direction, as indicated by arrows 33/33′, penetrating into and out of the backing B. the needles 12, in addition to shifting of the backing B, can be shifted in transverse directions, as indicated by arrows 37 and 37′.

In addition, in embodiments such as illustrated in FIG. 3C, a series of needle stroke support assemblies 90 can be provided for supporting the push rods 32 during their vertical, reciprocating movement during each needle stroke. While an embodiment showing one needle stoke assembly 90 with one push rod 32 is illustrated, it will be understood that multiple push rods and needle stroke assemblies generally will be utilized in the tufting machine, and further will be understood that the needle stroke assemblies can be used with various types of tufting machines, and are not limited to machines with only hollow needles.

In embodiments, as illustrated in FIGS. 3C-3E, each needle stroke support assembly 90 can include one or more upper support plate 91a and a strut or lower support plate 91b that can be mounted to a portion of the tufting machine frame. For example, in some embodiments, the upper support plate 91a can comprise a substantially flat plate that can be located along an underside portion of the head or upper frame portion of the tufting machine along the tufting zone, with the lower support plate 91b mounted to a lower surface of the upper support plate 91a and acting as a support or brace for the needle stroke support assembly, as indicated in FIGS. 3D-3E.

In embodiment, the upper support plate 91a further can include an opening 92 through which the push rod 32 is received. In the illustrated embodiment, the push rod 32 can be received in a bearing assembly 30 that can be mounted with the opening 92 of the upper support plate to secure the push rod within the upper support plate and help support the push rod during its linear, vertically reciprocating motion during each needle stroke. In embodiments, the bearing assembly 30 can include one or two sections, for example, as shown in FIG. 3D, including an upper section located on an upper surface of the upper support plate, and a lower section along the lower surface of the upper support plate, and can be attached together.

As shown in FIGS. 3D-3E, a push rod foot 32a adapted to receive a distal end of the push rod 32 therein will be positioned below the upper support plate 91a and can be configured to engage and mount along the needle bar 11 so as to attach the push rod to the needle bar. In embodiments, the push rod foot can comprise a push rod foot assembly 93 that can include the push rod foot 32a, a collar or clamp 94 mounted along an upper surface of the push rod foot, and which will be adapted to receive and clamp the distal end of the push rod therein to secure the push rod to the push rod foot. In embodiments, the collar or clamp can be mounted to the upper surface of the push rod foot with an adapter plate being positioned therebetween as needed.

In addition, in embodiments, each needle stroke assembly 90 can further include a first guide 95 mounted along the lower mounting plate and configured to engage with a second guide 96 that can be mounted to the push rod foot as shown in FIG. 3E. In embodiments, the first guide 95 can comprise a linear bearing slide and the second guide 96 can comprise a linear bearing guide that rides along the linear bearing slide as the push rod is reciprocated during a needle stroke. In other embodiments, the first guide or the second guide) can include a track formed from a reduced friction material that can be received in a channel or similar guide having a reduced friction surface. In some embodiments, the push rod foot can include a linear bearing slide or track and the lower support plate can include a linear bearing guide.

In some embodiments, an adapter 97 can be mounted along one or both of the pusher rod foot and the lower plate. For example, as shown in FIGS. 3D-3E, an adapter, which, in embodiments, can include a plate, can be mounted to a rear surface of the pusher rod foot for mounting the second guide 96 (e.g., a linear bearing channel) to the pusher rod foot.

In embodiments, the needle stroke assemblies 90 will be configured to guide the linear, vertically reciprocating movement of the push rods 32, and thus the needle bar 11 during each stroke of the needle bar. In embodiments, as indicated in FIG. 3D, the push rods 32 extend through the bearing assemblies 30 mounted within the openings 92 of the upper support plates 91a of the needle stroke assemblies and are received within the push rod feet 32a. In embodiments, each of the push rods 32 can be supported by the upper support plate 91a and by the engagement of the second guide 96 attached to their push rod feet with the first guide 95 mounted along the lower support plate 91b, which can help guide the linear movement of the push rods 32 during each needle stroke.

Still further, in embodiments, the support and guiding of the movement of the push rods during each needle stroke by the needle stroke support assemblies can act to reduce pressure or force transmitted to the pusher rods by engagement of the knives with the needles. Generally, the forces generated by the striking of the knives against the needles to form cut pile tufts (particularly when cutting yarns such as used to form artificial turf or grass) creates pressure that is applied to the pusher rods, and which, over time, can cause excessive wear and/or damage to the bushings of the push rods, and can cause vibration or other undesired movement of the pusher rods. The needle stoke assemblies 90 can help reduce the pressure or forces applied to the pusher rods and can help guide their linear movement to enable increased productions speeds and longer life of the push rods and their bearing assemblies. In some embodiments, the needle stroke support assemblies further can facilitate reciprocation of the needles over an extended or longer needle stroke to enable the formation of tufts having greater pile heights.

In various embodiments, the support plate 91a can have different dimensions, e.g., different thicknesses, or configurations to accommodate movement of the push rods along different length needle strokes. In addition, in some embodiments, the support plates could be slidably mounted to the tufting machine frame and can be configured to be moveable with the movement of the push rods and needle bar.

In some embodiments, a shift mechanism 40 can be coupled to the needle bar 11 and can be controlled to shift or move the needles transversely with respect to the path of travel P (FIG. 2A) of the backing B through the tufting machine 10. In addition, in some embodiments, multiple shift mechanisms can be used (e.g., positioned on opposite sides of the tufting machine) for shifting the needles 12 transversely across the backing B to form a tufted pattern. In embodiments, the shift mechanism(s) 40 can be driven by one or more servo motors or other actuators under control of the control system 15. For example, in embodiments, the shift mechanisms(s) 40 can include cam or motor drive shifters, a servo motor driven rack and pinion shift mechanism (such as Card-Monroe Corp.'s Smart Tech Shifter™), or other shifters.

In embodiments, the needles 12 can be shifted/moved transversely in a desired or prescribed number of shift steps or jumps, that can, for example, be based upon a gauge spacing between each of the needles 12, or at some multiple thereof to form a desired pattern. For example, in embodiments, the needles can be shifted by one, two, or more gauge increments, or portions thereof, according to pattern instructions for a tufted pattern being formed. In addition, in some embodiments, the shift mechanism(s) 40 can shift the needles by other selected or desired step lengths or distances, including moving the needles by ½ gauge or other off-gauge steps or spacings.

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

As generally illustrated in FIGS. 1B-1C, the shift mechanism(s) 40 can be coupled to the shuttle 18 or backing support 18 over which the backing B passes and is supported as it is fed though the tufting machine along its path of travel P. The shift mechanism(s) 40 can shift the backing B transversely with respect to its path of travel P. For purposes of illustration, one shift mechanism 40 is shown in FIG. 1C, though it will be understood that multiple shift mechanisms also can be used and mounted on one or both ends of the tufting machine.

In embodiments, the shuttle 18 can comprise a carriage 38 that can be coupled to the shift mechanism(s) 40, with one or more plates 41 mounted within the frame, or, in embodiments, being integrated with the frame 38. In some embodiments, at least one plate 41 can be positioned along each side of the carriage 38 and can have an upper surface 41a on which the backing B is supported. In other embodiments, additional plates can be mounted along a lower portion of the shuttle 18.

In some embodiments, such as illustrated in FIG. 1C, the shuttle 18 can be incorporated as part of the backing feed system 25. For example, in embodiments, the frame can include a pair of plates or supports 39 arranged so as to extend across the tufting zone of the tufting machine, and the backing feed rolls 26 can be mounted to the supports 39 along upstream and downstream ends 38a/38b of the frame 38 of the shuttle 18. In some embodiments, additional backing feed rolls (e.g., additional spike rolls) also can be positioned along the shuttle 18 adjacent the plates 41. The ends 26a of the backing feed rolls 26 can be coupled to motors or can be linked to the main drive shaft of the tufting machine for driving rotation of the backing feed rolls.

