Systems and methods for pre-tensioning backing materials of a tufted product. The systems can include at least first and second tensioning assemblies and a guide assembly. Each tensioning assembly can have a backing supply subassembly for supporting a backing material and a roller subassembly for effecting movement of the backing material at a desired tension. The roller subassembly can include a driven roller for pulling the backing material from the backing supply subassembly, and a compensator for receiving the backing material from the driven roller. The guide assembly can simultaneously receive the tensioned backing materials from the tensioning assemblies and position the backing materials in contact with each other for delivery to a tufting machine at the desired tension.

Systems and methods for pre-tensioning backing materials of a tufted product. The systems can include at least first and second tensioning assemblies and a guide assembly. Each tensioning assembly can have a backing supply subassembly for supporting a backing material and a roller subassembly for effecting movement of the backing material at a desired tension. The roller subassembly can include a driven roller for pulling the backing material from the backing supply subassembly, and a compensator for receiving the backing material from the driven roller. The guide assembly can simultaneously receive the tensioned backing materials from the tensioning assemblies and position the backing materials in contact with each other for delivery to a tufting machine at the desired tension.

A method of using an improved hollow needle tufting machine to make an artificial grass product includes features not present in prior art hollow needle tufting machines. Specifically, some embodiments have at least four inch long needles. Other embodiments have larger diameter feed rolls. Other embodiments have larger diameter guide tubes. Still other embodiments have a lowered backing support to provide an increased distance from the backing support to the needle bar.

A method of using an improved hollow needle tufting machine to make an artificial grass product includes features not present in prior art hollow needle tufting machines. Specifically, some embodiments have at least four inch long needles. Other embodiments have larger diameter feed rolls. Other embodiments have larger diameter guide tubes. Still other embodiments have a lowered backing support to provide an increased distance from the backing support to the needle bar.

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.

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.

A method for tufting lower loop heights than prior art machines could tuft with a hollow needle tufting machine is disclosed. Polishing and/or rounding edges of needles, which may be smaller in diameter than prior art needles were implemented with a straight edge backing bar, and dimensionally stable woven backing fabric to provide consistently lower loops than prior art efforts.

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.

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.

A yarn feed system configured to control feeding of individual yarns to the needles of a tufting machine, and which system can be manufactured as a substantially standardized unit or attachment that can be removably mounted to a tufting machine. The yarn feed unit includes a series of yarn feed devices each of which can include a motor package having two or more yarn feed motors coupled together with a shared or integrated motor controller configured for controlling each motor of the motor package independently. The yarn feed devices can feed one or more selected yarns to associated ones of the needles of the tufting machine according to pattern instructions for a pattern being tufted.