Abstract: A method of preparing a tufting process for tufting a fabric comprises the steps of: a) selecting at least one object to be shown on a tufted fabric as a three-dimensional tufting structure element (116), b) three-dimensionally scanning the at least one object for providing a set of three-dimensional scan data representing at least a portion of the three-dimensional structure of the at least one object, c) providing a set of tufting instruction data on the basis of the three-dimensional scan data, the tufting instruction data, in association with the at least one three-dimensional tufting structure element (116) to be tufted, comprising information relating to at least one tufting aspect of the piles to be tufted for providing the at least one three-dimensional tufting structure element (116).

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: Differential yarn twist has been found to increase the durability factor of carpet in an unexpected manner while providing a wide range of aesthetic effects. First and second adjacent yarns have different rates of twist. They can be tufted with a single needle or adjacent needles for various embodiments.

Abstract: An overtufting machine/method provides additional yarn per area in an area of design than in areas lacking the overtufted design. Specifically, for many embodiments, a carpet is first tufted, and then run past an overtufting station which preferably moves in a lateral direction relative to the direction of feed to direct at least one needle through the carpet in at least one selectable height option. Rails are preferably used to shuttle the needle supported by a head on at least one carriage to shuttle along the rail(s).

Abstract: A tufting machine for forming tufted articles such as carpets including one or more needle bars carrying a series of spaced needles. The needles are arranged in 2 or more transverse rows of needles, with the needles of each transverse row of needles being mounted in a mini-staggered arrangement along the one or more needle bars. A series of gauge parts are mounted below backing material passing through the tufting machine. The gauge parts each engage corresponding ones of the needles of each transverse row of needles following penetration of the backing material by the needles, so as to form multiple tufts of yarns in the backing material.

Abstract: A backing material shift system for controlling movement of a backing material through a tufting machine includes spaced, first and second backing feed roll assemblies each carrying a series of reduced length backing feed rolls. The backing feed rolls are connected in series, with their opposite ends being supported by a series of roll stabilizing blocks. The backing feed roll assemblies are slidably supported along the frame of the tufting machine and are movable or shiftable across the tufting zone of the tufting machine in a direction transverse to the path of travel or feeding of the backing material through the tufting machine by operation of a backing material shifter.

Abstract: The invention relates to a control system for a tufting machine configured for forming tufted carpet. The tufting machine can have a system controller in communication with the tufting machine and with a plurality of yarn feed controllers for controlling operation of yarn feed motors that are configured to supply yarn from a source of yarn to the tufting machine. The system controller is programmable to enable input of a plurality of predetermined yarn feed profiles for selected stitches of a programmed pattern to be tufted such that, although at least two of the predetermined yarn feed profiles can be different, substantially the same feed length of yarn is used from each of the plurality of yarns.

Abstract: A looper module for tufting machines in which loop pile tufts of yarns are formed in a backing material in a chained stitch formation includes a module body. The module body generally includes slotted openings in which a series of looper assemblies are received, and further can include a looper support section that projects upwardly from the module body. Each looper assembly can include a primary looper having loop pile looper and pattern looper portions. First and second transfer loopers are attached to the body of the primary looper and generally can include throat portions extending toward the primary looper for the transfer of loops of yarns thereto.

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 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 novel method of tufting carpets is provided to allow the use of four or more colors of yarn at sufficient stitch density to provide for a solid appearance of any of the selected colors at any location on the carpet, and utilizing natural tacking of rear yarns to minimize loose yarn on the backing.

Abstract: A cross-tufting machine and process for manufacturing carpet. The cross-tufting machine includes a sewing head and a tufting gun. The sewing head is movably mounted on support railing and a support platform is provided to support carpet that is to be provided with a tufted secondary pattern. The carpet moves in steps on top of the support platform in a machine direction and the sewing head traverses back and forth in a cross-wise direction wherein the tufting gun forms the tufted secondary pattern in the carpet.