As further illustrated in FIG. 1C, in embodiments, bearing guides 42 can be mounted along the frame 38. In embodiments, the bearing guides 42 can be mounted to a lower surface of the plates 41. In embodiments, the bearing guides 42 can comprise linear guides configured to engage with corresponding slides or bearings mounted along the frame to guide the shuttle 18 as the shuttle is moved by the shift mechanism(s) 40 to shift the backing transversely across the tufting zone. In addition, in some embodiments, bearing guides 42 and/or their corresponding slides can be mounted to the frame or to additional plates positioned below the shuttle 18.

In embodiments, as indicated in FIG. 1C, the frame 38 of the shuttle 18 can be coupled to a first or proximal end 43a of a rod or drive shaft 43 that extends through the frame of the tufting machine 10 and which can be coupled at its second or distal end 43b to the backing shift mechanism 40. In embodiments, the drive shaft 43 can comprise more than one section or part, and can be coupled to the shuttle 18 and/or the shift mechanism(s) 40 by mounting blocks, brackets, or other, similar connectors. As shown in FIGS. 2C and 2D, in embodiments, the backing B generally will be engaged between the upper surface of the shuttle 18 and the presser foot 22 during a tufting operation as the needles 12 penetrate the backing B. The backing B can further be held in position against the upper surface of one or plates 41 as the backing B is shifted transversely by the shift mechanism(s) 40. In embodiments, the backing B can be shifted in increments based upon a gauge spacing of the needles, or can be based on a multiple or a fraction of such gauge spacing of the needles 12 to reposition the backing for insertion of a desired color or type of yarn at a selected stitch location. After the tuft or stitch is formed in the backing B and the needles 12 retracted, the backing B can be moved in the direction of its path of travel P. For example, the backing B can be shifted transversely with respect to the needles 12, in addition to being fed or moved longitudinally along its path of travel P through the tufting machine 10 to enable the presentation of multiple different colors and/or types of yarns approximately within a selected pixel or stitch location. In some embodiments, the shifting of the backing further can enable retention of different numbers of tufts of yarns in the longitudinal and transverse directions of the pattern as needed.

In addition, in embodiments, the backing B can be shifted transversely by a less than a full gauge increment, e.g., the backing can be shifted by ½, ¼, ⅜ or other portion of the gauge spacing of the needles 12. By way of example only, the gauge spacing of the needles 12 can be set at ⅜″ to ½″ and the backing B can be shifted by a ¼″ to 7/16″ or other fraction of a gauge increment for the pattern.

As illustrated in FIGS. 2B-3B each of the needles 12 can be arranged along one end of a path of travel or pathway 44 along which the yarns are fed from the yarn feed system to and through the needles for insertion into the backing B. In embodiments, each of the needles 12 can comprise a hollow needle having a body 45 which can be formed as a hollow tube having, for example, a length of approximately three-four inches or greater. The body 45 can define a hollow passage or channel 46 along which the yarns Y are fed. Other lengths of the body 45, (e.g., 4-6 inches or more or less than 3-4 inches) also can be used. In addition, in embodiments, multiple yarns can be fed through passages 46 of each of the needles. For example, 1 to 3 yarns can be fed together through each needle, though in some embodiments, additional numbers of yarns also can be fed. The body 45 of each needle further generally can include a first or proximal end 47 that can be received within an opening along a lower surface of the needle bar 11, and can communicate with an internal passage and/or with the yarn tubes for receiving a yarn, and a second or distal end 48 at the opposite end of the body 45.

In embodiments, the needles 12 further can be formed with an extended length to provide an elongated passage, and/or to enable an increased length of the yarns inserted into the backing (e.g. such as to form tufts having an increased pile height) as needed. Thus, in embodiments, tufts of yarns having different pile heights, and which can include multiple yarns within the same tuft can be formed, and in some embodiments, loop pile tufts of yarns can be formed, in addition to or in place of cut pile tufts formed in the backing.

As indicated in FIG. 3B, in embodiments, the distal end 48 of each of the needles 12 can terminate at a tip 49 and can define an opening 50 which, in embodiments, can be substantially oval shaped, and through which the yarns Y are allowed to exit the internal passage of the needles 12. In embodiments, the opening 50 can have a cutting surface 51 formed thereabout, which can be configured to provide a shearing surface against which the yarns can be cut. For example, in embodiments such as illustrated in FIG. 3B, the distal end 48 of the needles 12 can include a cutting surface 51 with a flattened cutting angle that is formed about the opening 50. The opening 50 further can include a reduced area or recess 52 at an upper portion thereof, opposite the tip 49 of the needle. In embodiments, the recess 52 and cutting surface 51 of each of the needles 12 can be configured to provide a larger and substantially flattened shearing surface against which yarns, such as artificial grass or turf yarns or filaments or multiple combined ends of yarns, can be engaged by the cutting system.

In embodiments such as for forming turf fields, landscaping fabrics, etc. the yarns can comprise artificial grass or turf yarns. Such artificial grass or turf yarns can generally include one or more filaments that, in some embodiments, can be combined with one or more ribbon yarns. The artificial grass yarns also typically can be formed from various polymer materials and can have a substantially flat configuration to substantially replicate blades of grass. In embodiments, the configuration of the recess 52 and of the opening 50 formed at the distal end 48 of the needles 12 and the cutting surface 51 defined thereabout generally can be configured to guide and present such artificial grass filaments or yarns being fed through each needle in a substantially flat, straight arrangement to enable a cleaner cut of such artificial grass or turf yarns to help avoid fraying or other issues if the yarns are not cut cleanly.

In embodiments, as generally illustrated in FIGS. 2F-2H, the yarns can include multiple yarns Y (e.g., two or more ends of yarns Y) being fed to each of the needles 12 for insertion together into the backing B. In embodiments, multiple yarns can fed directly into the passage 46 of each needle. As shown in FIG. 2F, in embodiments, the needle bar 11 can be configured with the needles 12 arranged at a selected gauge spacing and with openings 57 of a passage 58 formed along the top of the needle bar 11 and in communication with the upper ends or the needles 12. Each of the yarns Y can be fed directly into the passage 46 their associated needle through the openings 57. For example, FIG. 2F shows two ends of yarns being fed directly into each opening 57 for feeding into the needles 12.

In addition, in embodiments, a yarn guide 53 (FIGS. 2G-2H) can be mounted adjacent the needle bar 11. The yarn guide 53 can have a plurality of openings 54 defined therealong which can be configured to receive two or more yarns Y therethrough. The needle bar 11 further can include a series of air passages 55 defined therethough, with openings 55A arranged on each side of the openings 57 leading to the internal passage 58 formed through the needles 12 for supplying flows of air to the needles.

In embodiments, the air passages 55 can be connected to an air induced yarn feed apparatus 59 of the yarn selection system 70, which can include a plurality of air injectors 67 that can connect to the openings 55A or the air passages 55 via air lines 68 that are coupled to an air supply. The air injectors 67 supply flows of air into the needle bar 11 which are directed along the air passages 55 and into the needles 12 as the yarns (e.g., 1-3 or more yarns per needle) are fed into and through the passage 46 of the needles to deliver the yarns into the backing B. The air flows can be selectively controlled by the control system to feed air as needed for delivery of the yarns into the backing for forming tufts of the yarns.

In embodiments, such as where multiple yarns Y (e.g., two or more yarns) are being tufted by each needle 12, the feeding of air from both sides of the needle bar can help deliver each of the yarns through the needles at substantially the same time and with a substantially consistent, and in embodiments, the same delivery velocity. In addition, the yarns can be consistently fed to their associated needles without the use of a funnel for feeding the yarns into a hollow needle.

In other, alternative embodiments, as further illustrated in FIG. 2E, a plurality of yarn tubes 56 can be mounted along the needle bar 11. The yarn tubes 56 generally can be received through openings 57 formed along the top of the needle bar 11, and each generally can be aligned with a corresponding needle 12 mounted along the lower side of the needle bar. Each of the yarn tubes 56, in embodiments, can include an elongated body 58 extending downwardly from a first or proximal end to a second, lower distal end that is received through an opening of the needle bar 11. The distal ends of the yarn tubes further can be aligned and in communication with the first or proximal end of its associated needle. Yarns can be fed from a yarn feed system through the yarn selection system and into the yarn tubes 56, with the yarns being directed at an angle through the tubes and into the needles 12 in communication therewith. In embodiments, the yarn tubes 56 can be oriented at an angle with respect to the needles 12, the angle and length of the yarn tubes being configured to help maintain the non-selected yarns within their respective needles (or at least within yarn tubes 56 for easy reinsertion into the needles) during periods when feeding of the selected yarns is halted or substantially slowed and when such non-selected yarns are not to be inserted into the backing.

