A tufted article having a backing material and a plurality of tufts. The plurality of tufts can include cut tufts having first and second tuft portions projecting from a face surface of the backing material. The first and second tuft portions of each cut tuft have respective pile heights relative to the backing material. Each cut tuft also has a backstitch that joins the first and second tuft portions and extends across a portion of a back surface of the backing material. The plurality of tufts includes a plurality of asymmetric cut tufts that have first and second tuft portions with unequal pile heights. Systems and methods for making tufted articles having asymmetric cut tufts are also disclosed.

A yarn color placement system for a tufting machine including a series of different color yarns being fed to the needles of the tufting machine by yarn feed mechanisms. A backing material is fed through the tufting machine at an increased stitch rate as the needles are shifted according to the programmed pattern steps. A series of level cut loop loopers or hooks engage and pick loops of yarns from the needles, with the clips of the level cut loop loopers or hooks being selectively actuated to form cut pile tufts, while the remaining loops of yarns can be back-robbed so as to be hidden from view in the finished patterned tufted article.

A yarn color placement system for a tufting machine including a series of different color yarns being fed to the needles of the tufting machine by yarn feed mechanisms. A backing material is fed through the tufting machine at an increased stitch rate as the needles are shifted according to the programmed pattern steps. A series of level cut loop loopers or hooks engage and pick loops of yarns from the needles, with the clips of the level cut loop loopers or hooks being selectively actuated to form cut pile tufts, while the remaining loops of yarns can be back-robbed so as to be hidden from view in the finished patterned tufted article.

A system and method for forming synthetic/artificial grass or turf products in which a series of tufts of artificial/synthetic grass filaments or yarns are formed in a backing material with various graphic pattern effects being formed therewith. The system generally will include at least one needle bar having at least one row of needles mounted along a tufting zone and reciprocated through the backing to a desired penetration depth, and will present a desired set or group of yarns to a series of pattern pixels or stitch areas. A series of level cut loop loopers or hooks will be aligned with and will engage the needles in order to form tufts of yarns in the backing material. Clips of the level cut loop loopers will be selectively controlled to control the retention of selected ones of the yarns presented at each pattern pixel. The remaining, non-selected yarns generally are not retained at the pattern pixels, and can be formed as lower pile tufts or removed from the backing material.

A system and method for forming synthetic/artificial grass or turf products in which a series of tufts of artificial/synthetic grass filaments or yarns are formed in a backing material with various graphic pattern effects being formed therewith. The system generally will include at least one needle bar having at least one row of needles mounted along a tufting zone and reciprocated through the backing to a desired penetration depth, and will present a desired set or group of yarns to a series of pattern pixels or stitch areas. A series of level cut loop loopers or hooks will be aligned with and will engage the needles in order to form tufts of yarns in the backing material. Clips of the level cut loop loopers will be selectively controlled to control the retention of selected ones of the yarns presented at each pattern pixel. The remaining, non-selected yarns generally are not retained at the pattern pixels, and can be formed as lower pile tufts or removed from the backing material.

Implementations herein describe an artificial turf having a backing layer and a plurality of rows of individual tufts tufted into the backing layer. Each tuft comprises at least three yarns per tuft and each one of the at least three yarns varies in at least one of material, color, texture, denier and cross-section. Each row of individual tufts is substantially similar to each adjacent tufted row and adjacent tufts on a given row are spaced apart at a predetermined gauge.

Implementations herein describe an artificial turf having a backing layer and a plurality of rows of individual tufts tufted into the backing layer. Each tuft comprises at least three yarns per tuft and each one of the at least three yarns varies in at least one of material, color, texture, denier and cross-section. Each row of individual tufts is substantially similar to each adjacent tufted row and adjacent tufts on a given row are spaced apart at a predetermined gauge.

A system, apparatus and methods for forming tufted articles can include a hollow needle tufting machine for forming patterned tufted articles including multiple colors of yarns. The hollow needle tufting machine can include a series of hollow needles arranged along a needle bar at a gauge spacing and will receive a series of different color and/or types of yarns from a yarn feed system. A funnel block having a series of funnels configured to receive a series of yarns will be provided adjacent the needle bar for directing selected yarns to a corresponding or associated hollow needle. The hollow needles will be reciprocated into and out of a backing to deliver a series of yarns; and can be engaged by corresponding knives to form tufts of yarns. The knives can be moved between no-cut and cutting positions to form loop and cut pile tufts of yarns in the backing.

A system, apparatus and methods for forming tufted articles can include a hollow needle tufting machine for forming patterned tufted articles including multiple colors of yarns. The hollow needle tufting machine can include a series of hollow needles arranged along a needle bar at a gauge spacing and will receive a series of different color and/or types of yarns from a yarn feed system. A funnel block having a series of funnels configured to receive a series of yarns will be provided adjacent the needle bar for directing selected yarns to a corresponding or associated hollow needle. The hollow needles will be reciprocated into and out of a backing to deliver a series of yarns; and can be engaged by corresponding knives to form tufts of yarns. The knives can be moved between no-cut and cutting positions to form loop and cut pile tufts of yarns in the backing.

A yarn color placement system for a tufting machine including a series of different color yarns being fed to the needles of the tufting machine by yarn feed mechanisms. A backing material is fed through the tufting machine at an increased stitch rate as the needles are shifted according to the programmed pattern steps. A series of level cut loop loopers or hooks engage and pick loops of yarns from the needles, with the clips of the level cut loop loopers or hooks being selectively actuated to form cut pile tufts, while the remaining loops of yarns can be back-robbed so as to be hidden from view in the finished patterned tufted article.