Cross Reference to Related Applications

[0001] The present Patent Application is a formalization of previously filed, copending United States Provisional Patent Application Serial No. 61/788,395, filed March 15, 2013 by the inventors named in the present Application. This Patent Application claims the benefit of the filing date of this cited Provisional Patent Application according to the statutes and rules governing provisional patent applications, particularly 35 U.S.C. § 1 19(a)(1) and 37 C.F.R. § 1.78(a)(4) and (a)(5). The specification and drawings of the Provisional Patent Application referenced above are specifically incorporated herein by reference as if set forth in their entirety.

Field of the Invention

[0002] The present invention generally relates to the design and assembly of gauge parts for tufting machines, and in particular to an assembly for mounting a series of needles within a tufting machine to enable accurate and efficient location and mounting of such needles within the tufting machine.

Background of the Invention

[0003] During the operation of tufting machines, a series of needles mounted along a reciprocating needle bar and carrying a series of yarns penetrate a backing material and are engaged by a series of hooks or loopers for forming cut and loop pile tufts of yarn in the backing material. Such engagement requires close precision in the positioning and operation of the needles and the hooks or loopers to ensure efficient and accurate operation of the tufting machine. During assembly of the tufting machines, therefore, it is important that the needles, loopers, hooks, and/or other gauge parts be accurately mounted along their respective gauge bars to ensure that such gauge parts are accurately and consistently spaced and positioned along their gauge bars. If the gauge parts are misaligned, the individual gauge parts can become broken or damaged, and tufts of yarns can be mis-sewn, resulting in inaccurate or irregular patterns being formed, which carpets have to be discarded. [0004] Accordingly, it has been common practice to assemble gauge parts, such as needles, loopers or hooks in modules, particularly cast modules in which the loopers or hooks are cast or mounted in a solid block or module, typically including five to ten, or more, individual gauge parts in a precisely spaced series. These modules then are mounted on a needle or hook/looper bar to help ensure substantially consistent and accurate spacing of the gauge parts. One problem that arises with conventional needle modules has been the difficulty of adjusting needle spacings to achieve a smaller or tighter stitch therebetween without use of specialty parts. Additionally, if a single gauging element or part of conventional cast modules fails, (such as becoming broken or dull), the whole gauge module generally must be replaced. Such replacement of the modules is often time consuming and expensive and can require removal and replacement of several undamaged or fully functional gauging elements or parts within each of the modules, which leads to potential waste of other gauging elements or parts in the module that are still operable. Also, while replaceable modules have been produced, it is important to make sure the replacement parts are accurately mounted to ensure consistent penetration of the needles to a depth needed for engagement by the holes/loopers, and that the parts will be secured against shifting or misalignment during use.

[0005] Accordingly, it can be seen that a need exists for an easily replaceable gauge module that addresses the foregoing and other related and unrelated problems in the art.

Summary of the Invention

[0006] Briefly described, in one embodiment, the present invention generally relates to modular gauging element assemblies for use in a tufting machine and further to a needle assembly for a tufting machine that facilitates and enables easy and accurate installation and replacement of needles within the tufting machine. It will be understood that the present invention also could be used for gauge parts including loopers, hooks, level cut loop loopers or hooks and other gauging elements. [0007] The needle assembly generally includes an elongated gauge bar, such as a needle bar, along which a series of spaced gauge modules are received and mounted. The gauge bar generally can have a substantially L-shaped profile or configuration including an upper body portion and a downwardly projecting front or guide portion. A shoulder or guide ledge/area thus is defined between a lower or bottom edge/surface of the upper body portion of the gauge bar and the front portion of the needle bar, and generally is configured for receiving the gauge modules in mating contact therealong.