As FIGS. 1A and 4A-4C illustrate, a yarn feed system 60 is provided for controlling the feeding of a series of yarns Y from a supply (e.g. a creel, cone, etc.) to each of the needles 12. In embodiments, the feeding of the yarns to each of the needles 12 can be controlled such that the yarns are carried with the needles as the needles penetrate and are reciprocated into and out of the backing B, with at least selected yarns being fed through the needles 12. As the needles penetrate the backing B and move toward a lower, bottom position of their reciprocating stroke or cycle, sufficient yarn lengths can be fed by the yarn feed system 60 to each of the needles to form tufts of desired pile heights, and the needles can be engaged by one or more knives or cutting blades of the cutting system mounted below the backing along the tufting zone T of the tufting machine. The feeding of yarns to the needles 12 further can be controlled so as to substantially pull back and/or hold or otherwise maintain non-selected yarns (e.g., yarns not to be tufted at a particular stitch location of the pattern) within their respective needles.

In embodiments, the yarn feed system 60 can comprise one or more yarn feed attachments or mechanisms 61 that can be mounted to the frame 16 of the tufting machine 10 adjacent the upper end thereof, as indicated in FIG. 4A. In embodiments, as illustrated in FIGS. 4A-4C, the yarn feed mechanism(s) 61 can include, for example, individual or single end yarn feed or multiple end yarn feed pattern attachments. In embodiments, such yarn feed mechanism(s) 61 further can comprise a unit or have a modular construction, which can include a housing and/or frame, with a series of motor driven yarn feed devices 62 mounted to or received therein. In embodiments, a plurality of yarn feed mechanisms can be mounted along the frame of the tufting machine for feeding at least one yarn per needle, or in embodiments, two or more than one yarn to each needle. In some embodiments, a single yarn can be fed to each needle by an associated one of the yarn feed devices 62; and in other embodiments multiple yarns can be fed by an associated one of the yarn feed devices 62 to each needle, or to a series of needles. In addition, other yarn feed mechanisms also can be used.

In embodiments such as illustrated in FIGS. 4B-4D, the yarn feed devices 62 each can include a motor 65 and one or more feed rolls 63 that can be configured to feed at least one or more yarns to selected needles. In embodiments, the yarn feed rolls 63 of the yarn feed devices 62 can be arranged in a set of 2-3 yarn feed rolls, which can be arranged in an engaging relationship (e.g., the feed rolls can have gear teeth that engage in an intermeshing arrangement). In some embodiments, the yarn feed rolls 63 can include a driven roller 64A that can be driven by the motor 65, and two feed rollers 64B/64C about which the yarns can extend for feeding the yarns along their pathways. The two feed rollers 64B/64C can be driven by the rotation of the driven roller 64A. In embodiments, the yarn feed rollers 64B/64C of the yarn feed devices 62 can be configured to feed selected or pre-determined amounts or lengths of yarn per individual tufting or stitch cycle to enable formation of tufts or yarns with selected or desired pile heights.

For example, as shown in FIG. 4D, in some embodiments, the feed rollers 64B/64C can have an expanded size or diameter that can be selected for feeding a desired or selected length of yarn per each revolution thereof. For example, in embodiments, the feed rollers 64B/64C can have a diameter of up to about 1″ or greater which can be selected for feeding a set length of yarn (for example, about 4″-5″) per revolution. Other amounts or lengths of yarns also can be fed using other varying size feed rollers to form tufts of other pile heights. In some applications, such as for artificial grass or turf, such as sports fields, a standard pile height of at least 2½″ can be required to provide for sufficient infill, resiliency and other parameters. With the present system and methods, greater pile heights, and further variations in pile heights of the tufts formed which meet or exceed such standards, can be provided.

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

In embodiments, each of the yarn feed devices 62 can be configured to feed one or more yarns to one or more associated needles 12. In some embodiments, single yarns can be fed to each needle, while in some embodiments, multiple yarns can be fed to each needle for tufting into the backing B. For example, in some instances (such as for forming artificial turf or grass products) 2, 3, 4, or more yarns (e.g., artificial grass filaments, etc.) can be combined prior to being received at the yarn feed system 60 or at the yarn feed system, and fed together to the needles 12, with each needle inserting 2-4 or more yarns per tuft.

The yarn feed mechanism(s) 61 can be operated in accordance with programming or pattern instructions for a pattern being run by the tufting machine 10 in order to control the feeding of the yarns Y along their path of travel or pathway 44 to each of the needles 12 or to a series of needles. The feeding of the yarns Y can be controlled to form tufts of selected or desired pile heights, and further can be controlled so that selected yarns or loops of yarns can be substantially slowed or stopped to avoid insertion of non-selected yarns into the backing B while still allowing the yarns to remain within the needles 12. The pile heights of remaining tufts of selected yarns further can be controlled by the amount(s) of yarn fed by the yarn feed mechanism(s) 61 to feed lengths of yarns as needed to create tufts of different heights. Thus, varying surface effects for each tuft or stitch can be formed to tuft/create textured patterns with high/low and/or shaded pattern effects in addition to shifted or different color placement effects.

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

In some embodiments, front and rear yarn feed mechanisms could be provided to feed yarns to alternating needles of the needle bar, e.g., the front yarn feed mechanism(s) can feed yarns to odd number needles, while the rear yarn feed mechanism(s) can feed yarns to even number needles.

In addition, in embodiments, the tufting machine 10 can include puller rolls 66 (FIGS. 1A, 2A and 2C) arranged along the path of travel or pathway 44 of the yarns Y, downstream from the yarn feed mechanism(s) 61. The puller rolls 66 can comprise grooved rollers that engage and pull the yarns fed from the yarn feed mechanism to provide a substantially consistent feeding of the yarns. The rotation of the puller rolls 66 can be controlled by the control system 15 to control pulling of the yarns Y from the yarn feed rolls 63 of the one or more yarn feed mechanism(s) 61 for feeding along their path of travel to their associated needles.

In some embodiments, the tufting machine further can comprise an air-induced yarn feed apparatus 59 configured to help direct/feed the yarns into and along the passages 58 of the needles 12. In embodiments, the air-induced yarn feed apparatus can be connected to the air supply and can comprise air lines 68 connected to a series of air injectors, nozzles, or other devices 67, arranged along the pathway or path of travel or pathway 44 of the yarns from the yarn feed system 60 and into the needles 12 and configured to supply/direct flows of pressurized air toward the yarns. In embodiments, the air-induced yarn feed apparatus can supply flows of pressurized air that can be directed along the yarn tubes 56 and through the needles 12 for directing the yarns through the needles to help provide consistent delivery of each yarn (or multiple yarns) to the associated needle at substantially the same time and with a substantially consistent delivery velocity. In some embodiments, the air-induced yarn feed apparatus can supply substantially continuous flows of air that can be exhausted through the openings of the distal ends of the needles to atmosphere.

In addition, in embodiments such as shown in FIGS. 5A-5D, the tufting machine further can include a yarn selection system 70 operable to selectively retract or hold back yarns fed from the yarn feed system 60 into the needles 12. In some embodiments, the yarn selection system 70 can include a series of yarn jerkers 71 arranged along the path of travel or pathway 44 of the yarns Y from the yarn feed mechanism(s) 61 or pattern attachment(s) of the yarn feed system 60 to the needles 12. One or more of the yarn jerkers 71 can be coupled to actuator(s) 72, such as an air cylinder. The yarn jerkers 71 can be selectively controlled to extend and retract along a selected length or travel (e.g., in embodiments, an approximately ½″ to about a 2″ travel (though other distances also can be used) to retract or pull back yarns from the needles.

