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 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 tufting machine has a needle bar for carrying a plurality of needles for reciprocating into and out of a base material. A sliding needle bar shift mechanism may shift the needle bar laterally according to a pattern. The needle bar is mounted for reciprocation and for lateral movement relative to the direction of reciprocation by a drive system including a first directional drive component having a foot secured to a respective push rod of the tufting machine and a second directional drive component connected to the shift mechanism. The first and second drive components will connect to the needle bar through linear bearings or bushings so that the motion of the needle bar in multiple different directions is controlled while permitting greater machine operating and needle bar shifting speeds.

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: 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: There is disclosed herein various floor coverings and methods for making the same. In one embodiment, there is disclosed a floor covering including a primary backing layer having a fibrous face and an underside, wherein the fibrous face is formed from a bulked continuous filament yam comprising a plurality of continuous filaments formed from a biobased polyhexamethylene sebacamide polymer or a blend of a biobased polyhexamethylene sebacamide polymer together with up to 80 wt % of at least one other polymer compatible with the biobased polyhexamethylene sebacamide polymer.

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 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 compressed air system adapted for use in connection with a tufting machine having a yarn applicator adapted to penetrate a backing of a surface covering and place a stitch in the backing of the surface covering, a presser foot and a funnel block. The compressed air system comprises an air source adapted to provide air to the compressed air system, a digital presser foot injector adapted to convey compressed air to the presser foot, and a funnel block injector adapted to convey compressed air to the funnel block. The compressed air system is adapted to convey compressed air to the digital presser foot injector and the funnel block injector only when the yarn applicator is in use. The method comprises conveying air to the presser foot only when the yarn applicator is in use, and conveying air to the funnel block only when the yarn applicator is in use.

Abstract: A tufted carpet has a high density portion and a low density portion. The high density portion has pile yarns implanted into a base fabric with high density. The low density portion has pile yarns implanted into the base fabric with low density. The fiber density of the high density portion is in the range of 280 to 700 g/m2. The fiber density of the low density portion is in the range of 200 to 500 g/m2. The fiber density of the high density portion is set to a value greater than the fiber density of the low density portion. The difference between the fiber density of the high density portion and the fiber density of the low density portion is set to a value in the range of 30 to 250 g/m2.

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: The present invention provides a cam follower bracket that is used in conjunction with textile tufting machines. Typically, the present invention is used with shifting tufting machines used to produce carpet and rugs. The cam follower bracket utilizes a floating lug design that self-regulates the amount of pressure that the cam follower bearings apply against the shifter block of the tufting machine. Because the bracket is able to self-regulate the pressure, the bracket generally lasts longer and does not need to be periodically monitored and/or tightened. Therefore, less user interaction is required and less machine downtime is needed when operating a tufting machine utilizing a bracket according to the present invention in comparison with known cam follower brackets.

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: An antivibratory system is provided by means of a servo motor driven shaker affixed to the head or bed frame of a tufting machine and programmed for rotation of a balancing weight to minimize vibration caused by operation of tufting machine at a particular speeds and needle stroke lengths.

Abstract: The specification discloses carpet making machinery (10) with at least one needle head (26) and an associated loop forming head (27) disposed on either side of a pile forming station (28) through which a backing material web (29) is adapted to move in incremental steps, the needle head (26) and the loop forming head (27) being arranged to move relative to the backing material web (29) at the pile forming station (28) selectably either in a transverse direction, a longitudinal direction, or both a transverse and a longitudinal direction of the backing material web (29) with the stitching of pile forming loops (96) occurring in one direction across the backing material web (29), the needle head (26) further including a plurality of needle units (47) carried by a rotatable carriage (66) rotatable about an axis (45), said carriage (66) being arranged upon rotation to move each said needle unit (47) selectably to an operative position.

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

Abstract: A tufting machine that includes spaced rows of needles of inserting yarns into a backing material. The needles are engaged by opposed loopers and level cut loop pile hooks that pass between one another so as to engage the opposite row of needles for forming cut pile and loop pile tufts of yarns in the backing material.

Abstract: A tufting machine and a method of controlling a tufting machine for forming cut and loop pile tufts of yarns in a backing material that includes a hook assembly having a series of hooks/loopers and a series of clips independently moveable between extended and retracted positions. The movement of the clips between their extended and retracted positions is selectively activated to cause transitions from cut pile tufts to loop pile tufts and loop pile tufts to cut pile tufts according to programmed pattern information.

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: The present invention relates to a method and apparatus for the automatic insertion of an individual upholstery tuft (3) and washer (1) from a plurality of connected tufts (4) and a plurality of connected washers (2) into an upholstered article. The apparatus has a cutting blade (35) to separate an individual tuft (3) from the plurality of connected tufts (4). The turf (3) is then engaged by a pair of arms (27, 28) and fed into a tuft insertion needle (14). The arms are connected to automatic washer feed apparatus which feeds an individual washer (1) from the plurality of connected washers (2) and aligns it with the tuft insertion needle (14) ready for insertion. The insertion needle (14) is pneumatically actuated to force the tuft (3) through the washer (1), into the upholstered article, release the tuft (3) and subsequently withdraw the needle (14) from the article.