[0008] Each of the gauge or needle modules generally includes a module body having front and rear faces, parallel sides, and upper and lower portions terminating at top and bottom surfaces or faces, respectively. A series of spaced needle-receiving openings, passages or slots generally can be formed through the module body of each gauge module, arranged spaced in series across the top and bottom surfaces of each module body. A series of needles or other gauging elements or parts will be received within these passages or openings for mounting of the needles or other gauge parts at desired spacings along the module body. The needles can be removably secured within the module body, such as by one or more fasteners inserted within fastener openings spaced along the front face of the module body in alignment with the needles, for engaging or holding the needles in place.

[0009] The gauge or needle bar further will include one or more complimentary needle guide or locating recesses/sites or other devices formed along the bottom surface of the top body portion thereof. Such locating recesses generally will be configured to receive the distal ends of the needles projecting through the needle receiving passages of the modules. The locating recesses can thus assist in guiding and mounting the needles to the needle bar with the needles each being located in a substantially consistent, desired depth or vertical alignment or position.

[0010] Various features, objects and advantages of the present invention will become apparent to those skilled in the art upon a review of the following detailed description, when taken in conjunction with the accompanying drawings. Brief Description of the Drawings

[0011] Fig. 1 is a side elevational view of a tufting machine incorporating a needle module assembly according to the principles of the present invention.

[0012] Figs. 2A-2B are perspective views illustrating the mounting of the needle modules to the needle bar to form the needle module assembly according to one embodiment of the present invention.

[0013] Fig. 3 is a perspective illustration of the needle module of Figs. 2A-2B, illustrating the projection of the needles therethrough.

[0014] Fig. 4 is perspective illustration illustrating the guide recesses of the needle bar which correspond to the needle receiving openings of the needle module.

Detailed Description

[0015] Referring now to the drawings in which like numerals indicate like parts throughout the several views, Fig. 1 schematically illustrates a tufting machine T in which a replaceable needle assembly 10 formed according to the principles of the present invention can be used. The tufting machine T generally can comprise a tufting machine such as disclosed in U.S. Patent Nos. 5,979,344, 7,096,806, 7,597,057, and/or 7,997,219, the disclosures of which are incorporated by reference as if fully set forth herein. It additionally will be understood by those skilled in the art that various other types of equipment utilizing replaceable assemblies, also can be used with the replaceable needle assembly formed according to the principles of the present invention.

[0016] As Fig. 1 illustrates, the tufting machine T generally includes a frame 1 1 which supports the various operative systems or assemblies of the tufting machine, including a main driveshaft 12, which generally will be driven by one or more motors 13, such as servo, stepper or other types of motors, including variable speed and/or reversible motors. The main driveshaft is linked to and drives a reciprocating needle drive assembly 16, so as to cause reciprocation of the needle drive assembly 16 in the direction of arrows 17 and 17'. The needle drive assembly 16 generally can include a series of pusher rods 1 8 (only one of which is shown in Fig. 1 ), which in turn support the replaceable needle assembly 10 via feet or brackets 19 that engage the replaceable needle assembly 10 at spaced locations or positions along the length thereof.

[0017] As additionally illustrated in Fig. 1 , a yarn feed mechanism 21 generally is provided along the frame 1 1 of the tufting machine and will feed a series of yarns Y to the needles 25 of the needle assembly 10. The yarn feed mechanism 21 can include a variety of different types of yarn feed mechanisms, for example, including scroll, roll, single end and/or double end type pattern yarn feed attachments, such as an Infinity™ or Infinity HE™ yarn feed attachment as manufactured by Card-Monroe Corp., or other yarn feed devices. As a backing material B is moved through a tufting zone 26 of the tufting machine T, as indicated by arrow 27, the needles 25 will be reciprocated in the direction of arrows 17 and 17' into and out of the backing material, with the needles being engaged by corresponding gauge part assemblies 28 located beneath the backing material and along the tufting zone 26, so as to form a series of loops or tufts of yarns 29 in the backing material B.