In embodiments, the actuator(s) 72 can include air cylinders each including a piston rod 73 (FIG. 5C) extensible therefrom. As illustrated in FIGS. 5C-5D, in embodiments, each of the yarn jerkers 71 can include a body 74 having an opening 76 defined therein. A yarn Y can extend through the opening 76. The body 74 of each yarn jerker further can be connected to a piston rod 73 of an associated actuator 72. The actuators can be selectively controlled to extend and retract their piston rods, and thus move the yarn jerkers 71 between extended and retracted positions. In embodiments, the yarn jerkers 71 can be moved up and down, and as the yarn jerkers are retracted, can pull back or retract the yarns extending therethrough.

In other embodiments, the actuator(s) 72 can be formed with or incorporated into jerker modules (e.g., the yarn jerkers can be coupled to jerker modules) that can be formed with a plurality of bores each receiving a piston rod therein. The yarn jerkers 71 can comprise a one or two piece structure. For example, in embodiments, as shown in FIGS. 5B-5C, the body 74 of each of the yarn jerkers 71 can include a yarn holder portion 74a in which the opening 76 is formed for passage of the yarns therethrough, and a mounting portion 74b that can be coupled to the yarn holder portion 74a (e.g., by a keyed engagement or other locking arrangement or by fasteners, etc.) and to a distal end of a piston rod 73 of one of the actuators 72.

In embodiments, other types of actuators—also can be provided. For example, in some embodiments, the jerker modules (or the actuators thereof) can comprise double acting air cylinders configured without a mechanical spring return, and using air supplied to different portions of bores of the jerker modules to cause selective movement of the pistons along the bores so as to control extension and retraction of the yarn jerkers. Providing or forming the jerker modules as double acting cylinders can, in embodiments, help increase a timing or speed of actuation of the yarn jerkers due to no spring being used. In addition, lower air pressure for operation of the yarn jerkers also can be utilized to operate the double acting cylinders.

Further, in embodiments such as indicated in FIG. 5A, the actuator(s) 72 (shown as cylinders) can be connected to an air supply by a multi-way valve 77, such as a 3-way valve. The valve 77 of each actuator can include an intake port 78a coupled to the air supply by an air line or conduit for supplying air to the actuator, and a first outlet port 78b through which air is directed to control the extension and retraction of the yarn jerker connected thereto, and a second outlet port 78c that can act as an air bleed to bleed off excess air. In some embodiments, the second outlet port 78c can be connected by an air line to one of the air injectors 67 of the air-induced yarn feed apparatus for supplying air to the air injector to assist in feeding the yarns to an associated needle. In embodiments, air injectors located along an opposite side of the needle bar can be connected to and receive air directly from the air supply.

The selective actuation of the yarn jerkers can be controlled together with the control of selected yarn feed devices of the yarn feed system to help control the amount of the selected yarns fed to each of the needles to help ensure a sufficient length of each of the selected yarns is provided to form tufts of a desired pile height (which can depend on the particular construction, application and/or use of the artificial turf or grass field). In embodiments, the control of the yarns by the yarn jerkers and the yarn feed system can maintain the yarns within the needles both when cut, and when not selected for insertion into the backing.

Also, in embodiments, by maintaining the application of pressurized air flows by the air-induced yarn feed apparatus along the pathway or path of travel 44 of the yarns into and through the passages 55 of the needle bar 11 and the passages 46 of the needles 12, the yarns can be kept within their pathways and further can be maintained within the passages 46 of their needles. For example, since the yarns typically used for artificial grass or turf tend to be flatter (e.g., to mimic a blade of grass) and have a natural resiliency that tends to cause them to snap or pull back when cut, and the application of air through the passages 55 of the needle bar 11 by the air injectors can help assist the yarn selection system 70 and yarn feed system 60 in substantially preventing the yarns from popping out of the needles by extending the path of travel or pathway 44 of the yarns into and through the needles such that the yarns can stay in contact with the corresponding needle in that pathway.

In addition, in embodiments, the cutting system 80 can be provided below the backing support or shuttle 18. As shown in FIGS. 6A-6B, in embodiments, the cutting system 80 can include a series of knives 81 each having a cutting edge 82. In some embodiments, the knives can be arranged in a substantially flat orientation with respect to the needles; and in some embodiments, can each be mounted in a module or holder 84 that can be mounted along a knife bar 86.

For example, as shown in FIGS. 7A-7C, in embodiments, a series of knives 81 can be mounted within modules 84 that can include a body 87 having front portion 87a including a series of slots 88 within which individual knives 81 can be received, and a rear portion 87b configured to mount along the knife bar. In the example embodiment shown in FIGS. 7A-7C, the module is shown with a series of mounting tabs 89a, but other mounting devices also can be used. In embodiments, the knives can be secured in a predetermined cutting position within their slots by fasteners 89 (FIG. 7B), such as set screws or other fasteners.

In embodiments, the modules can be placed in a jig for positioning the knives 81 at the predetermined cutting position within their modules, which predetermined cutting position can be based on a needle stroke length or depth of penetration of the needles into the backing to form tufts of selected pile heights. The knives can be secured in the modules using the fasteners, after which the modules can be mounted along the knife bar. The knives can be located at a predetermined position with respect to the downstroke or penetration depth of the needles to locate the knives at a location for cutting the yarns fed through the needles as the needles penetrate the backing.

In other embodiments, such as shown in FIG. 6C, each knife 81 can be mounted in its own module 84, with a plurality of knives 81 and modules 84 being individually mounted along the knife bar 86. Each module 84 can include a module body 87 having a front portion 87a and a rear portion 87b configured to mount along the knife bar 86. For example, in embodiments, one or more mounting tabs 89 can be provided along a surface of the rear portion 87a to assist in locating the modules along the knife bar, and the knife modules can be secured to the knife bar with fasteners such as set screws.

In addition, as further illustrated in FIG. 6C, in embodiments, the body 87 of the knife module 84 can have a generally Y-shaped or C-shaped configuration a knife holder assembly with an opening 84a defined along the front portion 87a of the body. In embodiments, the knife of each module shown in FIG. 6C can be slidably received within a knife mounting assembly 85. In embodiments, the knife mounting assembly 85 can include a first portion 85a to which the knife 81 can be attached (e.g., by fasteners), and a second portion 85b that can be configured to receive the knife 81 therein, and with can be attached to the front portion 87a.

In embodiments, the second portion 85b can be configured as a guide in which the knife can be slidably received such that each knife can be selectively moved vertically with respect to the stroke of the needles between a series of extended, engaging or cutting positions and a retracted, non-engaging or no-cut position. In embodiments, when in their extended cutting positions, the knives can cut the yarns carried by the needles to form cut pile tufts of selected yarns in the backing, which tufts can have varying pile heights. In other embodiments, the knives can be selectively moved to their retracted positions to form loop pile tufts of selected yarns in the backing.

In embodiments, an actuator 83 can be associated with each individual knife, for example, with a piston rod or other drive shaft 83a thereof coupled to the first portion 85a and can be selectively actuated by the control system to move the knife associated therewith between its series of extended engaging or cutting positions. Other types of actuators (in addition to or as an alternative to cylinders as shown in FIG. 6C) can be used.

In embodiments, the first portion 85a of the knife mounting assembly can be configured to enable the knives to move therealong. For example, as the actuators are engaged by the control system, the knives associated therewith will be extended or retracted, moving along the first portions 85a of the knife mounting assemblies (e.g., along a channel or passage of the first portion), which will guide and support the knives as they are moved between their extended and retracted positions.

In embodiments, the knives 81 can be arranged in positions aligned with associated or corresponding needles 12. In embodiments, the knives 81 can further be mounted in a substantially fixed position along the knife bar 86, with the cutting edges 82 of the knives located at an elevation to engage with the needles 12 and cut the yarns carried by the needles to form tufts of such yarns having a selected pile height. In general, the knives 81 can be positioned such that their cutting edges 82 can be located at a selected elevation with respect to the stroke of the needles 12, such that as the needles penetrate the backing B, the cutting surface 51 of each needle can engage the cutting edge of its associated knife, with any yarns being introduced (e.g., blown through the needle) being cut by the knives.