Abstract: A looper module for tufting machines in which loop pile tufts of yarns are formed in a backing material in a chained stitch formation includes a module body in which a series of looper assemblies are received. The module body generally includes a series of slotted openings in which the looper assemblies are received, and further can include a looper support section that projects upwardly from the module body and includes a series of slotted openings formed in spaced series therealong. The looper assembly generally includes a primary looper, having a loop pile looper portion and a pattern looper portion. First and second transfer loopers are attached to the body of the primary looper. Each of the transfer loopers generally includes a throat portion that generally extends along and inwardly toward a throat of the loop pile looper portion of the primary looper.

Abstract: An automated quilting and tufting system for application of tufts at selected locations along a web of material, including a sewing head receiving a series of tufts or rosettes from a supply. The tufts are removed from their supply and are placed at selected locations on the web of material for attachment to the web of material by the sewing head. Thereafter, the web of material can be cut to form a panel of a desired size.

Abstract: A method for using a tufting machine to produce athletic turf bearing precise graphic tuft patterns at a high throughput rate is disclosed. The utilized machine includes tenter frame and a series of tufting frames upon which tufting head components are mounted. The entire length of a piece of backing material is wrapped around the tenter frame, and the tenter frame circulates the backing past the tufting frames, and the tufting head components are shifted as may be necessary to form a desired graphic tuft pattern.

Abstract: A system and method for forming synthetic/artificial grass or turf tufted fabric materials in which a series of tufts or artificial/synthetic grass or turf yarns is formed in a backing material. The system generally will include a row of needles mounted along a tufting zone and which are reciprocated through the backing material to deliver a series of yarns into the backing materials. The needles are arranged in needle groups with the needle groups spaced apart along the length of the needle bar. A series of gauge parts, typically including cut-pile hooks, will be aligned with and will engage the needles in order to form cut and pile tufts defining spaced grass/turf tuft formations in the backing material.

Abstract: A process to manufacture tufted backing materials comprises the steps of a) providing a roll bearing a backing material which backing material comprises a first side exhibiting a first colour and a second side exhibiting a second colour, wherein the first colour is different from the second colour, the first side is the front side and the second side is the rear side, b) unwinding the backing material from the roll, c) tufting the backing material, d) cutting the backing material at a position between the roll bearing the backing material and the tufting device, e) rotating the roll bearing the backing material by an angle of 180°, f) unwinding the backing material from the roll in a second unwinding direction which is opposite to the first unwinding direction and guiding the backing material into the tufting device, and g) tufting the backing material.

Abstract: The invention relates to a control system for a tufting machine configured for forming tufted carpet. The tufting machine can have a system controller in communication with the tufting machine and with a plurality of yarn feed controllers for controlling operation of yarn feed motors that are configured to supply yarn from a source of yarn to the tufting machine. The system controller is programmable to enable input of a plurality of predetermined yarn feed profiles for selected stitches of a programmed pattern to be tufted such that, although at least two of the predetermined yarn feed profiles can be different, substantially the same feed length of yarn is used from each of the plurality of yarns.

Abstract: A carpet and method for producing same that comprises an enhanced seam suitable for separation of an installation portion of the carpet and sacrificial edge portions of the produced carpet.

Abstract: Methods of tufting a pattern in a backing material using a plurality of different yarns A, B, . . . n that are threaded in the needles of a needle bar in a non-repeating sequence or pattern of yarn sets across the width of the needle bar.

Abstract: Methods of tufting a pattern in a backing material using a plurality of different yarns A, B, . . . n that are threaded in the needles of a needle bar in a non-repeating sequence or pattern of yarn sets across the width of the needle bar.

Abstract: A method for using a tufting machine to produce athletic turf bearing precise graphic tuft patterns at a high throughput rate is disclosed. The utilized machine includes tenter frame and a series of tufting frames upon which tufting head components are mounted. The entire length of a piece of backing material is wrapped around the tenter frame, and the tenter frame circulates the backing past the tufting frames, and the tufting head components are shifted as may be necessary to form a desired graphic tuft pattern.