[0018] The gauging element assemblies 28 are shown in Fig. 1 as generally including a series of cut pile hooks 31 each of which generally includes a body 32 having a hooked or curved front end 33, and wherein the bodies of the hooks 31 generally can be mounted to a gauging element bar, such as a hook bar 34 or within modules 36 mounted to the gauge bar, whereby the gauging elements/hooks 31 will be reciprocated toward and away from engagement with the needles 25 in the direction of arrows 37 and 37'. A series of knives 38 also can be mounted to and moved with the drive mechanism 39 for the gauging element assemblies 28 so as to engage and cut the loops of yarns 29 formed or collected on the bill of the gauging elements/hooks to form cut pile tufts. It further will be understood by those skilled in the art that while cut pile hooks are illustrated as the gauging elements 31 of the gauging element assemblies 28 that cooperate with the needles 25 of the needle assembly 10 in the example embodiment shown in Fig. 1, various other types of gauging elements, including loop pile loopers, level cut loop loopers/hooks, cut loop clips or other types of gauging elements also can be used with the present invention. [0019] In one embodiment of the replaceable needle assembly 10 according to the principles of the present invention, as generally illustrated in Figs. 2A and 2B, the replaceable needle assembly will include at least one gauge bar such as needle bar 50 along which a series of needle modules 51 are mounted. Each of the needle modules 51 generally will include a series of needles 25 replaceably received and mounted therein, with the needles 25 generally being arranged in a predetermined, spaced alignment or orientation for mounting to the needle bar 50. The needle bar 50 and the bodies of each of the needle modules 51 can be cast, machined, formed by an electrical discharge machining process, or otherwise formed from various metal or metal alloy materials, such as steel, aluminum, etc., and can be formed in various configurations and/or sizes. The needle modules 1 further can be formed from additional, lighter weight materials such as various plastic, synthetic, composite, or other durable, substantially rigid and high strength materials so as to securely support the needles when mounted to the at least one needle bar.

[0020] In addition, although a single needle bar 50 is generally illustrated in Fig. 1 , it will be understood by those skilled in the art that the needle assembly 10 of the present invention also can be used in tufting machines including more than one needle bar, for example, in tufting machines including two spaced needle bars that each can carry a series of needle modules 51 in which a plurality of needles 25 are mounted, and with the needles further being arranged or spaced along the tufting zone T at a desired stagger or spacing from each other. Also, while the needles 25 generally are shown as being mounted in a substantially inline or parallel arrangement, other configurations or arrangements, including locating the needles at a predetermined stagger or offset along a single needle bar or along a pair of needle bars, also can be provided.

[0021] Each of the needles 25 generally will include an elongated shank or body 55

(Fig. 2B) having a first, upper or distal end 56 and a second, lower proximal end 57 terminating in a pointed tip 58 to facilitate penetration of the needles of each of the needles through the backing material. An eye or similar opening 59 generally will be formed at the distal ends of each of the needles, adjacent the tips 58 thereof as generally illustrated in Figs. 2A and 2B. The yarns Y (Fig. 1) will be received through the eyes 59 of each of the needles 25 so as to be carried with the needles as the needles are reciprocated into and out of the backing material B, as shown in Fig. 1 , to form the loops/tufts of yarns 29 within the backing material.

[0022] The needles 25 further are generally illustrated in Figs. 2A-2B and 4 as having a substantially square or rectangular cross section wherein the body 55 of each needle 25 generally is formed with a series of flat side surfaces 61. The needle module assembly of the present invention enables the use of needles having a non-cylindrical shape or cross section. Thus, a closer spacing of the needles can be provided at a reduced pitch or distance as compared with similar size or gauge needles which have substantially cylindrical or round shanks. For example, needles of a 3/16 gauge can be moved closer so as to be mounted on a 5/32 gauge or other, similar gauge, which in turn enables the adjustment of the gauge of a tufting machine without necessarily having to utilize specialty needles or gauge parts and the use of special holders in order to achieve the desired closer pitch or spacing therebetween. However, it further will be understood by those skilled in the art that while needles 25 having a substantially non-cylindrical shank or body are illustrated, the present invention also can be used with more conventional, substantially cylindrically-shaped needles and needles having other non-cylindrically-shaped configurations as well.

