Tufting system with mini-staggered needles

摘要

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.

主权项

1. A method of forming tufted articles comprising:
moving a backing through a tufting zone; feeding a series of yarns to a series of needles, wherein the needles are arranged in at least two rows along one or more needle bars, and wherein the needles of each row of needles are transversely spaced apart by a distance that is less than a prescribed gauge spacing for the tufts of the tufted article; reciprocating the needles into and out of the backing; engaging the needles of each row of needles with a series of gauge parts, at least a portion of the gauge parts engaging at least one needle of each of the rows of needles so as to pick at least one yarn from the at least one needle of each row of needles engaged thereby; and forming a series of tufts of yarns in the backing; wherein the tufted article is formed with a desired stitch density at an increased production rate.