Abstract: A tufting machine for forming tufted carpet having means for inserting loops of at least two different yarns into a backing material moving through the tufting machine and means for controlling the deviation of the ratio of different yarns projecting from a top surface of the backing material. It is contemplated that the tufting machine can be used to maintain the color of the tufted carpet at a desired color during the operation of the tufting machine.

Abstract: A method of tufting novel loop pile carpets is provided to allow the use of four or more colors of yarn at sufficient stitch density to provide for a solid appearance of any of the selected colors at any location on the carpet.

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 yarn feed system, enabling the control of individual yarns to the needles of a tufting machine, and which system can be manufactured as a substantially standardized unit or attachment that can be removably mounted to a tufting machine. The yarn feed unit includes a series of yarn feed devices each including a drive motor for feeding one or more selected yarns to the needles of the tufting machine, and a series of yarn feed controllers integrated with each yarn feed drive motor for monitoring and controlling the operation of the yarn feed devices to control the feeding of the yarns to the needles according to programmed pattern instructions.

Abstract: The invention relates to a control system for a tufting machine configured for forming tufted carpet. The tufting machine can have a system controller in communication with the tufting machine and with a plurality of yarn feed controllers for controlling operation of yarn feed motors that are configured to supply yarn from a source of yarn to the tufting machine. The system controller is programmable to enable input of a plurality of predetermined yarn feed profiles for selected stitches of a programmed pattern to be tufted such that, although at least two of the predetermined yarn feed profiles can be different, substantially the same feed length of yarn is used from each of the plurality of yarns.

Abstract: Creels having frames configured to receive one or more trays of yarn packages. The trays of yarn packages are removable from the frame and can be loaded with packages of yarn when not inserted into the frame. Separately loading trays with yarns can simplify and provide other benefits with respect to the process of loading a creel with yarn packages. Also disclosed is an assembly that is positioned with respect to a detachable header and a stationary header on a creel and that comprises an air flow unit that causes yarns to move through to an alignment mechanism that aligns the yarns for attachment to yarns already feeding into a tufting machine.

Abstract: A tufting machine for forming tufted carpet having means for inserting loops of at least two different yarns into a backing material moving through the tufting machine and means for controlling the deviation of the ratio of different yarns projecting from a top surface of the backing material. It is contemplated that the tufting machine can be used to maintain the color of the tufted carpet at a desired color during the operation of the tufting machine.

Abstract: A yarn feed system, enabling the control of individual yarns to the needles of a tufting machine, and which system can be manufactured as a substantially standardized unit or attachment that can be removably mounted to a tufting machine. The yarn feed unit includes a series of yarn feed devices each including a drive motor for feeding one or more selected yarns to the needles of the tufting machine, and a series of yarn feed controllers integrated with each yarn feed drive motor for monitoring and controlling the operation of the yarn feed devices to control the feeding of the yarns to the needles according to programmed pattern instructions.

Abstract: A crank adjusted shifting mechanism having a servo driven eccentric in communication with a drive rod and optional clamping assembly provides for a fast and programmable needle bar shifting mechanism for a tufting machine.

Abstract: A quasi-isotropic sandwich structure is provided for resisting loads along multiple axes. The structure includes a core material sandwiched by fiberglass reinforcements. Fiberglass rovings are inserted through the structure such that the rovings are oriented along three axes, with adjacent axes separated by approximately 120°. Machines and methods for forming the structures are also disclosed. In one case, a machine having a single stitch head is reconfigured in each of three passes of the material to form the sandwich structure. In other cases, a machine having three stitch heads is used to form the structure with a single pass of the material. In some embodiments, the machine includes an indexing stitch head oriented at approximately 0° and two stationary stitch heads oriented at approximately ?60° and +60° with respect to the machine direction. In other embodiments, the machine includes three stationary stitch heads oriented at approximately 90°, ?30°, and +30°.

