Tufting Machine and Method of Tufting

The present application is a continuation of co-pending U.S. patent application Ser. No. 18/747,518, filed Jun. 19, 2024, which is a continuation of U.S. patent application Ser. No. 17/843,011, filed Jun. 17, 2022, now U.S. Pat. No. 12,054,868, issued Aug. 6, 2024, and claims benefit of U.S. Provisional Patent Application No. 63/212,770, filed Jun. 21, 2021.

The disclosures of U.S. patent application Ser. No. 18/747,518, filed Jun. 19, 2024, U.S. patent application Ser. No. 17/843,011, filed Jun. 17, 2022, now U.S. Pat. No. 12,054,868, issued Aug. 6, 2024, and U.S. Provisional Patent Application No. 63/212,770, filed Jun. 21, 2021, are incorporated by reference herein for all purposes as if set forth in their entireties.

The present disclosure generally relates to tufting machines and methods of forming tufted fabrics. In particular, the present disclosure relates to tufting machines including selectively controllable gauge parts, as well as methods of forming patterned tufted fabrics.

In the tufting field, particularly with regard to commercial and hospitality carpets, there has been increased demand for the production of carpets and rugs with new visual patterns, including the use of multiple different colors, in an effort to keep up with changing consumer tastes and increased competition in the marketplace. Carpet designers and manufacturers thus have placed increased emphasis on the creation of newer, different and more eye-catching patterns for carpets, rugs and other tufted fabrics, including patterns having the selective placement and display of yarns of particular colors or types within pattern fields thereof, and with the resultant tufted fabrics being formed with a substantially true pattern density of the visible tufts of the pattern. It further has been desirable to try to replicate as closely as possible the look and feel of patterned carpets, rugs or other fabrics formed on a loom, but which can be created and formed therein on broadloom tufting machines so as to enable increased efficiencies in production of such patterned tufted carpets, rugs and/or other fabrics. In addition, there generally is a desire to provide increased control of the formation of tufts of selected colors or types of yarns for formation of patterned carpets, without substantially affecting the operation of tufting machines, including increasing the need for maintenance or placement of parts such as gauge parts thereof, or the output of such tufting machines.

Accordingly, it can be seen that a need exists for a system and method of forming tufted fabrics such as carpets and rugs that addresses these and other related and unrelated problems in the art.

Briefly described, the present disclosure generally relates to a tufting machine and method of forming patterned tufted articles in which the placement and the pile height of tufts of yarns or stitches formed in a backing can be selectively controlled so as to enable formation of patterned tufted articles, such as carpets, having a variety of pattern effects, including the formation of tufted articles with free-flowing multi-color and/or multi-pile height patterns, as well as having substantially woven or loom formed appearances.

In one aspect, the tufting machine typically will include a control system for controlling the operative elements of the tufting machine to form or create tufted articles according to desired or designed patterns. The resultant tufted articles can include various pattern effects, including having multiple, varied or different pile heights, different types of tufts in the same and/or varying tuft rows, and other textured effects, as well as the placement of various color and/or type yarns to be visible at selected locations and pile heights across the backing; with, at least in some embodiments, the resultant tufted articles being provided with a density of retained and/or visible color yarns/stitches per inch that substantially matches a desired or prescribed pattern density or stitches per inch for the pattern being formed/tufted.

In embodiments, the tufting machine will include one or more needle bars having a series of needles mounted therealong. The needles can be arranged in in-line, staggered or other arrangements. As a backing material is fed through a tufting zone of the tufting machine, yarns will be introduced therein as the needles are reciprocated into and out of the backing material. A shift mechanism further can be provided for shifting the needle bar(s) transversely across the tufting zone, and multiple shift mechanisms can be utilized as needed. The shift mechanism(s) generally will be operable in response to instructions or communications from the control system, for stepping or shifting the needle bar(s) transversely across the backing in accordance with programmed and/or designed pattern shift steps for a pattern being tufted to present the yarns carried thereby to tuft or stitch locations along/across the backing.

