Abstract: A tufting machine for producing pile fabric having a pile height of approximately at least 50 mm has divider plates between adjacent needles to prevent yarn loops and especially the legs of cut loops from becoming trapped between an adjacent needle and its associated yarn feed. The divider plates may take the form of plates forming an extension of the fingers of the needle plate between each pair of which a needle reciprocates and may be mounted on a block on the bed plate beneath the needle plate, or may be plates upstanding from the hook bar.

Abstract: A tufting needle which has a transverse eye between the blade of the needle an the point and has a clearance above the eye in the blade on one side and has no yarn guide and protection groove on the opposite side. Also, disclosed is a conventional tufting needle which has the conventional yarn guide and protection groove.

Abstract: A tufting machine configured to provide needles co-linearly along a tufting plane from opposing needle holders provided in a needle module. The needle holders may be selectively latched with latch pins connected to limbs extending from a yoke connected to the push rod of the tufting machine. The needle holders are biased in a dis-engaged position with compression springs which extend between caps on the needle holders and a guide plate which locates the needle holders laterally while spacing the opposed needle holders from one another.

Abstract: A needle module contains a plurality of needles having a shank and an eye at a first end and a mounting portion at the second end mounted in a module body. A rod is mounted on and spaced apart from the module body transversely to the needles. Yarn stands pass over the rod and are directed through the eyes of the needles.

Abstract: A tufting machine has a yarn feed roller assembly with a plurality of rotatable driver rollers driven at different speeds and a plurality of actuators in the form of a pivotable arm having in one embodiment a pair of yarn feed reels one of which is arranged to selectively press yarn into engagement with one of the drive rollers and the other arranged to selectively press yarn into engagement with another drive roller. Yarn is engaged by each actuator and a selected drive roller for a period of time determined by a pattern. The longer the actuator engages the high speed roller during the stroke of a tufting machine needle the greater will be the pile height of the tufts produced and alternatively the longer the actuator engages the lower speed roller during the needle stroke the lower will be the pile height. Pile height variations between a high pile and a low pile may be obtained by controlling the proportion of time during the stroke that the yarn engages with the high and low speed rollers.

Abstract: A needle, which may be one of a plurality of needles in a needle module, has a rod attached to the shank adjacent the yarn guide groove or to the blade in the guide groove and extending laterally or transverse to the axis of the needle committing yarn to be directed readily into the yarn groove with a minimum angular deviation in its path. When the needle is one of several in a needle module the rod may be common to all of the needles and passed through an aligned hole in each of the needles and secured therein by bending of the rod. A yarn entrance guide is formed by each respective needle, the adjacent needle, the rod and the module body and this entrance permits ready threading of each needle.

Abstract: A tufting machine has a reciprocating needle bar which may be shifted laterally by a drive which includes at least one linear motor. Each linear motor has two major elements which may be coupled together electromagnetically. One of the elements is connected to a fixed portion of the tufting machine and another of the elements is connected to the needle bar. When electrical power is supplied to the motor, the element connected to the needle bar moves relatively to the other thereby moving the needle bar.

Abstract: A tufting machine with a pair of closely spaced apart needle bars which reciprocate together but the needles carried by one bar may be controlled selectively to be either in a position to form pile or be retracted to a position where they do not form pile when the needle bars are driven toward the backing material selectively. A control system is provided to control the selection of the needles of the one needle bar and also the feeding of yarn to the needles of the one needle bar so that yarn from needles which are not tufting is drawn tight on the backing. The needles may be mounted in modules and selected needle modules may be independently controllable by pneumatic cylinders so that various overtufted patterns may be made by the controlled needles in a background formed by the needles in the other bar that tuft on every stitch.

Abstract: A hand-held mending gun for tufting stitches into a backing material has a hollow needle reciprocally driven axially to form stitches in a backing material. A drive mechanism couples a rotary motor to a needle carrier for reciprocation along the axis of the needle. A yarn feed roll connected to a yarn drive disk may be selectively changed in speed by changing the position of the yarn feed disk relative to a radius of a drive disk through a pneumatic cylinder having a piston relocatable between an extended and a retracted position. With the speed of rotation of the drive disk constant, the speed of the yarn feed roll may be changed between a high and a low pile height setting, or position, by changing the distance of a contact point of the yarn feed disk on the drive disk from the center of the disk drive. A pneumatic selector switch allows a single operator to control the selection of the high or low pile height position.

Abstract: A tufting machine has a yarn feed pattern assembly including a housing having a mounting plate for mounting a multiplicity of yarn feed rollers from the exterior of said mounting plate and a multiplicity of servo motors connected to said mounting plate on the interior of said housing. Each servo motor is connected to a respective feed roller. A multiplicity of tubes extend within said housing, half the tubes directing yarn from a source to respective rollers and half of the tubes directing yarn from the rollers to respective needles. The guide tubes direct yarn from the interior of said housing through said mounting plate where the yarn is trained about a respective roller and directed back into the yarn guide leading toward the needles of said tufting machine.

Abstract: The hooks of a cut pile tufting machine have a cam or chamfer surface in the form of an inclined ramp in the shank of the hook adjacent the throat extending to the cutting edge, the hooks being positioned in a hook module with a dual or compound angle relatively to the body of the module. The knife which cooperates with the hook to cut loops of yarn seized by the hook is positioned vertically relatively to the hook but is tilted relatively to the hook. The hook is inclined horizontally toward the knife and is tilted vertically away from the knife. The result is that initial knife tension against the hook is substantially eliminated while additional knife tension is created during the cutting stroke. The vertical positioning of the knife and the angular positioning of the hook away from the knife results in substantially eliminating J-cutting.