In embodiments, the knives 81 can be held in a stationary position as the needles 12 penetrate the backing B. As the needles 12 reach a selected penetration depth, the cutting surfaces of the needles can and engage the cutting edges of the knives. In embodiments, the cutting edges 82 of the knives can engage with the cutting surfaces of the needles at selected shear angle to facilitate a substantially clean cutting of the flatter artificial grass or turf yarns. In embodiments, the shear angle between the cutting surfaces of the needles and the cutting edges of the knives can be substantially flat or can be oriented at a slight shear angle.

In some embodiments, the knife bar 86 can be coupled to at least one actuator 83 (FIG. 6C) that can be controlled to move the knives 81 between their non-engaging and cutting positions. In addition, in some embodiments, one or more of the knives 81 can be coupled to an associated actuator (such as an air cylinder) and can be individually controlled so as to be moved between a no-cut or non-engaging position and one or more cutting positions for selectively cutting the yarns as the yarns are implanted into the backing B. In other embodiments, all of the knives 81, or at least a portion thereof, can be moved together as a set or group of knifes into a cutting position for cutting the yarns.

In embodiments, the knives 81 (FIGS. 6A-6C) generally can be arranged in positions that are fixed in a lateral direction with respect to the needles 12. The knives 81 can be moved in a substantially straight path of travel in a vertical direction that can be generally in-line with the cutting surfaces 51 of the needles 12. For example, in embodiments, the cutting edges 82 of the knives 81 can be substantially centered with the cutting surfaces 51 formed at the distal ends of the needles 12. The cutting edges 82 of the knives 81 can engage with the cutting surfaces 51 of the needles, e.g., at a substantially flat or slight shear angle, to facilitate a substantially clean cutting of the flatter artificial grass or turf yarns.

In addition, in some embodiments, a cutting blade or a series of cutting blades can be provided in place of the knives of the cutting system. The cutting blade(s) can have an elongated cutting edge configured to engage and cut a plurality of yarns. In embodiments, multiple cutting blades can be used in place of groups or sets of knives.

In embodiments, the tufting machine 10 can include a control system 15 which, in embodiments, can include programming for controlling the operation of the various operative systems and/or operative components of the tufting machine, such as the yarn feed system, backing feed system, needle bar drive system, yarn selection system, cutting system, shift mechanisms (for shifting the needles, the backing, or for shifting both the needles and the backing), and components of each of such systems, so as to produce a patterned tufted article in accordance with a selected pattern. The control system 15 further can be configured to control the supply of pressurized air from an air supply (e.g., a blower, compressor, or other source of pressurized air) to various ones of the operative systems or components of the tufting machine.

In some embodiments, the supply of pressurized air can also include or be in communication with a distribution device such as a manifold that can be configured to supply air to different operative components of the tufting machine such as, without limitation, one or more of the actuators controlling actuation of the yarn jerkers, actuators for the knives of the cutting system, the air-induced yarn feed apparatus, and/or other components.

In embodiments, the various operative systems of the tufting machine 10 can be controlled by the control system 15, based on programming configured to receive and execute/run a desired pattern. In some embodiments, the control system 15 can include a controller 100, schematically illustrated in FIG. 1A as including a control cabinet linked to the tufting machine 10, and which can have a user interface 101 such as a touch screen, keyboard, etc. . . . It will also be understood that, in embodiments, the controller 100 can be incorporated with the tufting machine 10, e.g., mounted to the frame or otherwise included with the tufting machine; while in other embodiments, the controller can comprise a stand-alone unit or a more remote controller or, central server/controller.

In embodiments, the controller 100 can include one or more processors and a memory that can be configured to receive and store pattern information, and further can include programming or instructions adapted to control operation of the hollow needle tufting machine and the various operative components thereof. For example, in embodiments, the controller of the control system can include programming or instructions executed by the one or more processors for selectively controlling the yarns fed to the needles to enable substantially consistent yarn feeding to each of the needles, in cooperation with the engagement/selective operation of the knives and yarn jerkers, and/or shifting of the needles (and in some embodiments, shifting the backing), based on received or programmed pattern information to form a desired pattern with multiple color and/or types of yarns.

In addition, in embodiments, the control system can control the feeding to the backing so as to feed the backing at an actual stitch rate that is generally equivalent to a pattern stitch rate as designed or adjusted for the pattern being tufted, or which comprises an effective process stitch rate that can be increased compared to the desired stitch rate of the pattern as designed. In some embodiments, the backing can be fed at an effective process stitch rate that is determined based on a number of colors of the pattern or as used in a thread-up sequence of the needles multiplied by the desired stitch rate for the pattern (the desired stitch rate can be determined from the stitch rate of the pattern as designed based on the number of ends of yarns being fed to each needle to form each tuft, thickness and/or weight of the yarns, and other factors).

In some embodiments, the control system further can include programming adapted to apply dynamic advance parameters to advance operation of various operative components of the hollow needle tufting machine based on an operating speed (RPM) of the main shaft of the hollow needle tufting machine. For example, the control system can advance operation of one or more operative components, such as engaging selected yarn jerkers, engagement (e.g., turning on and off) of the air blower(s), yarn feed of selected yarns being fed to each needle, movement of the knives between cutting and non-engaging or no-cut positions, shifting and other operative elements, in advance or ahead of a next stitch or tuft placement step for the pattern, based on rotation of the main shaft of the tufting machine.

In embodiments, the control system can control the yarn feed system (e.g., control selected ones of the yarn feed devices or the yarn feed mechanisms or units thereof) to deliver portions of the lengths of yarns to be fed to each needle during each stitch or individual sewing operation within a portion of the revolution of a main shaft of the hollow needle tufting machine.

The tufting machine can be configured, in some embodiments, to provide single level cut-pile tufted fabrics, and the control system can include programming, which can utilize yarn feed control to control formation of multi-level loop pile tufts of yarns, without necessarily requiring movement of knives for cutting loops of yarns from a cut (cylinder extended) position to a loop (cylinder retracted) position.

In embodiments, the length of the tufting machine, the spacing of the needles, and the number of needles can vary depending on the product to be produced and the desired rate of production. For example, in embodiments, the tufting machine can be configured to produce carpets, turf, rugs, or other articles of a selected size or a range of sizes. For example, in embodiments, the needles can be arranged at a gauge spacing that can be substantially matched to the selected or desired gauge of the tufting machine, e.g., needle gauge spacings of about ¼″ to ⅜″ or greater, including needle gauge spacings of ¼″, 5/16″, ⅜″, 7/16″ ½″, ⅝″, 9/16″, ¾″, ⅞″, 1″ or greater, can used to form substantially true gauge tufted products that, in some embodiments, can be matched to the tufting machine.

By way of example, in embodiments of a method according to the principles of the present disclosure, the method can utilize a tufting machine configured with single or double end yarn feed mechanisms or pattern attachments with enlarged roll systems to enable the yarn feed mechanisms to feed lengths of yarns that can correspond to selected tuft lengths or pile heights for artificial grass, turf or shag carpets, fields, and/or rugs. For example, in embodiments, the tufting machine can feed tuft lengths with a pile height exceeding three inches.

In embodiments of the method, the yarns pass through a series of yarn jerkers that are controlled by the control system to actuate at a proper/selected sequence based on the rotation of the main shaft (for example, being actuated based on a position of the main shaft during a tufting cycle). In embodiments, actuators (e.g., cylinders) can be controlled to move the yarn jerkers in two directions (e.g., up/down), between a first, extended position, and a second, retracted position. In embodiments, when a yarn jerker is retracted, then the length of the yarn can be at least partially retracted and held within the corresponding needle so as to not be exposed for cutting. When a cylinder is extended, thereby extending the yarn jerker coupled thereto, the yarn is allowed to flow through the needle to form a tuft length.

In embodiments of the method, the yarns pass through the yarn jerkers and can be directed by the air-induced yarn feed apparatus directly into the needles, as shown in FIGS. 2F, 2H and 5A, and will be urged through the passages of their associated needles by the air-induced yarn feed mechanism. In some embodiments, the yarns further could be fed through a series of yarn tubes that are each in communication with a corresponding needle. In embodiments, selected yarns, e.g., those selected to be used to form a retained tuft of the pattern, will be directed through the needle bar and through their associated needles by air flows supplied by the air injectors of the air-induced yarn feed mechanism as the needles are reciprocated into the backing.