[0023] The gauge or needle bar 50 of the replaceable needle assembly 10 generally is illustrated in Figs. 2A and 2B as having an angled, substantially L-shaped configuration, though it will be understood that other configurations adapted to be engaged by the needle modules 51 in a mating, substantially cooperative engagement also can be used. The needle bar 50 will include an upper or main body portion 65, which typically can include a substantially flat upper or top surface 66, and a substantially flat lower or downwardly facing bottom surface 67. Guide slots or channels 69/71 also can be formed along front and rear sides of the needle bar, adjacent the upper surface 66. As generally indicated in Fig. 1, these slots or guide channels 68 of the needle bar 50 can be configured to receive corresponding projections or tongues 72 of the push rod feet or brackets 19 so as to support the needle bar from the push rods for movement of the needle assembly 10 in a vertically reciprocatable manner as indicated in Fig. 1 . The guide channels or slots further can enable the shifting of the at least one needle bar under control of a shift mechanism, such as a cam or servo driven shift mechanism, for example, a SmartStep™ shift mechanism manufactured by Card-Monroe Corp., or other type of shift mechanism (not shown).

[0024] The needle bar 50 also is shown as having a downwardly projecting front or guide section or portion 73, defining a front face 74 of the needle bar as shown in Figs. 2A-2B. A series of fastener bores 76 generally will be formed at spaced intervals along the front face 74 of the needle bar, and can receive fasteners 77 such as set screws, bolts, rivets, or various other types of fasteners for mounting the needle modules 51 to the needle bar 50. The downwardly projecting front section further includes a rear surface 78, which is typically arranged at an angle with respect to the lower or bottom surface 67 of the main body portion 65 of the needle bar, forming a ledge/shoulder or guide area 75 defining a module receiving area or portion 79 along the needle bar and against which the needle modules 51 can be received and located for mounting of the modules in an accurate, substantially consistent manner along the needle bar.

[0025] As generally shown in Figs. 2B-4, each of the needle modules 51 includes a body 81, here shown as having a generally substantially rectangularly-shaped configuration. Other configurations of the module body 81 also can be used, with the configuration of the module body being generally selected/formed in order to substantially fit within and cooperate/mate with the receiving area 79 defined along the lower side of the needle bar, as indicated in Figs. 2A-2B and 4. In addition, locating features 82, such as a step, shoulder, guide channel, tab or other feature also can be formed along a portion of the body 81 of each needle module 51, and can engage the needle bar to facilitate the accurate location of each of the needle modules therealong. The body of each needle module generally will include an upper or top surface or portion 83, a bottom or lower surface or portion 84 and front and rear facing surfaces 86 and 87. As also illustrated in Fig. 3, the locating device or feature 82, if provided along the needle modules, typically can be formed along the upper and/or front facing surfaces thereof, such as at the corner or junction portion 88 therebetween. Still further, a corresponding locating feature or device also can be formed along the receiving area of the needle bar to further assist in locating the needle modules along the needle bar.

[0026] A series of open-ended needle receiving passages 91 will be formed through the modules 51 at spaced locations along the length thereof. Each of the needle receiving passages generally comprises a slotted opening, channel or passage that extends through the module body from the lower or bottom side surface 84 (Fig. 4) thereof to its top surface 83 such that the upper ends 56 of the needle shanks 55 can be received through an associated one of the needle receiving passages 91 , with the upper or distal ends 56 of the needle shanks generally projecting outwardly from the upper or top surface of the needle modules at a desired distance or spacing as illustrated in Figs. 2A and 3.