The tufting machine further generally will include at least one yarn feed mechanism or attachment for controlling the feeding of the yarns to their respective needles. Such a yarn feed mechanism or pattern attachment can include, without limitation, various roll, scroll, servo-scroll, single end, double or multiple end yarn feed attachments, such as, for example, a Yarntronics™ or Infinity™/Infinity IIE™ yarn feed attachment as manufactured by Card-Monroe Corp. Other types of yarn feed control mechanisms also can be used. The control system generally will include programming for control of the at least one yarn feed mechanism or pattern attachment, which can be operated to selectively control feeding of yarns to their needles for forming tufts of yarns, which can include forming tufts having selected pile heights and/or forming no tufts, to create the desired pattern appearance.

In some embodiments, the control system can further comprise or operate with a stitch distribution control system; through which control of the backing feed and control of the operation of the shift mechanism(s) for shifting of at least a portion of the needles can be coordinated with control of the at least one yarn feed mechanism such that various yarns can be presented to various stitch locations or pixels, and the yarns to be shown on the face or surface of the tufted article generally can be fed in amounts sufficient to form tufts of desired heights while the non-appearing yarns, which are not to be shown in the tufted field generally will not be picked-up when the gauge part is lowered to a no-sew position. Thus, for each pixel or stitch location of the pattern, a series of yarns can be presented, and pick-up of the yarns not selected to be visible or appearing at such a stitch location can be avoided when the gauge parts are in a no-sew position. In addition, in some embodiments, the yarn feed also can be controlled to include withdrawing or pulling some yarns lower, to form sculptured or varying pile height effects, and/or lengthening loops of yarns picked up by movement of the gauge parts in conjunction with the yarn feed control. In addition, some yarns can be pulled back or low out to a level or extent so as to leave a sufficient portion of a non-appearing within the backing to hold or tack the non-selected or non-appearing yarns to the backing without interference with the face or retained, visible tufts of yarns of the pattern by such non-appearing yarns substantially minimized. Thus, in embodiments, only desired or selected yarns/colors to be placed at a particular stitch location may be retained at such stitch location, and can form tufts or different pile heights and colors; while the remaining yarns/colors can be removed or pulled back to an extent that they can be tacked or held to the backing, but will not appear or show in the pattern fields being sewn at that time. The control system further can control and coordinate operation of one or more selected gauge part assemblies with the yarn feed mechanism(s) of the tufting machine according to the instructions for the pattern being formed to control selective formation of loops and/or tufts of yarns, and the lengths or pile heights thereof.

In addition, a gauge part assembly is located below the backing material. The gauge part assembly generally will comprise a series of gauge parts, including, for example and without limitation, loopers, hooks, level cut loop loopers, cut/loop clips, etc., The gauge parts will be positioned along the tufting zone, and are moveable in a first direction so as to be reciprocated into engagement with the needles as the needles penetrate the backing material to pick loops of yarns therefrom. In some embodiments, the gauge parts further each can be selectively movable in a second or additional direction that is generally normal to their direction of reciprocation. For example, the gauge parts can be moved in a substantially vertical, e.g., up-and-down, motion with respect to the stroke or reciprocation of the needles onto and out of the backing, as well as being moved in a reciprocating motion toward and away from the needles, to selectively pick up and form loops of yarns in the backing material. In addition, the movement of the gauge parts in their second direction (e.g. in a vertical or other direction) can be controlled so as to form varying length loops of yarns of varying pile heights in the backing material, including formation of different pile height loops or even no loops of yarns in the backing. In still further embodiments, other configurations and/or combinations of loop pile loopers, cut pile hooks, cut/loop hooks, level cut loopers or hooks, and/or other gauge parts also can be used.

In some embodiments, the gauge parts can include loopers or hooks, each with a body slidably mounted within a gauge module or gauge block, and having a first portion and a second portion, which can include an elongated throat terminating at a pointed proximal end or bill. The first portion of the body of each gauge part can extend through the gauge block or module and can be coupled at a distal end to a drive system including a plurality of actuators that each can be selectively actuated to control movement of the gauge parts in their second direction, and which will be coupled to an associated or corresponding one of the gauge parts by a connector assembly.

