Abstract: A loop gripper (10) for a tufting machine has a gripper body (11) with a gripper finger (12) extending in an extension direction E from a retained end (13) to a free end (14). On the gripper finger (12) underside (16), a cutting region (20) transitions into a sliding surface (19) at a transition point (21). A retaining element (35) near the transition point (21) is mounted to be pivotable about a pivot axis S relative to the gripper finger (12). The pivot axis S extends in a transverse direction Q at right angles to the extension direction E. The retaining element (35) is urged into a starting position A by a force, for example a spring force and/or a weight force. In the starting position A, a retaining surface (37) of the retaining element (35) extends obliquely or at right angles away from the sliding surface (19).

Abstract: A replaceable needle module assembly for tufting machines includes a series of needle modules mounted in spaced series along a needle or gauge bar. Each needle module includes a module body having a series of needle receiving passages formed therethrough. The needles are received within and extend through each of the needle receiving passages, with the upper ends of the needles being received and engaged within corresponding recesses formed along an underside surface of the needle bar when the needle modules are mounted thereto. As a result, the needles can be securely and accurately located at a desired elevation along the needle bar.

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 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: 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 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. The system generally will include spaced rows of needles mounted along a tufting zone and which are reciprocated through the backing to different penetration depths. A series of loopers and a series of hooks will be aligned with and will engage the needles in order to form cut and loop pile tufts of yarns having varying lengths in the backing material.

Abstract: A tufting machine capable of producing individual articles of athletic turf bearing precise graphic patterns is disclosed. The machine includes a support frame to which a backing material is statically held, a tufting frame that spans above and below the backing and is computer-controlled to travel along the support frame, a yarn-inserting needle carriage disposed above the backing along the tufting frame and a yarn-catching looper carriage disposed below the backing along the tufting frame. The carriages are computer-controlled to asynchronously shift relative to each other as may be necessary for their individual yarn-inserting components and yarn-catching components to cooperate.

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 stitch distribution control system for a tufting machine for controlling placement of yarns being fed to the needles of the tufting machine by yam 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 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 replaceable gauging element assembly includes a series of gauge modules mounted in spaced series along a gauge bar. The gauge modules each include an upper section having a front face, an intermediate section and a lower section. A series of slots are formed in the front face of the gauge modules for receiving a series of gauge parts therein, with the gauge parts releasably secured within the modules by one or more fasteners. Access openings are formed in the modules for facilitating removal of broken gauge parts from the slots.

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 needle assembly for use with a tufting machine is disclosed that comprises at least one gauge block or needle bar having a row of back gauge elements disposed thereon. The respective back gauge elements are spaced from one another a first distance along a back longitudinal axis. The tufting needle assembly further comprises a row of front gauge elements disposed on the at least one gauge block or needle bar and extending along a front longitudinal axis spaced parallel to the back longitudinal axis. At least one gauge element being spaced from one respective adjacent front gauge element at a distance greater than the first distance.

Abstract: A narrow gauge hollow needle tufting apparatus is provided with longitudinally aligned yarn feed openings, longitudinal funnel slots, self aligning hollow needles, and a castellated backing support bar.

Abstract: A tufting needle assembly for use with a tufting machine is disclosed that comprises at least one gauge block or needle bar having a row of back gauge elements disposed thereon. The respective back gauge elements are spaced from one another a first distance along a back longitudinal axis. The tufting needle assembly further comprises a row of front gauge elements disposed on the at least one gauge block or needle bar and extending along a front longitudinal axis spaced parallel to the back longitudinal axis. At least one gauge element being spaced from one respective adjacent front gauge element at a distance greater than the first distance.

Abstract: A narrow gauge hollow needle tufting apparatus is provided with longitudinally aligned yarn feed openings, longitudinal funnel slots, self aligning hollow needles, and a castellated backing support bar.

Abstract: A tufting needle assembly for use with a tufting machine is disclosed that comprises a first gauge block or needle bar having a first series of tufting needles disposed thereon. The respective tufting needles are spaced from one another along a first longitudinal axis extending in the lengthwise direction of the gauge block. At least one tufting needle is offset with respect to the first longitudinal axis and the adjacent ones of the tufting needles in the series of tufting needles in the range of from 0.005 to 0.100 inches. The tufting needle assembly further comprises a second series of spaced tufting needles extending along a second longitudinal axis spaced parallel to the first longitudinal axis.

Abstract: A tufting needle assembly for use with a tufting machine is disclosed that comprises a first gauge block or needle bar having a first series of tufting needles disposed thereon. The respective tufting needles are spaced from one another along a first longitudinal axis extending in the lengthwise direction of the gauge block. The tufting needle assembly further comprises a second series of spaced tufting needles extending along a second longitudinal axis spaced parallel to the first longitudinal axis.

Abstract: A tufting needle assembly for use with a tufting machine is disclosed. The tufting needle assembly comprises a first gauge block or needle bar having a first series of tufting needles disposed thereon. The respective tufting needles are spaced from one another along a first longitudinal axis extending in the lengthwise direction of the gauge block. At least one tufting needle is offset with respect to the first longitudinal axis and the adjacent ones of the tufting needles in the series of tufting needles in the range of from 0.005 to 0.100 inches. A shank of the at least one tufting needle may be offset with respect to the first longitudinal axis and those of the adjacent tufting needles, or alternately the shank may be aligned with those of the adjacent tufting needles and a needle tip of the at least one tufting needle is offset with respect to the first longitudinal axis and the needle tips of the adjacent ones of the tufting needles in series.

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: 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.