Abstract: A tufting machine comprising a yarn applicator adapted to receive feed yarn and penetrate a surface covering backing and a cutting means adapted to cut the feed yarn to produce a stitch. The tufting machine also comprises a yarn control module that includes a yarn feed wheel adapted to guide the feed yarn, an actuator adapted to move the yarn feed wheel between an engaged position and a disengaged position, and a yarn feed gear adapted to engage the feed yarn when the actuator moves the yarn feed wheel into the engaged position. The tufting machine further comprises a power source adapted to move the yarn feed gear and a remote process control computer system adapted to send a first signal and a second signal to the yarn control module. The tufting machine produces a patterned surface covering having a plurality of yarn colors and a plurality of pile heights.

Abstract: A tufting machine and a method of controlling the tufting machine to form a tufted article having varying pattern effects, such as forming cut and loop pile tufts of yarn in a graphics type pattern, defining a yarn feed effect pattern and a shifting needle bar effect pattern, and combining the two patterns. The yarn feed of the tufting machine is controlled to compensate for pattern shifts while a hook assembly having a series of hooks/loopers and a series of clips independently moveable between extended and retraced positions is selectively controlled to cause a transition from cut pile tufts to loop pile tufts and loop pile tufts to cut pile tufts according to the programmed pattern information.

Abstract: A hook/looper module assembly for a tufting machine is provided that allows for broken and damaged hooks of a level cut loop tufting machine to be replaced. The hook/looper module assembly includes modular blocks having a series of slots in which a series of hook or looper are received. Locking mechanisms secure the hook/looper within their respective slots in the modules and allows for removal of individual hook/looper from the module as needed for repair and replacement.

Abstract: A recyclable tufted carpet meeting EPA recyclable content standards and having improved dimensional stability that reduces skew, bow, and wrinkles during manufacture and installation is formed by combining prior art primary and secondary backings into a single, fiber-reinforced primary backing layer. Consolidating either a glass fiber fabric layer, a glass veil, or a glass mat with a fiber-reinforced extruded film forms the fiber-reinforced primary backing layer. An additional glass fabric fiber layer can also be introduced to the primary backing to provide additional dimensional stability.

Abstract: A textile-based plate implant (and related methods) that supports tissue ingrowth within the implanted implant structure and is suitable for use in a variety of surgical applications, including but not limited to anterior, posterior and lateral surgical approaches directed towards the lumbar, thoracic and cervical regions of the spine.

Abstract: A system for forming multiple patterned, tufted articles, includes a tufting machine having a series of distinct machine sections each adapted to form a desired patterned, tufted articles and each operable independently of the other machine sections. A system control can be programmed with pattern parameters for each of the patterned tufted articles to be formed, and will control the machine sections to form each of the patterned tufted articles.

Abstract: A system and method for controlling the yarn feed for a tufting machine to form tufted patterns having different pattern fields or areas. Predetermined yarn feed amounts can be input for one or more selected yarn feed zones of selected stitches of the pattern to enable different pile heights and/or different tufts of yarns to be formed in the different pattern zones. A yarn feed device for the tufting machine will be controlled to selectively feed varying amounts of yarns for each of the yarn feed zones of the selected stitches of the pattern.

Abstract: A tufting machine is provided with two transverse rows of needles, one row being associated with transverse row of loopers and the other second row of needles being associated with a transverse row of gated hooks. Novel and low pile height tufted fabrics can be created with this configuration.

Abstract: A fabric is provided having discrete surface portions of a primary backing and tufted yarns exposed on the technical face of the fabric. To form the fabric, the yarn feed controlled by servomotors is adjusted in increments to rob back yarn sufficient to pull out the previously tufted loops in selected portions of the fabric, leaving the primary backing portion of the pulled-out loops exposed on the technical face. By the selection process, random or patterned tufted portions and exposed primary backing surface portions are provided on the technical face of the fabric.