In some embodiments, the gauge modules each can include a module or block body having a first or rearward section adapted to couple or mount along a gauge bar, and a second or forward section having at least one channel or passage formed therethrough, and through which the gauge parts will be received. The modules further can include replaceable inserts that can be received within the passage or channel formed within the module body, the replaceable inserts further including slots or recesses adapted to receive and guide the gauge parts during movement of the gauge parts through/along the passage of the module block. Alternatively, the inserts could be integrated with the modules, such as by being bonded or otherwise substantially permanently affixed or secured to the bodies of their modules or gauge blocks, and in some embodiments, can be substantially affixed while still enabling at least serviceable removal thereof if needed.

In embodiments, the replaceable inserts will be formed from hardened materials that can include, without limitation, various metal carbides, metals, ceramics and/or synthetic materials, while the body of the module can be manufactured from lighter weight materials such as aluminum and/or other metals, as well as various composites or synthetic materials. The inserts further can include openings or slots configured to receive guide pins or other locating devices, as well as one or more fasteners, for securing the inserts in the gauge modules. The openings further generally will be configured to enable adjustment of the inserts in at least one direction, e.g., longitudinally, and/or in multiple directions e.g., longitudinally and/or laterally, for adjusting a position of the inserts, and thus the arrangement or positioning of the gauge parts across and/or along their gauge modules. The inserts further can be interchangeable so as to enable easy removal of the inserts, and thus the replacement of one or more of the gauge parts received therein, for example to replace a worn or broken gauge part, or for changing a spacing between the gauge parts.

As a further alternative, in some embodiments, the modules or gauge blocks themselves can be removed and can be replaceable with other gauge blocks or modules, each including a set or series of gauge parts mounted therein, such as to provide for a change out of gauge spacing between gauge parts, a change out of the type of size gauge parts being used, or for a replacement of substantially all or at least a large portion of worn or broken gauge parts as a unit. In addition, the guide slots or recesses formed within the inserts generally will be configured to receive the bodies of the gauge parts with a clearance that is generally sufficient to enable substantially free sliding movement of the gauge parts therethrough, but without enabling undue shifting or twisting of the gauge parts so as to create a misalignment of the bills or throats of the gauge parts with their respective needles. The slots or recesses of the inserts further can terminate at a rear end or portion that can be configured or adapted to enable the edges of the bodies of the gauge parts to be seated against and/or provided with a base or engagement area along which they can slide so as to help maintain a desired alignment of the gauge parts as they are reciprocated or moved through their modules.

The gauge parts additionally can be arranged so as to engage the needles, including being arranged in a substantially in-line, offset or staggered, and/or other configurations as needed to engage in-line, staggered and/or dual needle bar arrangements. In embodiments, each of the gauge parts further can be arranged at an angle with respect to the needles as the needles penetrate the backing. For example, in some embodiments, the gauge parts can be arranged and/or be extensible/retractable along a path of travel oriented at an angle that can range from approximately 1° to approximately 10° from the vertical with respect to the needles and/or the stroke or vertical motion thereof, while in other arrangements, no offset, i.e., a 0° angle, can be provided. The offset of the gauge parts with respect to the needles further can be varied so that the gauge parts can be extended and retracted along an angled or offset path of travel with respect to the needles as needed to minimize potential engagement with the needles as the gauge parts are moved, depending upon the spacing and/or arrangement of the needles.

In various embodiments, the drive system will include a series of selectively controllable actuators driving movement of the gauge parts, which actuators can comprise electric cylinders, hydraulic or pneumatic cylinders, solenoids, motors such as stepper motors, servo motors or other motors, linear actuators, moving coil or voice coil actuators, as well as other, similar actuators, and/or combinations thereof. The actuators associated with or corresponding to each of the gauge parts further can be selectively controlled in accordance with pattern instructions so as to cause the gauge parts to be moved to a desired vertical position with respect to associated needles for pickup of loops of yarns from the needles, including picking up loops of yarns at different points of the needles' stroke so as to form loops/tufts of different pile heights, as well as being retracted to a “no-sew” position wherein a loop of yarn of a selected type or color generally will not be picked up by such gauge parts.

For example, the actuators can be connected to associated or corresponding ones of the gauge parts by connector assemblies for selectively driving movement of such gauge parts in a second direction with respect to the needles as the gauge parts are reciprocated in their first direction toward and away from engagement with the needles. The control system further can include programming to selectively engage each actuator to control the movement of the gauge parts for forming tufts of yarns in accordance with the pattern being run by the tufting machine, including moving the gauge parts to form or not form tufts, and/or for formation of tufts of varying pile heights.

