Tuft replacement machine and method therefor
View Patent ↗A sheet of artificial athletic turf bearing a graphic design formed by an arrangement of tufts of different colors of grass-simulating synthetic yarns. The backing substrate element of the turf is, first, thoroughly tufted with at least one background color of yarn and prior to permanently binding those tufts to the backing, some of the tufts are removed from the backing, and the area of the backing surface vacated by their removal is repopulated with tufts of supplemental colors of yarn arranged in the pattern of the graphic design.
1 . A machine for selectively removing and replacing yarn tufts from a tufted backing sheet, the machine comprising:
a tuft removal mechanism that wholly removes inserted yarn tufts from a backing fabric to create a tuft removal footprint;
a tuft insertion mechanism capable of inserting yarn tufts into the backing within the tuft removal footprint; and
a computer for storing tuft removal and insertion position information and for selectively controlling operation of the removal and insertion mechanisms according thereto.
2 . The machine of claim 1 , wherein said removal footprint comprises non-contiguous areas.
3 . The machine of claim 1 , wherein said insertion mechanism is capable of inserting multiple colors of yarns that form a discernable design within the removal footprint.
4 . The machine of claim 1 , wherein said removal mechanism removes whole yarn tufts from the backing by plucking, sucking, or abrading them therefrom.
5 . The machine of claim 1 , wherein said removal and insertion mechanisms are travelable relative to the backing.
6 . The machine of claim 1 , wherein said machine further comprises a conveying mechanism capable of advancing the backing relative to said removal and insertion mechanisms.
7 . The machine of claim 6 , wherein said conveying mechanism comprises:
at least one endless chain;
gripping elements that are disposed along the at least one chain and are configured to engage the backing so that the backing advances, relative to said removal and insertion mechanisms, as the at least one chain moves;
a drive mechanism configured to impart chain movement; and
wherein said computer controls the drive mechanism in coordination with the removal footprint.
8 . The machine of claim 6 , wherein said conveying mechanism is configured to tension the backing multi-directionally.
9 . A machine for selectively removing and replacing yarn tufts from a tufted backing sheet, the machine comprising:
a tuft removal mechanism that wholly removes yarn tufts from a plurality of replacement positions along a backing fabric;
a tuft insertion mechanism capable of inserting yarn tufts into the backing at the replacement positions; and
a computer for storing the replacement position information and for selectively controlling operation of the removal and insertion mechanisms in coordination therewith.
10 . The machine of claim 9 , wherein said insertion mechanism is capable of inserting multiple colors of yarns at the replacement positions to form a discernable design.
11 . The machine of claim 9 , wherein said removal mechanism removes whole yarn tufts from the backing by plucking, sucking, or abrading them therefrom.
12 . The machine of claim 9 , wherein said removal and insertion mechanisms are travelable relative to the backing.
13 . The machine of claim 9 , wherein said machine further comprises a conveying mechanism capable of advancing the backing relative to said removal and insertion mechanisms.
14 . The machine of claim 13 , wherein said conveying mechanism comprises:
at least one endless chain;
gripping elements that are disposed along the at least one chain and are configured to engage the backing so that the backing advances, relative to said removal and insertion mechanisms, as the at least one chain moves;
a drive mechanism configured to impart chain movement; and
wherein said computer controls the drive mechanism in coordination with the removal positions.
15 . The machine of claim 13 , wherein said conveying mechanism is configured to tension the backing multi-directionally.
16 . A method for removing and replacing inserted yarn tufts from a tufted backing sheet by design, the method comprising:
attaching the backing to a retaining mechanism;
removing whole inserted yarn tufts from the backing, according to a predetermined removal footprint, with a removal mechanism; and
tufting yarn into the backing, within the removal footprint and according to a predetermined insertion pattern, with a tufting mechanism.
17 . The method of claim 16 , wherein said removing whole yarn tufts is done by plucking, sucking, or abrading.
18 . The method of claim 16 , wherein said removal footprint comprises non-contiguous areas.
19 . The method of claim 16 , wherein said insertion pattern comprises multiple colors of yarns that form a discernable design.
20 . The method of claim 16 , further comprising bonding inserted yarn tufts to the backing.