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

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

Abstract: A tufting machine for selectively forming tufts of yarns, including different color or type yarns, for forming patterned tufted articles such as carpets. A series of needles are reciprocated into and out of a backing material being fed through the tufting machine and are engaged by a series of gauge parts so as to pick-up loops of yarns from the needles. The gauge parts will be selectively controlled by actuators to extend or retract the gauge parts to positions or elevations sufficient to pick-up or not pick-up loops of yarns from the needles. The feeding of the yarns to the needles further can be controlled in conjunction with the movement of the gauge parts, while the backing feed can also be controlled, to enable formation of tufts of yarns at an increased rate over the pattern stitch rate for the pattern of the tufted article being formed.

Abstract: A shift mechanism for a tufting machine for controlling the transverse, lateral shifting movement of a series of needles of the tufting machine across a backing material for forming a series of cut and/or loop pile tufts of yarns in the backing in accordance with a pattern. The shift mechanism will include a motor controlled rack and pinion shift control assembly having one or more pinions, each driven by a motor, that engage and drive a rack coupled to at least one needle bar of the tufting machine, for controlling the transverse shifting movement of the needles.

Abstract: A system and method for tufting sculptured and multiple pile height patterned articles, including controlling placement of yarns fed to the needles of the tufting machine by a yarn feed mechanism to form varying patterns includes a backing support over which the backing is fed, and which lifts/and biases the backing to a raised position. As the backing material is fed through the tufting machine, a series of loopers or hooks engage and pick loops of yarns from the needles. The yarn feed mechanism will be controlled to create a tension in selected loops of yarns, to cause the backing material to be pulled against the bias or spring force applied by the backing support toward the needle plate of the tufting machine to create tufts of different pile heights.

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

Abstract: A tufting machine for selectively forming tufts of yarns, including different color or type yarns, for forming patterned tufted articles such as carpets. A series of needles are reciprocated into and out of a backing material being fed through the tufting machine and are engaged by a series of gauge parts so as to pick-up loops of yarns from the needles. The gauge parts will be selectively controlled by activators to move the gauge parts to positions or elevations sufficient to pick-up or not pick-up loops of yarns from the needles. The feeding of the yarns to the needles further will be controlled to pull back the yarns not picked-up by the gauge parts, while the backing feed will be controlled to enable formation of tufts at an increased rate over the pattern stitch rate for the pattern of the tufted article being formed.

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

Abstract: A system and method for forming synthetic/artificial grass or turf products in which a series of tufts of artificial/synthetic grass filaments or yarns are formed in a backing material with various graphic pattern effects being formed therewith. The system generally will include at least one needle bar having at least one row of needles mounted along a tufting zone and reciprocated through the backing to a desired penetration depth, and will present a desired set or group of yarns to a series of pattern pixels or stitch areas. A series of level cut loop loopers or hooks will be aligned with and will engage the needles in order to form tufts of yarns in the backing material. Clips of the level cut loop loopers will be selectively controlled to control the retention of selected ones of the yarns presented at each pattern pixel. The remaining, non-selected yarns generally are not retained at the pattern pixels, and can be formed as lower pile tufts or removed from the backing material.

Abstract: A system and method for forming patterned tufted fabrics such as carpets, including the formation of patterns having cut pile and loop pile tufts therein. The system includes a pair of needle bars each carrying a series of needles to which a plurality of yarns are fed. Cut pile hooks are arranged along a cut pile side of a tufting zone, in a position to engage the needles of one of the needle bars, while loop pile loopers are arranged along the opposite loop pile side of the tufting zone, in a position to engage the needles of the other one of the needle bars. A backing material is fed through the tufting zone, and as loop pile tufts of yarns are formed in the backing material, the needles mounted along a needle bar extending along the cut pile side of the tufting zone can be shifted to an off-gauge position, with the yarn feed to these needles further being controlled, to substantially prevent engagement and pick-up of the yarns carried by such needles by the cut pile hooks.

Abstract: A tufting machine for selectively forming tufts of yarns, including different color or type yarns, for forming patterned tufted articles such as carpets. A series of needles are reciprocated into and out of a backing material being fed through the tufting machine and are engaged by a series of gauge parts so as to pick-up loops of yarns from the needles. The gauge parts will be selectively controlled by activators to move the gauge parts to positions or elevations sufficient to pick-up or not pick-up loops of yarns from the needles. The feeding of the yarns to the needles further will be controlled to pull back the yarns not picked-up by the gauge parts, while the backing feed will be controlled to enable formation of tufts at an increased rate over the pattern stitch rate for the pattern of the tufted article being formed.