In further embodiments, the actuators can be controlled/triggered to move their gauge parts with a loop of yarn captured thereon so as to elongate or pull such captured loop(s) to provide other pile heights and/or for other effects, such as for tip shearing or other pattern or textured effects. For example, the gauge parts can engage and pick-up loops of yarns from selected needles, and thereafter can be moved, e.g. retracted, to a lowered position, with the feeding of the yarns for such loops also being controlled, so as to draw or pull the loops to a lowered or extended length position to create varying pile height effects. The movement of the gauge parts to a raised or extended position with loops of yarns captured thereon also can be controlled by the control system, with the yarn feed for such loops of yarns further being controlled to pull back such yarns to maintain tension therein and/or to form various pattern pile height effects.

In another aspect of the tufting machine and method of forming patterned tufted articles, the gauge parts can be configured to move or pivot between raised, operative positions, including a fully raised, first operative position, and a lowered, no-sew position, with a distal end or tip of the gauge parts generally being oriented and/or arranged below a penetration depth or stroke of the needles, typically below the pick-up points or take-off areas of the needles, and potentially below the tips of the needles. The gauge parts can comprise loopers, hooks, level cut loop loopers, or other gauge parts, with a body pivotally mounted to a support or holder, and with a throat projecting forwardly from the body and terminating at the generally pointed tip or distal end. The actuators corresponding to such gauge parts can be selectively engaged or operated so as to cause the body of their corresponding or associated gauge part to be pivoted for moving the throats and distal ends of the gauge parts to a desired lowered elevation with respect to the needles.

In various aspects, the gauge parts are coupled to their respective or corresponding actuators of the drive system by connector assemblies including connectors or gates configured to extend between an actuator shaft or rod and the distal end of an associated or corresponding gauge part. In some embodiments, the connectors or gates can include an arm or linkage having a first end portion configured to engage or connect to the drive rod of its actuator, an intermediate section projecting from the first end portion, and a second end portion that generally will be configured to engage the distal end of an associated gauge part. In embodiments, the linkage or arm of each of the connectors or gates further can be received within a housing or support structure. In one example embodiment, such a housing or support structure can include a body formed from a durable, lightweight material, such as a carbon filled nylon material or other, similar composite or plastic material selected to provide durability and support for the linkage or arm while enabling a reduction in weight. Other materials including various metals, synthetic and/or composite materials also can be used. The configurations of the gates and the housings thereof further can be varied as needed.

As each actuator is activated or deactivated, it extends or retracts an actuator shaft to cause the connector or gate coupled thereto move its associated or corresponding gauge part in a desired direction with respect to the needles. For example, in some embodiments, the actuators can drive the gauge parts in a substantially vertical direction with respect to a directional reciprocation of the needles into and out of the backing, such as for adjusting a height of the gauge parts with respect to the needles as the gauge parts are reciprocated toward and away from the needles. In other embodiments, the actuation of the actuators and movement of the connectors can help control movement of the gauge parts, or portions thereof, such controlling movement of clips of level cut loop loopers, toward and away from the needles in a direction substantially along the direction of reciprocation of the gauge parts toward and away from the needles.

In still other aspects, the gauge parts are coupled to associated or corresponding actuators of the drive system by connector assemblies that each include a gate or connector comprising a body having a first end along which the first portion of the body of a corresponding gauge part is received, and a second end. In some configurations, a series of biasing members can be located between the second end of each gate and a spring plate. One or more linkages, which can include arms, rods, cables, or other, similar members, can extend between the actuators and the connectors or gates; and in some embodiments, can be coupled to the gauge parts.

Each linkage generally can have a first end portion extending through the spring plate and adapted to connect to the second end of its corresponding gate, or to a gauge part, and a second end portion coupled to a corresponding or associated actuator. In embodiments, the linkages will extend along a path from the actuators to their corresponding or associated gauge parts/gates. In some embodiments, the linkages further can extend through guides. In such embodiments, the guides can be configured to adjust the pulling force applied by the actuators.

