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: An anti-puckering apparatus for forming, on a work piece, a line of stitching substantially free from puckering is disclosed. The apparatus includes a removable base which is added to a sewing machine bed surface proximate to a needle and a stitch formation zone. The apparatus also includes a carrier mounted on, and moveable relative to, the base and an endless row of flexible filamentary elements carried by the carrier. The carrier progressively moves subsets of filamentary elements into and out of a stitch formation zone during the formation of a line of stitching. The filamentary elements are presented across a stitch formation zone in advance of an intended line of stitching at an oblique angle relative to a sewing machine bed surface.

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 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 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 tufting gripper (16) comprises a pocket (26) with an insert (25) that is associated with a spring means (34) in order to at least temporarily clamp and secure said insert in place in the pocket in a prespecified position. The spring means (34) pushes the insert (25) preferably in the direction of the tip of the gripper and creates a particularly smooth transition at this location between the base body (19) of the tufting gripper (16) and the insert (25), in particular the tip (33) of said insert.

Abstract: In order to reduce or to prevent wear on the tufting gripper (16) at the contact point with the tufting needle (18), an additional insert 28 is provided in addition to a wear-resistant cutting insert (27), said additional insert (28) being directed at interacting with the tufting needle (18). Said additional insert consists of a material that, paired with the tufting needle (18), forms an optimal sliding combination. Preferably, the additional insert (28) is a soft needle-saving insert. Preferably, the cutting insert (27) is a hard wear-resistant insert. The two inserts (27, 28) may be accommodated separately in different pockets (36, 37) or together in one pocket (31). They may be connected with each other or be made in one piece.

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 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 tool 1 for a textile machine with the tool having a wear-minimizing coating on its basic tool body 2, which wear-minimizing coating acts as an anti-wear element 15. In order to accommodate this coating, the basic tool body 2 is provided with a recess at a suitable location, and the coating is built up on the bottom of the recess, for example, by plasma-spraying. Preferably, an oxide-ceramic material is used for the coating.

Abstract: A gated looper apparatus has an array of individually mounted pressurizable air cylinders with piston rods acting in communication with looper gates. The air cylinders are designed to be responsive to pneumatic pressure to extend and retract the associated piston rods.

Abstract: A gripper (3) for a tufting machine comprises a gripper body (9) having a cutout (22) for a cutting insert (10), said cutting insert preferably consisting of a hard metal. Connecting means acting in a form-closed manner are provided for the connection of the cutting insert (10) with the gripper body (9). In their simplest embodiment, said connecting means are formed by the deformation regions (37, 38) that are provided on the gripper body (9) and that reach around matching cutouts (33, 34) of the cutting insert (10).

Abstract: A gripper device in accordance with the invention comprises a gripper (3) and a counter knife element (4) that are fabricated separately and joined. As a result of this, optimal material combinations are possible, which will deal with both types of wear, namely between the gripper (3) and the tufting needle (5), on the one hand, and between the knife (6) and the counter knife element (4), on the other hand. The gripper module (1) accommodates the counter knife element (4), which, in turn, supports the gripper (3). The two parts may be joined by caulking, cementing, riveting, screwing or similar measures, or they may be cast together in the gripper module (1). The cutting of the loop is done exclusively between the counter knife element (4) and the knife (6).

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 gripper (3) for a tufting machine comprises a gripper body (9) having a cutout (22) for a cutting insert (10), said cutting insert preferably consisting of a hard metal. Connecting means acting in a form-closed manner are provided for the connection of the cutting insert (10) with the gripper body (9). In their simplest embodiment, said connecting means are formed by the deformation regions (37, 38) that are provided on the gripper body (9) and that reach around matching cutouts (33, 34) of the cutting insert (10).

Abstract: The new gripper design provides a gripper (3) for tufting machines, said gripper comprising a slider (18) that is supported so as to be movable in longitudinal direction. This slider is arranged in a slider receiving space (17) which, preferably, is configured as a slit. The slit extends from the lower narrow side (12) of the gripper body (4) into said gripper body. Said slit is limited by two thin walls (19, 20) or, alternatively, by only one thin wall (20). A cutting edge insert receiving space 39 is provided above the slider receiving space (17), said receiving space (39) extending from the flat side (9) and being recessed in the gripper body (4). Between the cutting edge insert receiving space (39) and the slider receiving space (17), a strip (40) is provided that preferably extends in longitudinal direction of the gripper body (4) and separates the receiving spaces (39, 17) from each other. This design is suitable for the creation of very narrow grippers (3) that permit a division of less than 1/10 Inch.

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 gated looper apparatus has an array of individually mounted pressurizable air cylinders with piston rods acting against biased slider bars in communication with looper gates. Baising elements are mounted external of pneumatic cylinders about slider bars with protective ferules to provide greater responsiveness and ease of maintenance.

Abstract: A needle plate module is provided with fingers having a bent portion received in a lateral channel portion enabling standard screw sizes to the fingers into the module over a wide range of finger gauge spacings.

Abstract: Loop pile hook module for use in a tufting machine, the module has a body member including a plurality of tufting machine hooks therein in side-by-side relationship, the hooks being formed from cylindrical, or other profile, pins which protrude from the body member to form a beak of the hooks.

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.