Abstract: A system and method for tufting sculptured and multiple pile height patterned articles, including controlling placement of yarns fed to the needles of the tufting machine by a yarn feed mechanism to form varying patterns includes a backing support over which the backing is fed, and which lifts/and biases the backing to a raised position. As the backing material is fed through the tufting machine, a series of loopers or hooks engage and pick loops of yarns from the needles. The yarn feed mechanism will be controlled to create a tension in selected loops of yarns, to cause the backing material to be pulled against the bias or spring force applied by the backing support toward the needle plate of the tufting machine to create tufts of different pile heights.

Abstract: A stitch distribution control system for a tufting machine for controlling placement of yarns being fed to the needles of the tufting machine by yarn feed mechanisms to form a desired pattern. A backing material is fed through the tufting machine at an increased stitch rate as the needles are shifted according to calculated pattern steps. A series of loopers or hooks engage and pick loops of yarns from the needles. The yarn feed mechanisms further can be controlled so that selected loops of yarns can be back-robbed so as to be hidden from view in the finished patterned tufted article.

Abstract: A level cut loop looper or hook and clip assembly for a tufting machine includes at least one module carrying a series of level cut loop loopers or hooks. Each level cut loop looper or hook generally can include a looper body along which a clip is slidably moved. Each clip will be moved between retracted and extended positions as the level cut loop loopers or hooks are reciprocated toward and away from engagement with their associated needles of the tufting machine. Actuators can be engaged to secure the clips in their extended positions as needed to selectively form cut and loop pile tufts in a backing material.

Abstract: A yarn color placement system for a tufting machine including a series of different color yarns being fed to the needles of the tufting machine by yarn feed mechanisms. A backing material is fed through the tufting machine at an increased stitch rate as the needles are shifted according to the programmed pattern steps. A series of level cut loop loopers or hooks engage and pick loops of yarns from the needles, with the clips of the level cut loop loopers or hooks being selectively actuated to form cut pile tufts, while the remaining loops of yarns can be back-robbed so as to be hidden from view in the finished patterned tufted article.

Abstract: A variable stroke drive system for a tufting machine includes a series of drive assemblies mounted along the frame of the tufting machine. Primary drive shafts extend through the drive assemblies and are each driven by a drive motor. A series of first drive members are mounted to the primary drive shafts and are linked to associated second drive members such that the driving of the first drive members by the primary drive shafts in turn drives the second drive members. Cam arms are connected to the second drive members and to rocker arms to which push rods are mounted, the cam arms being vertically reciprocated by the rotational movement of the second drive members so as to drive the reciprocation of the push rods, and thus the needle bar(s) connected thereto along a desired stroke or reciprocating path of travel. Controlling the rate at which the primary drive shafts are driven enables control of the stroke of the needle bar(s).

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

Abstract: A system and method for forming synthetic/artificial grass or turf products in which a series of tufts of artificial/synthetic grass filaments or yarns are formed in a backing material with various graphic pattern effects being formed therewith. The system generally will include a pair of needle bars each having at least one row of needles mounted along a tufting zone and reciprocated through the backing to a desired penetration depth, and will present a desired set or group of yarns to a series of gauge parts mounted at differing elevations. A first or upstream one of the needle bars will be shifted to an off-gauge position to move the needles thereof into positions so as to not be engaged by their associated gauge parts. The yarns fed to these needles further can be controlled to substantially pull back or otherwise prevent tufts of such yarns from being formed in the backing.

Abstract: A yarn feed system, for control of the feeding of one or more yarns to the needles of a tufting machine, which can be manufactured as a substantially standardized unit or attachment removably mounted to a tufting machine includes a series of yarn feed devices each having a drive motor with a replaceable yarn feed roll drive system mounted thereto. Each yarn feed roll drive system can include a set or series of yarn feed rolls mounted within a housing and having a series of gear teeth formed thereabout, with the gear teeth of the yarn feed rolls engaged in an intermeshing arrangement so that as one of the yarn feed rolls is driven by the drive motor, the other yarn feed rolls likewise are actively driven thereby. Each of the yarn feed rolls further will include a textured roll surface that can provide for enhanced grip and control of the feeding of the yarns which are extended thereabout to the needles of the tufting machine in accordance with a tufted pattern being formed.

Abstract: A shift mechanism for a tufting machine for controlling the transverse, lateral shifting movement of a series of needles of the tufting machine across a backing material for forming a series of cut and/or loop pile tufts of yarns in the backing in accordance with a pattern. The shift mechanism will include a motor controlled rack and pinion shift control assembly having one or more pinions, each driven by a motor, that engage and drive a rack coupled to at least one needle bar of the tufting machine, for controlling the transverse shifting movement of the needles.