Upon actuation, each selected actuator moves the linkage connected thereto, for example, by pulling or retracting the linkage so as to cause the gate and/or the corresponding gauge part to be moved in its second direction toward a retracted position and against the biasing force of one or more of the biasing members, generally compressing the biasing members as the gauge part is moved toward its retracted position. Upon deactivation of the actuator, the linkage can be released such that the one or more biasing members can decompress and/or bias or urge the corresponding gauge part toward its fully extended position. In embodiments, the biasing members can assist in control of the movement of the gauge parts in their second direction with respect to the needles to enable a substantially incremental movement and location of the gauge parts at varying positions of elevations. Such positional variations can be used to create or vary the lengths of the loops of yarns picked-up by the gauge parts and thus enable variations on pile heights of the tufts of yarns formed in the backing, as well as movement to a no-sew position where the gauge parts are moved to a position where they will not engage the yarns being carried by the needles.

In other embodiments, the connector assemblies can include linkages coupled to the body of one of the gauge parts and to a corresponding or associated actuator. For example, the actuators can comprise motors and the linkages comprise cables, rods, arms of combinations thereof. In embodiments, the motors also can include drive members, which, in embodiments, can include an eccentric, cam, or a pulley or similar drive member configured to translate a rotary motion to linear motion. As the drive member is rotated by its actuator, the linkage is caused to be extended or retracted, which in turn drives the motion of the corresponding or associated gauge part in the second direction between its extended and retracted positions, including moving the gauge part to a no-sew position.

In some embodiments, the connector assemblies can include linkages comprising a first arm or rod having a first end coupled to a drive member, such as an eccentric or pulley, coupled to and drive by an associated one of the actuators, and a second end coupled to a second arm or rod at a first end thereof. The second arm can have a second end pivotally connected to the first portion of the body of its corresponding gauge part. As each drive member is rotated by its motor, the first arm is extended and retracted along a first axis of movement, causing the second arm to pivot and move the corresponding gauge part along a second axis of movement between its extended and retracted positions.

In still further embodiments, each connector assembly can include a linkage that can comprise or can be connected to an extension piece connected to or integrated with the body of a corresponding gauge part. The opposite end of the linkage can be coupled to an actuator, for example, being coupled to drive member (e.g. an eccentric or pulley) driven by a motor. As the motor rotates its drive member, the linkage can be extended or retracted to move the corresponding or associated gauge part between its extended and retracted positions.

In some aspects of the present disclosure, a tufting machine is provided, comprising at least one needle bar having needles mounted therealong; backing feed rolls feeding a backing material; at least one yarn feed mechanism; at least one yarn feed mechanism feeding yarns to the needles; a gauge part assembly positioned below the backing material and having a plurality of gauge parts moveable in a first direction toward and away from the needles as the needles are reciprocated into and out of the backing, and in a second direction; and a control system including programming for controlling the at least one yarn feed mechanism to control feeding of the yarns to the needles in coordination with control or actuation of one or more actuators linked to the gauge parts so as to cause retraction or extension of selected ones of the gauge parts so that the throats of the selected ones of gauge parts are moved between a fully retracted no-sew position and a fully extended position with respect to the stroke of the needles into the backing material, for engaging the needles and forming tufts of yarns in the backing material according to a pattern being formed.

In some embodiments, the gauge part assembly can comprise at least one module carrying a series of gauge parts in a reciprocating motion in a direction toward and away from engagement with the needles as the needles are reciprocated into the backing material; wherein the at least one module comprises a module body that can be machined, cast, molded or otherwise formed from a metal, polymer, composite or synthetic material, or combinations thereof, and will have a first hardness. The module body will be adapted to mount along a gauge bar and will be configured with a passage defined therethrough. Inserts will be mounted to the module body on opposite sides of the passage, each insert having a series of spaced slots formed therein, the slots each configured to slidably receive at least a portion of one of the gauge parts therein. In embodiments, the inserts can be machined, cast, molded or otherwise formed from a metal or metal carbide or powdered metal material having a second or additional hardness greater than the first hardness of module body, and with the slots formed or defined therein.

In some embodiments, the modules can include a module body and one or more inserts.

