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.

Yarn injection device for injecting yarn sections into a substrate, wherein the yarn injection device comprises:a yarn storage for holding a number of spools with yarn,a feeding device configured to feed lengths of yarn to an injection unit, the feeding device comprising: ?a number of yarn tubes, each yarn tube defining a yarn channel configured to accommodate a respective yarn, ?a number of cutting devices located being configured to cut a number of yarn sections,the injection unit comprising: ?an injection needle guide defining a number of first passages extending over a vertical distance and a number of second passages extending over a horizontal distance, ?a number of moveable injection needles configured to pass through the first holes of the injection needle guide, wherein yarn sections in the yarn tubes located below the moveable injection needles are injected into the substrate when the moveable injection needles move downward through the injection needle guide, ?at least one needle actuator configured to move the number of moveable injection needles,a fluid flow assembly, wherein at least one fluid communication channel extends between the injection needle guide and the depressurized or pressurized compartment, wherein the fluid flow assembly is configured to create a flow of fluid through each fluid communication channel, each injection needle guide and each yarn tube in order to apply a drag force on the yarns and move the yarns through the second passages in the injection needle guide.

Yarn injection device for injecting yarn sections into a substrate, wherein the yarn injection device comprises:a yarn storage for holding a number of spools with yarn,a feeding device configured to feed lengths of yarn to an injection unit, the feeding device comprising: ?a number of yarn tubes, each yarn tube defining a yarn channel configured to accommodate a respective yarn, ?a number of cutting devices located being configured to cut a number of yarn sections,the injection unit comprising: ?an injection needle guide defining a number of first passages extending over a vertical distance and a number of second passages extending over a horizontal distance, ?a number of moveable injection needles configured to pass through the first holes of the injection needle guide, wherein yarn sections in the yarn tubes located below the moveable injection needles are injected into the substrate when the moveable injection needles move downward through the injection needle guide, ?at least one needle actuator configured to move the number of moveable injection needles,a fluid flow assembly, wherein at least one fluid communication channel extends between the injection needle guide and the depressurized or pressurized compartment, wherein the fluid flow assembly is configured to create a flow of fluid through each fluid communication channel, each injection needle guide and each yarn tube in order to apply a drag force on the yarns and move the yarns through the second passages in the injection needle guide.

A roller assembly having a central axis can comprise a roller having an outer surface and defining an inner bore. The apparatus can further comprise a bushing comprising a sleeve having an outer surface and defining an inner bore. The inner bore of the sleeve can have an operative circumference. The sleeve comprises a bladder that is configured to expand radially upon receipt of a fluid to reduce the operative circumference of the inner bore. The bushing can further comprise a flange extending radially outwardly from the sleeve. The flange defines a vessel containing fluid therein. The vessel is in fluid communication with the bladder of the sleeve. The bushing comprises an actuator that is configured to cause the fluid from the vessel of the flange to flow into the bladder of the sleeve. An alignment feature can be configured to rotationally position the roller relative to the bushing.

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 actuators to extend or retract 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 can be controlled in conjunction with the movement of the gauge parts, while the backing feed can also be controlled, to enable formation of tufts of yarns at an increased rate over the pattern stitch rate for the pattern of the tufted article being formed.

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 actuators to extend or retract 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 can be controlled in conjunction with the movement of the gauge parts, while the backing feed can also be controlled, to enable formation of tufts of yarns at an increased rate over the pattern stitch rate for the pattern of the tufted article being formed.

A roller assembly having a central axis can comprise a roller having an outer surface and defining an inner bore. The apparatus can further comprise a bushing comprising a sleeve having an outer surface and defining an inner bore. The inner bore of the sleeve can have an operative circumference. The sleeve comprises a bladder that is configured to expand radially upon receipt of a fluid to reduce the operative circumference of the inner bore. The bushing can further comprise a flange extending radially outwardly from the sleeve. The flange defines a vessel containing fluid therein. The vessel is in fluid communication with the bladder of the sleeve. The bushing comprises an actuator that is configured to cause the fluid from the vessel of the flange to flow into the bladder of the sleeve. An alignment feature can be configured to rotationally position the roller relative to the bushing.

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 extend or retract 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 back-rob 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.

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 extend or retract 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 back-rob 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.

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.