[0027] A series of fastener openings 94 also will be formed along the front facing surface 86 of the body 81 of each needle module. As indicated in Figs. 2A-4, there can be a fastener opening 94 associated and aligned with each of the needles received within the needle module 51 , with each of the fastener openings extending or projecting rearwardly through the body of each needle module and opening into or otherwise communicating with the needle receiving passages 91 of the module body. Fasteners 96, such as set screws, bolts, etc., will be received within each of the fastener openings and can be tightened into engagement with the needles to hold the needles in a fixed condition or alignment within the module bodies. Alternatively, fewer fasteners and fastener openings can be provided along the module bodies, with a bearing member further being inserted through the module bodies and being engaged at selected locations by fewer fasteners in order to attach the needles therein. Still further, the needle modules 51 are securely mounted to the needle bar 50, as indicated in Figs. 2A and 2B through the receipt of the fasteners 77 through the fastener openings 76 of the needle bar and into corresponding mounting fastener openings 97 formed in each of the needle modules.

[0028] As indicated in Fig. 4, a series of needle receiving recesses or sites 100 generally will be formed in spaced series along the underside facing surface of the main body portion of the needle bar 50. Such needle receiving recesses or sites 100 generally will be substantially aligned with corresponding ones of the needle receiving passages formed through the needle modules 51. The needle receiving recesses 100 or sites also generally will be formed at a desired depth so as to help locate the needles 25 at a desired elevation or vertical position that will be substantially consistent along the needle bar. The recesses further can have a configuration that substantially matches the upper or distal end of each needle, or can be otherwise configured for receipt of the distal ends of the needle shanks, including needle shanks of various sizes and/or shapes, to accommodate different size and configuration needles and modules without requiring change-out of the needle bar. As a result, the needles can be inserted through their needle receiving passages of their needle modules and the upper or distal ends of the shanks of the needles received and seated or otherwise located at a substantially consistent desired depth or vertical position along the needle bar to ensure substantially consistent and accurate depth of penetration of the needles through the backing material. The needles can thereafter be secured via the set screws or other fasteners inserted through the fastener openings of the module bodies in order to accurately and consistently attach or mount the needles along the needle bar. To the extent that a needle becomes worn, broken or otherwise damaged and needs to be replaced, the fastener associated with that particular needle can be removed and the needle thereafter removed and replaced, with the new needle being inserted and located at a desired elevation along the needle bar after which the fastener can be replaced to secure the needle in place. Thus, the entire needle module does not have to be replaced, rather each needle can be individually or independently replaced as needed and such replacement can be accomplished quickly and accurately by the location of the upper ends of the shanks of the needles within the guide passages and needle receiving recesses of the needle modules and needle bar to maintain consistency in the depth of the needle penetration along the needle bar. The needle module also can remain in place along the needle bar during such needle replacement. Still further, the needle receiving recesses and the corresponding engagement of the upper or distal ends of the shanks of the needles within the needle receiving recesses of the needle bar can help provide additional stability to the needles during operation. By the engagement and supports of the upper ends of the needles within the needle bar itself, the tendency of the needles to flex, twist, or otherwise be deflected upon engagement with their corresponding gauge parts below the tufting zone, can be further resisted to help ensure consistent operation and penetration of the needles even over extended use.

[0030] It also will be understood by those skilled in the art that while the present invention is disclosed with respect to a needle module, the principles of the present invention further can be adapted for use with other replaceable gauging parts or gauging assemblies. For example, the principles of the present replaceable needle module assembly also can be used for the replaceable mounting of other gauge parts, such as cut pile hooks, loop pile loopers, level cut loop loopers, reed fingers, cut loop clips and a variety of other replaceable parts as needed or desired.

[0031] Various features, advantages and aspects of the present invention further may be set forth or apparent from consideration of the following detailed description, when taken in conjunction with the accompanying drawings. Moreover, it will be understood that the accompanying drawings, which are included to provide a further understanding of the present disclosure, are incorporated in and constitute a part of this specification, illustrate various aspects, advantages and benefits of the present disclosure, and together with the detailed description, serve to explain the principles of the present disclosure. In addition, those skilled in the art will understand that, according to common practice, various features and drawings discussed below are not necessarily drawn to scale, and that dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present disclosure.