In embodiments, the gauge parts can each include a body at least partially received within opposed slots of the inserts and moveable through the passage of the module body in an additional direction with respect to a stroke of said needles, the body of each gauge part having a first portion extending through the passage of the at least one module and a second portion having a throat configured to pick-up loops of yarns from the needles.

In embodiments, a series of actuators are coupled to said gauge parts for controlling movement of the gauge parts though the module body; and a control system including programming for controlling the at least one yarn feed mechanism to control feeding of the yarns to the needles in coordination with control of the actuation of one or more of said actuators so as to extend or retract selected ones of the gauge parts such that said throats of the selected ones of gauge parts are moved between a no-sew position and an engaging position with respect to the stroke of said needles into the backing material for selectively forming tufts of yarns in the backing material according to a pattern being formed.

In various embodiments of the tufting machine, the gauge parts comprise level cut loop loopers, loop pile loopers, cut pile hooks, or cut/loop clips, and/or combinations thereof. In still further embodiments of the tufting machine, the actuators can comprise hydraulic or pneumatic cylinders, solenoids, motors such as stepper motors, servo motors or other motors, linear actuators, moving coil or voice coil actuators, as well as other, similar actuators, and/or combinations thereof.

In still other embodiments of the tufting machine, the gauge part assembly further can comprise a series of connectors extending between each gauge part and an associated actuator, each of the connectors including a linkage received within and movable through a housing. In some embodiments, the housing of each connector will comprise a body that can be formed from a polymer, composite or synthetic material or combination thereof and having a channel extending therethrough; and wherein each linkage comprises a metal or composite material or combinations thereof.

In other embodiments, the body of each housing can comprise a composite material including a polymer or plastic with a fibrous fill material, and has a channel defined therein and along which the linkage is moveable; and wherein the linkage of each connector can comprise a hardened metal body or arm, or a series of arms, extending along a passage defined through the body of the housing, with a proximal end configured to engage the first portion of one of the gauge parts, and a distal end configured to be engaged by the actuator associated with the gauge part for translating movement by the actuator to the gauge part.

In addition, in embodiments, the inserts of the modules generally will be configured to overlap an upper surface of the module body and each include a slotted opening adapted to receive a fastener therethrough for adjustably mounting each of the first and second inserts to the module body with the inserts arranged at a selected spacing from each other and at a selected location with respect to the passage defined through the module body. In addition, the inserts can be molded or encased, encapsulated, or otherwise substantially integrated within the module body. The inserts also can include tabs or flange portions that can engage opposite side surfaces of the module body; and a plate or intermediate section can be provided therebetween. The intermediate section can connect the tabs or flanges of the inserts, with the slots of the inserts at least partially formed therein and extending therealong. Alternatively, a bearing plate of support can be received along the first and second side surfaces of the passage, between the tabs or flanges of the inserts.

Thus, in some aspects of the present disclosure, a gauge part assembly for a tufting machine, comprising at least one module having a module body with a passage defined therethrough; and a series of gauge parts received within the passage of the module body, each gauge part including a body with a first portion and a second portion having a throat, wherein the gauge parts are carried with their modules in a first direction toward and away from engagement with associated needles of the tufting machine to pick up loops of yarns from the needles along the throats of the gauge parts, and wherein the gauge parts are selectively movable in a second direction along the passage of the module body; wherein the first and second inserts are arranged along opposite sides of the passage of the module body, each insert formed from material having a hardness that can be greater than a hardness of the metal or composite material of the module body and having a series of spaced slots configured to receive at least a portion of one of the gauge parts therealong; wherein the slots of the first and second inserts are substantially aligned across the passage; and a plurality of actuators each actuator coupled to the first portion of an associated gauge part of the series of the gauge parts and adapted to move their associated gauge parts in the second direction through the passage of the at least one module, whereby the gauge parts are extended or retracted through the module body so as to move the throats of the gauge parts between extended positions for engaging and picking loops of yarns from the needles and a retracted position to substantially avoid picking loops of yarns from the needles.

In still other embodiments, the gauge part assembly can include first and second inserts that each comprise a body machined, molded or cast from a metal, carbide or powdered metal material and including a tab or flange portion in which the slots are formed. Still further, the body of each of the first and second inserts further comprises upper and lower tab or flange portions engaging upper and lower surfaces of the module body, with the slots extending through the upper and lower tab or flange portions.