Abstract: A textile product with enhanced flame and/or smoke retardant properties and a method of forming the same is disclosed. The textile product is comprised of a textile material having a primary layer or backing with intumescent particles coated, sprayed, sprinkled, or otherwise applied to the upper surface thereof. Additionally or alternatively, the particles may be incorporated into the tufting primary or backing. The intumescent particles may also be complexed with additional agents, such as antimicrobial agents, softening agents, pliability agent, stain resistant agents, waterproofing agents, static resistance agents and combinations thereof.

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.

Abstract: The present invention is a device for the automatic tufting of upholstery units using tufts comprising a retaining link with a tuft element at either end and associated with further tufts is provided. The device comprises engagement device for a tuft device for separating the engaged tuft from the associated tufts; device for driving one tuft element and the retaining link of the engaged tuft through an upholstery unit and withdrawing the engagement device once the tuft is released; and device for automatically reloading the device with a further tuft. A method of automatically tufting upholstery units using such a device is also provided.

Abstract: A device for the automatic tufting of upholstery units using tufts (22) comprising a retaining link (12) with a tuft element (14a, 14b) at either end and associated with further tufts (24, 26) is provided. The device comprises engagement device (30, 34) for a tuft (22); device (20) for separating the engaged tuft (22) from the associated tufts (24); device for driving one tuft element (14a) and the retaining link of the engaged tuft (22) through an upholstery unit (40) and withdrawing the engagement device once the tuft is released; and device for automatically reloading the device with a further tuft. A method of automatically tufting upholstery units using such a device is also provided.

Abstract: A device for the automatic tufting of upholstery units using tufts (22) comprising a retaining link (12) with a tuft element (14a, 14b) at either end and associated with further tufts (24, 26) is provided. The device comprises engagement means (30, 34) for a tuft (22); means (20) for separating the engaged tuft (22) from the associated tufts (24); means for driving one tuft element (14a) and the retaining link of the engaged tuft (22) through an upholstery unit (40) and withdrawing the engagement means once the tuft is released; and means for automatically reloading the device with a further tuft. A method of automatically tufting upholstery units using such a device is also provided.

Abstract: An improved tufting machine push rod housing gland seal assembly for use with a tufting machine is disclosed. The gland seal assembly of the invention includes an elongate carrier formed by a longitudinal axis, having a first end and a spaced second end, constructed for being received within a gland seal receiving cavity defined within a push rod housing. A concentric throughbore is defined within the carrier about the longitudinal axis. A first continuous annular groove is defined in a side wall of the bore, and an axially spaced second continuous annular groove is also defined in the side wall of the bore. The two grooves together define therebetween a continuous annular bearing surface for supporting and guiding the push rod as it is reciprocated through the gland seal assembly and along the axis, thus minimizing the impact of push rod flexure or oscillation on the gland seal assembly, and the push rod housing.

Abstract: There is disclosed a material or fabric making or processing operation involving needle penetration of a fibre, fabric or material layer (12) in which the needle penetration action is controlled by control means (18) by which the needle penetration characteristics can be varied within the penetration action and as between penetration actions.

Abstract: An apparatus for producing a stitched pile surface structure is disclosed. The apparatus has a plurality of transversely spaced needles forming a needle array, with each needle having a predetermined width dimension (142D). The needles in operation being movable to penetrate a backing at a plurality of needle penetration points as the backing is conveyed along a path of travel through the apparatus. A plurality of laterally adjacent sinker fingers extends forwardly in the direction of travel. Each needle is disposed laterally intermediate adjacent fingers. Each finger has a forward end thereon. The sinker fingers extend forwardly in the direction of travel past the needle penetration points, the height dimension of at least that portion of each finger that extends forwardly past the needle penetration points being uniform. In addition, the fingers have a base region, with adjacent fingers being spaced from each other by a lateral spacing distance (132) not greater than 1.

Abstract: Processes for tufting substrate or primary carpet backing using conventional double needle bars but in which the needles may be shifted less than a full gauge. Processes of the present invention may employ a conventional double needle bar tufting machine to which is added means for shifting or indexing the hook bar laterally to the machine direction of the substrate being tufted. Timing of shifting of the hook bar may be coordinated with timing of shifting of the needle bar and advance of the substrate through the machine to allow piles to be tufted into the substrate at any desired lateral position with respect to previously tufted piles. The invention creates additional pile color pattern alternatives and eliminates repetitive patterns otherwise necessitated by full gauge shifting. Elimination of repeat color sequences reduces matching color sequences on adjoining edges of adjacent carpet tiles made from such substrate which otherwise accentuate or highlight the seams between carpet tiles.