Abstract: A multi-cylinder module has a common block within which the cylinders are formed and having a piston disposed within each cylinder and an output rod connected to each piston. Pressurized air acts on the piston against the bias of a corresponding spring to drive the respective rod outwardly from the module. Each rod has a coupling member which is coupled to the gate of a hook of a tufting machine having gated hooks for forming both loop and cut pile. The modules are mounted directly to the hook bar of the tufting machine and require no additional linkages between the coupling and the gate with the inherent lost motion and other inefficiencies associated with such additional linkages.

Abstract: A tufting needle construction in which the mounting shank is offset from the axis of the blade and the yarn guide groove which extends to the eye and point portion of the needle. The yarn guide groove extends from a yarn entry mouth spaced from the shank so that yarn entering the groove from the mouth lies entirely within the groove and does not feed into the groove at an angle. Accordingly, when the needle pierces a backing material during the tufting process, the yarn is not crushed between the blade and the backing material. In one embodiment the shank is perpendicular to the blade. In another embodiment the shank has a first portion perpendicular to the blade and another portion parallel to the blade.

Abstract: An individually controlled needle tufting machine has a reciprocable latch bar for latching and unlatching selective needle holders, each needle holder being guided between a pair of guide plates and carrying a respective needle so that each needle selectively may be driven by the latch bar. The guide plates each include a plurality of curvilinear ridges and the edges of the needle holder are curvilinear and are received within a respective spaced apart pair of ridges within which they are guided as the needle holder reciprocates. The plates include vertically spaced apart inserts within which the ridges are formed. The needle holder has a yarn clamp mounted internally adjacent the bottom and a leaf spring has a leg mounted externally of the holder and has a leg entering internally to act upon and urge the yarn clamp.

Abstract: A controlled needle tufting machine has a cyclically reciprocating latch bar to which the needles may be selectively latched in accordance with a pattern to reciprocate and insert loops of yarn into a backing material or to not be latched and remain stationary above the backing material includes yarn detection apparatus for determining whether the feeding of yarn for the needle is correct. The detection apparatus includes a yarn fault detector for detecting whether yarn is moving between a source and a respective needle and for providing a signal in response to such movement. The yarn movement signal is compared with a signal from the pattern control and if the needle is latched and yarn is supposed to be moving, a fault signal is provided if the yarn is not moving. If the needle is supposed to be stationary but the detector indicates that yarn is moving, a fault signal may also be provided. In either case the fault signal is displayed and the machine may be stopped.

Abstract: An individual controlled needle tufting machine has a reciprocating latch bar for latching and unlatching to selective needle carriers, each needle carrier being guided in a respective guide formed in a guide block and carrying a respective needle so that each needle selectively may be driven by the latch bar. The tufting machine has mechanism for laterally shifting the latch bar and needle carriers, whether latched or unlatched to the latch bar, together with guide blocks. The latch bar and the brackets to which the guide blocks are mounted are formed from aluminum alloy to which laterally extending tubes are fastened. Water, cooled by refrigeration, is circulated through the tubes so that the thermal expansion of the aluminum alloy elements are not substantially greater than the remainder of the tufting machine.

Abstract: A tufting machine includes a pattern attachment mounted between a yarn feeding device and the needles, the yarn feeding device feeding yarn to the needles at a constant rate in an amount sufficient to accommodate the yarn requirements of the needle and looper system. The pattern attachment includes a series of slats rotatable about an axis in timed relationship to the reciprocation of the needles. Each slat includes a yarn receiving groove corresponding to each needle, certain of the grooves being shallower than others. A first yarn guide directs yarn from the feeding device to the pattern attachment while a second yarn guide directs yarn from the pattern attachment toward the needles. The slats are mounted on chains fastened to sprockets mounted on a driven shaft.

Abstract: A hand-held mending gun for tufting stitches into a backing material has a hollow needle reciprocably driven axially and oscillated laterally so as to form stitches in a backing material laterally offset from other stitches. Zig-zag backstitches may thus be formed as may other laterally offset stitches. A crank drives a needle carrier in a reciprocating path extending longitudinally along the axis of the needle. The elongated path is defined by constraining the needle carrier to move within a slot in a pivotally mounted yoke member having a pair of spaced apart tines disposed about a cam so that rotation of the cam oscillates the yoke member about the pivot. The cam is driven by gears such that it may make one cycle For each two cycles of reciprocation of the needle to form alternate laterally offset stitches. Cams of various configurations may be utilized so that more than one stitch may be provided at each lateral side.

Abstract: A cut/loop hook and clip module for use in a tufting machine has a molded body member including a plurality of tufting machine hooks cast therein in side-by-side relationship. The hooks have a beak at one end, a blade extending from the beak to a shank and a mounting portion of the shank extending remote from the beak. An elongated groove is formed in the shank and the mounting portion for receiving the tail portion of a cooperating clip. The clip includes a creased and bowed flag portion at one end of the tail portion. The hook includes a detent in the form of a notch adjacent the groove and the tail portion includes a detent in the form of a nub which is positionable into the notch to locate the clip so that the creased flag portion is in proper relationship relative to the beak of the hook. The flag portion of the clip is positioned on the side of the hook opposite to that having the groove with the flag portion biased against the blade adjacent the end of the beak.

Abstract: A tufting machine has a yarn feed pattern assembly including a housing having a mounting plate for mounting a multiplicity of yarn feed rollers from the exterior of said mounting plate and a multiplicity of servo motors connected to said mounting plate on the interior of said housing. Each servo motor is connected to a respective feed roller. A multiplicity of tubes extend within said housing, half the tubes directing yarn from a source to respective rollers and half of the tubes directing yarn from the rollers to respective needles. The guide tubes direct yarn from the interior of said housing through said mounting plate where the yarn is trained about a respective roller and directed back into the yarn guide leading toward the needles of said tufting machine.