In some aspects of the present disclosure, a method of operating a tufting machine is disclosed, wherein, according to one example embodiment of the present disclosure, as the needles of the tufting machine are reciprocated into and out of the backing, the gauge parts will be reciprocated in a first direction toward engagement with the needles. In addition, the actuators of at least selected ones of the gauge parts can be selectively engaged or disengaged so as to move their corresponding gauge parts between a fully retracted or no-sew position at which gauge parts will not engage an associated or corresponding needle, and thus no loop of yarn will be formed thereby, and varying extended or raised positions, including a fully extended position. In their raised or extended positions, the gauge parts engage the needles at the take-off portions thereof, as the needles pass into and out of the backing material, to pick-up loops of yarns from the needles.

In addition, in embodiments, as the needles are reciprocated out of the backing, the yarn feed therefor also can be controlled so as to cause non-selected yarns, e.g. yarns that are not engaged or picked-up by associated ones of the gauge parts when such associated gauge parts are in a lowered, no-sew position, so as to be generally retained with their needles and be retracted, withdrawn, or otherwise pulled back or out of the backing material with their needles. In other instances, the gauge parts can be moved to elevated or raised positions prior to or while engaging loops of yarns, and the yarn feed can be controlled to retract, back-rob or pull back some loops of yarns to an extent sufficient to prevent such yarn from being shown at that stitch location in the finished patterned article. The loops of yarns picked up from the needles also can have varying pile heights or lengths depending upon the position and/or movement of the gauge parts with respect to their associated or corresponding needles. For example, in a fully raised position, a smaller or decreased length loop of yarn can be formed by control of the yarn feed for such yarn(s) for controlling a pile height thereof, e.g. for creating a lower pile height, or even substantially hidden loops of yarns in the backing, including such loops being substantially removed (e.g. such as by being maintained/retained with their needles and not picked-up by the gauge parts in a lowered, no-sew position) by control of the yarn feed thereof.

In embodiments, longer loops of yarns can be picked up and formed by loopers as the loopers are moved to lowered positions, pulling the loops of yarns therewith, as needed, so as to create higher or greater pile height tufts of yarns in the backing. In addition, the actuators further can be controlled to selectively cause their corresponding gauge parts to be lowered or retracted with a loop of yarn captured thereon, to form still longer loops of yarns to enable additional patterning effects, such as for tip shearing and the like.

The needles further generally can be shifted laterally with respect to the longitudinal movement of the backing through the tufting zone in order to present different color or different type yarns to each stitch location of the pattern being formed in the backing material. For example, the needles of the needle bar or bars can be threaded with a series of desired colors in various thread-up sequences. In addition, the backing material typically can be run at an actual or effective stitch rate that is substantially greater than the prescribed or desired pattern stitch rate for the pattern being formed. As a result, as the needles are shifted, a desired number of different color or type yarns can be presented to each stitch location. By control of the positioning and/or movement of the gauge parts, loops of yarns can be selectively formed in the backing material, and with the formation of such loops of yarns further being controllable for forming varying pile heights of the resultant tufts in some embodiments. For example, in various aspects, a series of different color or type yarns can be presented to each stitch location as the needle bars are shifted, and if a tuft of a particular color or type yarn is not selected to be sewn at that stitch location, the corresponding gauge part can be held in a retracted or lowered position such that the loop of such a non-selected yarn generally will not be formed.

Still further, in embodiments, the feeding of the backing material will be controlled. For example, in embodiments, the backing feed can be controlled in conjunction with the shifting of the needles, the control of the yarn feed and control of the positioning of the gauge parts, such that the backing feed can be fed at a higher operative, effective or actual stitch rate to enable formation of a substantially increased number of presentations of yarns into the backing material to provide substantially full gauge coverage of tufts of selected colors of types of yarns remaining in the face of the tufted article and substantially avoid a missing color or type of yarn or gap being created, shown or otherwise appearing in the pattern fields of the patterned tufted article. The finished patterned tufted article thus can be provided with a density of tufts per inch that substantially matches a desired or prescribed pattern stitch rate, i.e., for patterns designed with a pattern stitch rate of 8, 10 or 12, or other numbers of stitches per inch, the resultant finished patterned tufted article can be formed a density of visible and/or retained face yarns or tufts per inch that can approximately match the pattern stitch rate.