In embodiments of the method, the yarns are cut by a cutting system. In embodiments, the cutting system can include a series of flat knife blades that are selectively moveable into contact the lower portion of the needles when the needles penetrate the primary backing to cut the yarns for forming tufts in the backing. In certain scenarios, the ends of the needles may be flattened to better cut flat ribbon yarns.

In embodiments of the method, the needles each can be threaded with a selected different color or type of yarn. In other embodiments, multiple (e.g., two or more) yarns can be fed to each needle. Using an example of an application for forming a turf field (e.g., as shown in FIGS. 9A and 10A), which can include various different colors such as for forming yard markings, lines, logos, etc. . . . the needles can be fed artificial grass or turf yarns that can include at least one filament together with at least one substantially flat ribbon yarn. In other example embodiments, such as for forming tufted carpets, rugs and other tufted products, each needle can be assigned and fed two or more colors of yarns, (e.g., for forming a shag carpet such as shown in FIG. 11A).

The needles can be threaded with their various assigned colors of yarns to be tufted for a desired pattern according to a selected thread-up sequence. For example, for a pattern with 4-8 colors being used, the yarns can be threaded to the needles in a selected or desired thread-up sequence such as an ABCD, ABCDE, ABCDEF, ABCDEFG, ABCDEFGH sequence, with two or more of the different colors of yarns fed to a selected needle in the sequence, and the thread-up sequence can then be repeated along the length of the needle bar. Other thread-up sequences also can be used in other embodiments. In addition, in some embodiments, where the pattern calls for extended portions or fields of one color, the needles could be grouped or arranged in sets with different thread-up sequences.

By way of example, many sports fields today include areas where logos or other different color designs are presented. In embodiments, the needles can be provided with a thread-up sequence in accordance with the different colors to be used, and the needles can be threaded with 4-6 colors depending on a portion of the sports field being tufted. In an example embodiment shown in FIG. 9A, a section of a sports turf filed is shown, including five colors-green, white, brown, black, and orange. A five color thread-up sequence (e.g., an ABCDE thread-up) can be used with at least two of the needles being assigned primary colors such as green and white, and with the other needles being assigned to tuft the remaining (accent) colors brown, black and orange. In some embodiments, thread-up sequences of six colors or more also can be used, such as where additional colors or yarns might be needed for other areas of the field, with the feeding of such additional yarns being selectively controlled so that they may not be presented in areas, or even during some tufting runs, when not required.

In some embodiments, the backing can be shifted in conjunction with or separately from the needles. In some embodiments, the backing can be shifted without the needles being shifted. In some embodiments, the needles can be maintained in a substantially consistent lateral position such that they are not moved transversely with respect to the longitudinal path of travel of the backing. Instead, the backing can be shifted, in addition to being moved longitudinally. In such instances, the backing can be shifted transversely in various increments or steps, which can include shifting the backing by a distance based on the gauge spacing of the needles, or which, in some embodiments, the distance may not be tied to the gauge spacing of the needles (e.g., the backing can be shifted across distances or lengths that are less than or greater than the gauge spacing between the needles).

In embodiments, the backing can be shifted multiple times in both longitudinal and transverse directions across the tufting zone to enable presentation of the selected color yarns to corresponding stitch locations of the pattern, and insertion or formation of tufts at such stitch locations at an actual stitch rate that is generally equivalent to the pattern stitch rate as designed or adjusted as it is moved along its path of travel per the pattern steps.

In some embodiments, the longitudinal movement of the backing further can be controlled so that the backing is fed at an actual stitch rate that substantially matches the pattern stitch rate of the pattern being tufted or, in some embodiments, the actual stitch rate at which the backing is fed can comprise an effective process stitch rate that is greater than a desired stich rate for the pattern. For example, some sports turf applications (e.g., a sports field such as for football, soccer, lacrosse, or other sports) have a desired stitch rate being about 3-5 stitches per inch due to the requirement of an amount of fill to be provided between the tufts. In other turf applications, a closer spacing may be desired, particularly where lesser amounts of fill are required.

In embodiments, the backing can be fed at an actual stitch rate that can be based on a selected pattern stitch rate and/or desired density of the turf product, the number of colors used in the thread-up sequence of the needles, or combinations thereof. For example, in some embodiments, if a 6-color yarn thread-up sequence is used, the backing can be fed at an effective process stitch rate of approximately 18 stitches per inch, even if the pattern only calls for the use of 3-5 colors during a particular tufting run for the tufted product.

Moreover, since, in some embodiments, the backing can be shifted to present each stitch location to a needle carrying the selected color yarn to be placed as such stitch location, a closer spacing of the tufts can be provided. In some embodiments, such as where the needles are shifted, the backing can be fed at an effective process stitch rate and each needle can be fed and selectively present multiple yarns during each penetration of the needles into the backing. Thus, larger tufts that include multiple yarns can be selectively formed at each stitch location or pixel of a pattern being formed.

In embodiments, such backing feed methods can further enable the face of the patterned tufted product to be formed with a denser appearance, such as shown in FIGS. 8A, 9A, 10A, 11A and 12, while the back stitch on the rear side of the backing can be substantially minimized or reduced, and in some cases, as shown in FIGS. 8B-8C, 9B, 10B and 11B, can be formed without trailing lengths of yarns that were not selected to be retained and/or shown on the face of the patterned tufted product.

In some cases, the effective process stitch rate may not be based on the gauge of the tufting machine (e.g., based on a selected gauge spacing of the needles or the desired gauge of the tufted product). This can provide a fabric construction in which the number of tufts in the longitudinal direction does not match the number of tufts in the lateral or transverse direction.

In addition, in embodiments, the needle bar 11 can be configured with the needles 12 arranged at a gauge spacing that substantially matches a gauge of the tufting machine, and two or more ends of yarns can be fed to each of the needles while the backing is moved at an effective stitch rate based on the thread-up sequence and the yarn feed rate. This can enable multiple colors of yarns to be presented to each pixel or stitch location during each penetration of each needle so as to form larger retained tufts of yarns or yarns at each stitch location, and/or to enable the tufts to be formed with less spacing therebetween. This can provide a fuller tufted appearance with a reduced amount of yarn required for the back stitching, e.g., without a trailing back stitch along the back side of the backing, such as shown in FIGS. 8A-8C and 10A-11B.

In embodiments, shifting of the needles with or without shifting the backing, or by shifting the backing alone while the needles are maintained in their home positions, combined with the thread ups of the needles can, in embodiments, permit increased variability on the designs formed. For example, a designer can use a selected/designed shift profile, yarn feed control and selected thread-up sequences that extends/repeats across the width of the machine to plan out where a logo, accent features, or portions thereof are going to be in terms of a completed turf field. After formation of such strips or panels, the panels can be matched and seamed or otherwise attached together to form a completed field, such as indicated in FIG. 9A.

In an example, as generally indicated in FIGS. 8A-8B, using the tufting system and methods of the present disclosure, tufted turf and artificial grass products in which a plurality of different color and/or types of yarns (e.g., 2, 3, 4 or more colors of flat ribbon type yarns) can be formed. FIG. 8A shows a section of a tufted turf product having a variety of different colors mixed together as part of a single tufted turf product. FIG. 8B shows a back stitch for the product of FIG. 8A, in which it can be seen that four different colors of yarns have been tufted. The back stitch shows a zig-zag shifting motion wherein the needles are shifted back and forth. In embodiments, the needles, the backing, or a combination thereof can be shifted in a first direction (e.g., to the right in FIG. 8B) four times based on the use of four colors in the pattern, and subsequently shifted in a second direction (e.g., to the left in FIG. 8B) four times. Other shifting motions also can be used.