Abstract: The present invention provides for tufted needlefelts with partially or totally obscured loop bights that provide good tuft bind.

Abstract: A tufting machine control system for controlling the tension applied to a backing material as it enters the tufting zone of the tufting machine, including a pair of driven backing feed rolls for feeding the backing material. The drive motors for the backing feed rolls are monitored by the control system and are adjusted to control the amount of tension applied to the backing material as it enters the tufting zone of the tufting machine.

Abstract: A system and method for producing multi-colored carpets using a tufting machine. The present invention features a system and method for: providing a multi-colored pattern which is analyzed for validity with reference to a particular tufting machine; collecting parameters concerning a particular tufting machine; determining the colors of yarn to load with each needle of the particular tufting machine; and generating a report including a palette of colors used within the pattern, a chart indicating which color of yarns are used within each needle position, and a summary of the number of yarn cones needed to create a carpet of a predetermined size with the particular tufting machine.

Abstract: A manufacturing method of embroidery having a pile structure which may be performed by a general embroidering machine is disclosed. The method is accomplished by providing a base fabric, a first sheet having a predetermined thickness, and a second sheet in order, and embroidering a predetermined pattern on the base fabric together with the first and second sheet. An adhesive is applied over the back surface of the base fabric to fix the threads, and then the threads are cut over the first sheet. Finally, the first sheet and the second sheet are removed from the base fabric to form the resultant embroidery having a pile structure.

Abstract: A tufting machine control system for controlling the tension applied to a backing material as it enters the tufting zone of the tufting machine, including a pair of driven backing feed rolls for feeding the backing material. The drive motors for the backing feed rolls are monitored by the control system and are adjusted to control the amount of tension applied to the backing material as it enters the tufting zone of the tufting machine.

Abstract: A system and method for producing multi-colored carpets using a tufting machine. The present invention features a system and method for: providing a multi-colored pattern which is analyzed for validity with reference to a particular tufting machine; collecting parameters concerning a particular tufting machine; determining the colors of yarn to load with each needle of the particular tufting machine; and generating a report including a palette of colors used within the pattern, a chart indicating which color of yarns are used within each needle position, and a summary of the number of yarn cones needed to create a carpet of a predetermined size with the particular tufting machine.

Abstract: The present invention provides alternative scroll-type yarn feed attachments for tufting machines characterized by independent servo-motor control of sets of yarn feed rolls, and a software design system to facilitate use of the attachment to produce novel patterns and photo images.

Abstract: The invention concerns a tufting machine having at least one needlebar, loopers, hooks to pick up yarn delivered through the needles of the needlebar, knives to cut yarn loops and driving means, with the needle action and/or the looper action and/or the hook action, and/or the knife action being a non-simple harmonic motion. In said machine the needles, the hooks, the knives and the loopers have separate drive systems. So the motion of the needles, the hooks, the knives and the loopers can be such that first of all the pickup of the yarn or the cutting of the yarn loop can be improved. When the drive system is computer controlled more accurate machine set up can be achieved. Moreover different set ups can be achieved automatically for different products. Patterning effects are also possible.

Abstract: A stitched pile surface structure and a process and apparatus for producing and finishing the same is disclosed. The stitched pile surface structure includes a backing having a thickness T. A plurality of parallel lines of stitches extends longitudinally along the backing. Each stitch has a predetermined stitch length dimension S. A plurality of rows of pile elements (either as loop pile or cut pile) is formed from one or more pile yarn(s) having an effective predetermined yarn diameter D. The total weight of the yarn used to form the pile loop elements is G grams. Substantially all of the stitches have a thread length DKL that satisfies the relationship: DKL<=D·(1+?/2)+(2·T)+(2·S) A mass of binder material having a weight of less than G grams is disposed on the pile surface structure.