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 and the claims, taken in conjunction with the accompanying drawings. Moreover, it is to be understood that both the foregoing summary of the disclosure and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the present disclosure.

Referring now to the drawings in which like numerals indicate like parts throughout the several views,generally illustrate an embodiment of a tufting machineand method for forming patterned tufted articles, according to the principles of the present disclosure, wherein placement of stitches or tuftsof yarns Y can be at desired locations in a backing material B can be controlled. Such tufts or stitches can be formed with a sculptured, multi-pile height tufted appearance, and further can be placed with enhanced selectivity and/or control, for formation of further varying or free-flowing pattern effects. For example, the tufted article can be formed with the tufts of yarns formed at varying pile heights to provide sculptured looks, and with different color or type yarns for formation of multi-color patterns of various geometric and/or free-flowing designs. Additionally, it will be understood that various numbers of different type and/or color yarns (i.e., two color, three color, five color, six color, etc.), can be used to form multiple pile height patterned tufted articles according to the principles of the present disclosure.

As generally illustrated in, in one embodiment, the tufting machinewill include a frame, which can include a head or upper portionhousing a needle bar driveand defining a tufting zone T. The needle bar drive mechanism() typically includes a series of push rodsthat can be connected to a needle bar drive(such as a gear box/assembly) shown inor similar mechanism, by connector rods, which needle bar drivein turn can be connected to and driven off a main drive shaftof the tufting machine, for example by one or more drive belts or drive chains, and with the main drive shaftitself being driven by a motor such as a servo motor. Alternatively, the push rodsof the needle bar drive mechanismcan be connected via connector rodsto the main drive shaftso as to be driven directly off the main drive shaft, or by an independent drive system (not shown).

An encoder or similar sensor additionally can be provided for monitoring the rotation of the main drive shaft and reporting the position of the main drive shaft to a control system() controlling the operation of the tufting machine. The control systemgenerally can comprise a tufting machine control including a computer/processor or system controllerwith an operator interfaceA, such as a touch screen, keyboard, mouse, etc., through which the operator can input patterns, make adjustments, etc. In some embodiments, the control systemcan comprise or include a stitch distribution control system such as disclosed in U.S. Pat. No. 8,359,989, the disclosure of which is incorporated by reference as if set forth fully herein, with the controllerfurther including programming for control methodology for forming tufted patterns, including sculptured patterns having tufts formed at multiple pile heights, as well as with various color/stitch placement controlled patterns such as disclosed in U.S. Pat. No. 8,359,989.

The control systemgenerally will include programming enabling the monitoring and control of the operative elements of the tufting machine, such as the needle bar drive mechanism, yarn feed attachments, backing feed rolls, the main drive shaft, a needle bar shift mechanism() and a gauge part assemblymounted beneath the tufting zone T of the tufting machine in accordance with the calculated/determined pattern instructions, as discussed more fully below. The control system() further can receive and execute or store pattern information in memory storage of the system controller. In response to developed/programmed pattern instructions, the control systemwill control the operative elements of the tufting machinein order to form the desired tufted patterns in the backing material B as the backing material is passed through the tufting zone T in the direction of arrowby the backing feed rolls, as indicated in.

In some embodiments, the system controllerof the control systemgenerally can be programmed with instructions for forming one or more desired patterns for one or more tufted articles, including a series of pattern steps, which steps can be created or calculated manually or through the use of design centers or design software as understood by those skilled in the art or can receive such patterns via input from a disk, USB or other external drive, or through a network connection. Alternatively, the controllercan include image recognition software to enable scanned and/or designed pattern images, such as designed patterns, including pile heights and other characteristics such as placement of loop pile and cut pile tufts in the pattern shown by, for example, different colors or similar markers or indicators, as well as photographs, drawings and other images, can be input, programmed, recognized and processed by the control system, including receiving inputs from a design center or through various design software systems, or via a scanner or other imaging device(). The control system can recognize and identify various pattern characteristics, including colors and/or difference in texture of a designed pattern image indicative of texture effects such as placement or location of loop and/or cut pile tufts, and can assign selected yarns thereto.