By control of the yarn feed through operation of the yarn feed devices and the yarn jerkers, in conjunction with the shifting of the backing, the needles, or a combination thereof, yarns of each color or type can be selectively fed to their corresponding needles such that only the yarns of a selected color or type will actually be introduced into the backing. The movement of the backing along its path of travel P further can be controlled to feed the backing at an effective stitch rate or actual stitch rate that is increased over a desired or selected stitch rate for the pattern being tufted. In one example, for a four color pattern, the effective or actual stitch rate can be about four times the desired or selected stitch rate for the pattern being tufted (e.g., a pattern can be designed with a designed pattern stitch rate that can be run by the tufting system as the desired or selected stitch rate). In some instances, this designed pattern stitch rate can be adjusted, such as to achieve a desired weight or based on other factors, to develop the desired or selected stitch rate.

The tufting system, in embodiments, thus can present and tuft only the color or type yarns to be tufted at a particular stitch location, while non-selected yarns can be maintained in a retracted position, without having to be tufted but without creating gaps or reduced coverage of tufts. As a result, a mix of multiple colors or types of yarns can be tufted to form various designs or accent features. FIG. 8A and FIG. 9A show a four color patterned turf product comprising a portion of a football in a field of green with laces/stripes on the football and a team logo within the football. In addition, as shown in FIGS. 8B-8C and 9B, the back stitch formed on the back side of the backing may contain only the yarns actually tufted into the backing, which can help reduce yarn consumption.

Still further, in embodiments as shown in FIG. 9A, strips or panels of turf, such as a fifteen foot/five yard wide strip, can be tufted with large portions or sections thereof being all green, and at a certain interval in the formation of the strip or panel, a design, logo, field accessories, or a portion thereof can be inserted.

FIGS. 10A-12 show additional embodiments of tufted products and their back stitching formed using a tufting system and methods of tufting in accordance with the principles of the present disclosure. The tufting system and methods of FIGS. 10A-12 use tufting machines having needles arranged at a gauge spacing that is substantially matched to the gauge of the tufting machine, and with the backing being shifted while the needles are maintained in a substantially stationary transverse position with respect to the longitudinal path of travel of the backing, The backing can be fed at an actual or effective stitch rate based on a desired stitch rate increased (e.g., multiplied) by the number of yarns in the thread-up of the needle bar, or by a number of colors of yarns in the pattern.

FIG. 10A shows an example of a sports carpet utilizing various different color turf or artificial grass yarns, with FIG. 10B illustrating an example of the back stitches thereof. FIG. 11A illustrates an example of a shag carpet, including two colors of yarns, with FIG. 11B illustrating an example of the back stitches thereof. As can be seen, different types of yarns, including various thicknesses and material yarns, filaments, etc. can be used for forming patterned tufted products using embodiments of the tufting systems and methods of tufting of the present disclosure. Non-selected or non-retained yarns/tufts presented at each stitch location of the pattern are removed as needed which, in some embodiments, can include withholding or drawing back the yarns within their assigned hollow needles, thus providing a cleaner back stitching as illustrated.

FIG. 12 shows an example of an artificial turf or grass field having an integrally formed, substantially seamless design tufted therein utilizing the tufting machine and methods of tufting according to the principles of the present disclosure. In FIG. 12, an artificial turf or grass field is shown with an eagle design and an American flag background integrally tufted with the remainder of an entire tufted artificial turf or grass field such that there are no seams formed at transitions between the pattern color yarns forming the eagle and flag designs and the green base color yarns (e.g., the green “grass” yarns) making up the rest of the turf field, nor are seams formed between the pattern color yarns defining the eagle design and the different pattern color yarns defining the American flag background for the eagle. While FIG. 12 shows an embodiment in which more narrow sections of an artificial turf or grass field (e.g., sections formed using a sample machine size tufting machine) that can be attached in series, it can be seen that the portions of the designs themselves in each section are substantially seamless with the green grass portions of each section. It will further be understood that, in embodiments, much larger or wider tufted turf fields or sections thereof, incorporating an entire design such as the eagle and flag design of FIG. 12 also can be created using larger size tufting machines.

By enabling the creation of artificial turf or grass tufted products having integrated, substantially seamless designs or patterns tufted therein (e.g., having borders or transitions between the different color pattern yarns defining the pattern and base color yarns making up the rest of the turf field without seams or substantial bleeding of the colors together), substantial savings in terms of time, labor and costs of installation of artificial turf or grass fields can be achieved. For example, utilizing the tufting machine or apparatus and methods of tufting of the present disclosure, the need to separately form designs or patterns of different color, and then cut and sew and/or glue such designs into an overall turf field during installation can be avoided. This can lessen the time for installation of the turf field from several days to, in some instances, much less than a day, and significantly reduce the labor required.

In embodiments, during operation of the tufting machine or apparatus 10, utilizing one or more shift mechanisms coupled to the needle bar and/or the backing support or shuttle, the needle bar and/or the backing support can be shifted to displace the colors or types of yarns of the needle bar thread-up to provide the ability to present each of the colors threaded in the needles (e.g., a four or six color or more thread-up) to each pixel or stitch location, and, in some embodiments, enable mixing of the colors in the face of the tufted product/turf so that at selected or desired locations during the formation of the tufted panels or strips, additional colors can be presented and retained as needed to form the design, logo, or field accessories, or a portion thereof. However, when a color or type of yarn is not desired in the face, the yarn feed system can be controlled to substantially stop such color or type yarn from being feed and the yarn jerkers associated with the yarn can retract the yarn from the needle, which can provide enhanced color control in the design.

In addition, embodiments of the tufting machines and methods of the present disclosure can comprise a tufting machine for forming artificial grass or turf products with patterned designs, comprising a plurality of needles configured to penetrate a backing positioned upon reciprocation of the needles; wherein the needles comprise hollow needles, each having an upper end and a lower end, with a passage defined between the upper and lower ends; a yarn feed system for supplying a plurality of yarns, the yarn feed system configured to selectively feed one or two yarns to each of the needles for delivery of the yarns into the backing to form tufts or yarns therein; a shift mechanism for shifting the needles across the backing or shifting the backing with respect to the needles to enable presentation of different colors or types of yarns to each of a plurality of stitch locations of a pattern being formed; a yarn selection system coupled to an air supply and including a plurality of yarn jerkers adapted to be moveable between an extended position to allow passage of the selected yarns from the yarn feed system to the needles, and a retracted position to retract and/or hold back yarns supplied by the yarn feed system to one or more of the needles; and a cutting system arranged below a backing support and including at least one knife or cutting blade configured to cut the selected yarns as selected yarns are carried into the backing with the reciprocation of the needles into and out of the backing.

In embodiments, the tufting machine further can comprise a control system configured to control operation of the yarn feed system for feeding the selected yarns to the needles, and operation of the yarn jerkers.

In embodiments, of the tufting machine, the control system can include programing configured to dynamically advance the operation of the yarn feed system and the yarn jerkers in advance of a next stitch placement step of a pattern being formed.

In embodiments, the tufting machine further can comprise at least one needle bar along which the needles are mounted, the needle bar having a series of openings spaced therealong and in communication with the passage of a corresponding needle; wherein the yarns are directed through the openings in the at least one needle bar and into the passages of the needles.

In embodiments of the tufting machine, the needles are arranged along the at least one needle bar at a selected gauge spacing based on a gauge of an artificial grass or turf product of the tufting machine.

In embodiments, the tufting machine further can comprise a series of angled yarn tubes mounted along an upper surface of the needle bar with each of the yarn tubes in communication with a corresponding needle; and an air induced yarn feed mechanism coupled to an air supply for directing the yarns through the yarn tubes and the needles.

In embodiments of the tufting machine, the shift mechanism comprises a rack and pinion shift mechanism.

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

In embodiments of the tufting machine, the needles comprise hollow needles each having a body with an internal passage defined therein, a first end received within a needle bar; and a second end terminating at a tip and having a flattened cutting surface configured for cutting flat ribbon yarns or filaments.

In other embodiments, a tufting machine can be provided, which is configured to produce tufted turf or artificial grass products with integrated designs (e.g., logos) or panels of tufted turf or artificial grass products that include portions of larger designs and that can be attached together to form a sports carpet or an artificial grass or turf field.

Still further, the present disclosure further includes methods adapted to enable single end designs to be produced within a machine frame of a tufting machine for production of tufted turf or artificial grass products with integrated designs (e.g., logos) or panels of tufted turf or artificial grass products that include portions of larger designs and that can be attached together to form a field.

In embodiments, a method is provided, which can comprise comprising feeding a plurality of yarns from a plurality of yarn feed devices along a path of travel to each of a plurality of needles; reciprocating the needles into and out of a backing; shifting the backing or shifting the needles in a transverse direction to movement of the backing along a path of travel; selectively controlling the yarn feed devices to substantially stop or slow feeding of non-selected yarns to the needles, and actuating one or more yarn jerkers to engage and pull back the non-selected yarns; selectively controlling the yarn feed devices and yarn jerkers as movement of the backing feed along its path of travel is controlled to enable presentation of different yarns to each of a plurality of stitch locations to form an artificial grass or turf product having one or more of a design, accent feature, logo, or portions thereof integrated therein.

In some embodiments, the method further comprises reciprocating a plurality of hollow needles into and out of a backing; as the hollow needles are reciprocated into and out of the backing, selectively feeding multiple yarns to each of the hollow needles and shifting the backing transversely relative to a longitudinal path of travel.

Still further, various tufted articles can be produced using the tufting machine, apparatus and methods of the present disclosure, including artificial turf or grass that can have various colors, designs, text, or other patterns, and can be formed in sections or panels configured to be attached as part of a larger field or patterned article.

The present disclosure has been described herein in terms of examples that illustrate principles and aspects of the present disclosure. The skilled artisan will understand, however, that a wide gamut of additions, deletions, alterations, and modifications, both subtle and gross, may be made to the presented examples without departing from the spirit and scope of the present disclosure. All such modifications which do not depart from the spirit of the disclosure are intended to be included within the scope of any of the aspects and/or claims provided by the present disclosure.

Claims

1. A tufting machine for forming artificial grass or turf products with patterned designs, comprising: at least one needle bar having a plurality of needles positioned therealong;wherein the needles comprise hollow needles;a yarn feed system configured to feed a plurality of yarns to the needles;wherein the needles are moved in a reciprocating movement toward and away from a backing moving along a path of travel through the tufting machine so as to introduce selected yarns into the backing as the needles penetrate the backing;at least one shift mechanism for shifting the backing transversely;a yarn selection system arranged along a path of travel of the yarns between the yarn feed system and the needles, the yarn selection system configured to retract and/or hold back non-selected yarns supplied by the yarn feed system to one or more of the needles; anda cutting system arranged below the backing and including at least one knife or cutting blade configured to cut the selected yarns as selected yarns are carried into the backing with the reciprocation of the needles into and out of the backing.

2. The tufting machine of claim 1, further comprising a control system including programming configured to control operation of the yarn feed system for feeding a length of each of the selected yarns to the needles to substantially sufficient to form a tuft of predetermined pile height, operation of the yarn selection system, and operation of the at least one shift mechanism to enable presentation of different colors or types of yarns to each of a plurality of stitch locations of a pattern being formed.

3. The tufting machine of claim 2, wherein the yarn selection system further comprises a plurality of yarn jerkers adapted to engage the yarns being fed to the needles and a plurality of actuators each linked to at least one yarn jerker and adapted to move the yarn jerkers between an extended position to allow passage of the selected yarns from the yarn feed system through the needles, and a retracted position to retract and/or hold the non-selected yarns supplied by the yarn feed system within the needles.

4. The tufting machine of claim 3, wherein the control system includes programing configured to dynamically advance operation of the yarn feed system and the yarn jerkers or the yarn selection system in advance of a next stitch placement step of a pattern being formed.

5. The tufting machine of claim 1, wherein the at least one needle bar comprises a series of openings spaced therealong and in communication with a passage extending through a corresponding needle; wherein the yarns are directed through the openings in the at least one needle bar and into the needles.

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

7. The tufting machine of claim 1, further comprising an air-induced yarn feed apparatus coupled to an air supply and configured to direct flows of air through the at least one needle bar to assist feeding of the yarns through the needles.

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

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

10. The tufting machine of claim 1, wherein the needles each comprise a body having an internal passage defined therein, a first end received within a needle bar; and a second end terminating at a tip and having a flattened cutting surface configured for cutting flat ribbon yarns or filaments.

11. A tufting machine, comprising: a plurality of needles configured to penetrate a backing;a yarn feed system configured to selectively feed a plurality of yarns to the needles;wherein the needles comprise hollow needles, each having a first end and a second end, with a passage defined between the first and second ends through which one or more yarns are fed;wherein the yarns comprise a plurality of different type of color yarns;at least one shift mechanism for shifting the needles across the backing or shifting the backing with respect to the needles;a yarn selection system including a plurality of yarn jerkers adapted to be moveable between an extended position to allow passage of selected yarns from the yarn feed system to the needles, and a retracted position to retract and/or hold back non-selected yarns supplied by the yarn feed system to one or more of the needles; andwherein as the needles are reciprocated into and out of the backing, feeding of the selected and non-selected yarns is controlled by the yarn feed system and the yarn jerkers are moved between their retracted and extended positions to enable insertion of the selected yarns into the backing to form loop pile or cut pile tufts of the selected yarns in accordance with a pattern being tufted.

12. The tufting machine of claim 11, further comprising a cutting system including at least one knife or cutting blade configured to cut the selected yarns to form the cut pile tufts of yarns in the backing.

13. The tufting machine of claim 11, further comprising a control system having programming configured to control operation of the yarn feed system for feeding the selected yarns to the needles, and programing configured to dynamically advance feeding of the yarns by the yarn feed system and movement of the yarn jerkers between the extended and retracted positions in advance of a next stitch placement step of a pattern being formed.

14. The tufting machine of claim 11, further including at least one needle bar along which the needles are mounted; wherein the needles are arranged along the at least one needle bar at a selected gauge spacing based on a gauge of an artificial grass or turf product produced by the tufting machine.

15. The tufting machine of claim 11, further comprising an air supply, and an air-induced yarn feed apparatus coupled to an air supply for directing the yarns through the needles.

16. The tufting machine of claim 11, wherein the second end of each of the needles includes a tip and having an opening through which the one or more yarns exit the needle, and a flattened cutting surface surrounding configured for cutting flat ribbon yarns or filaments.

17. The tufting machine of claim 11, wherein the tufting machine is configured to produce tufted turf or artificial grass products with integrated designs (e.g., logos) for tufted turf or artificial grass products.

18. A method, comprising: moving a backing along a path of travel; feeding a plurality of yarns from a plurality of yarn feed devices along a path of travel to each of a plurality of needles; reciprocating the needles into and out of the backing; shifting the backing or shifting the needles in a direction transverse to movement of the path of travel of the backing; selectively controlling the yarn feed devices to substantially stop or slow feeding of non-selected yarns to the needles, and actuating one or more yarn jerkers to engage and hold or pull back the non-selected yarns such that the non-selected yarns are substantially maintained within the needles; selectively controlling the yarn feed devices and yarn jerkers as movement of the backing along its path of travel is controlled to enable presentation of different yarns to each of a plurality of stitch locations; and forming a plurality of tufts of selected yarns in the backing; wherein the yarns comprise artificial grass or turf yarns including one or more colors so as to form a tufted artificial grass or turf product having one or more of a design, accent feature, logo, or portions thereof integrated therein.

19. The method of claim 18, wherein shifting the backing or shifting the needles comprises shifting a backing support over which the backing is moved.

20. The method of claim 18, further comprising moving at least one cutting blade into engagement with a cutting surface of each needle as the needles penetrate the backing and cutting the selected yarns to form the tufts of the selected yarns in the backing.

21. A tufted artificial grass or turf product comprising: a backing; anda plurality of spaced tufts of artificial grass or turf yarns formed in the backing;wherein the artificial grass or turf yarns include a base color yarn and a one or more pattern color yarns of different color than the base color yarn;wherein selected colors of the base color and one or more pattern color yarns are retained in the backing at selected stitch locations within a field of an artificial turf or grass so as to define at least one patterned area of the one or more pattern color yarns being formed within a field of the base color yarn the backing; andwherein transitions between the at least one patterned area of pattern color yarns and the field of the base color yarn is substantially seamless.