System and method for forming artificial/synthetic sports turf fabrics

A method of forming an artificial/synthetic turf, comprising:

• moving a backing along a path of travel through a tufting zone;
• engaging the backing with a first row of spaced needles carrying a plurality of yarns through the backing to a first penetration depth;
• engaging the backing with a second row of spaced needles, transversely spaced from the first row of needles across the tufting zone and carrying a second plurality of yarns through the backing to a second penetration depth that differs from the first penetration depth of the first plurality of yarns;
• moving a plurality of hooks across the tufting zone between the needles of the second row of needles and into engagement with the yarns carried by the needles of the first row of needles through the backing to a first penetration depth;
• reciprocating a series of knives into contact with the yarns engaged by the hooks to form cut pile tufts in the backing;
• and
• moving a series of loopers arranged at a second elevation that is vertically spaced from the hooks across the tufting zone between the needles of the first row of needles and into engagement with the yarns carried by the needles of the second row of needles through the backing to the second penetration depth to form the loop pile tufts in the backing;
• wherein the loop pile tufts and cut pile tufts are formed at different pile heights.

A system for forming artificial/synthetic grass turf products, comprising:

• a plurality of needles reciprocably moveable into and out of a backing material, including a first series of needles carrying synthetic grass yarns through the backing material to a first penetration depth, and a second series of needles carrying synthetic grass yarns through the backing material to a second penetration depth that differs from said first penetration depth by a defined vertical spacing;
• a plurality of loopers mounted beneath said first series of needles and adapted to engage said second series of needles for forming loop pile tufts in the backing material;
• and
• a plurality of cut pile hook assemblies mounted in an opposite facing arrangement from said loopers, comprising a series of cut pile hooks adapted to engage said first series of needles and pick loops of yarns therefrom, and a series of knives each aligned with one of said hooks for engaging and cutting the loops picked by cut pile hooks to form cut pile tufts in the backing material;
• wherein said cut pile hooks are located at an elevation corresponding to said first penetration depth of said first series of needles, and said loopers are vertically spaced from said cut pile hooks and are located at an elevation corresponding to said second penetration depth of said second series of needles and engage said second row of needles to form the loop pile tufts at a different height than the cut pile tufts.

A tufting machine for forming artificial/synthetic grass turf products, comprising:

• a first group of needles reciprocably moveable into and out of a backing material, wherein said first series of needles carry a series of synthetic grass yarns through the backing material to a first penetration depth;
• a second group of needles transversely spaced from said first series of needles and reciprocably moveable into and out of the backing material, wherein said second series of needles carry an additional series of synthetic grass yarns through the backing material to a second penetration depth that extends to a depth that differs from said first penetration depth;
• a series of loopers mounted beneath the backing material and adapted to engage selected needles of said second group of needles for forming loop pile tufts in the backing material;
• and
• a series of cut pile hook assembles mounted beneath the backing material in an opposite facing arrangement from and spaced from said loopers, said cut pile hook assemblies each comprising a series of cut pile hooks adapted to engage selected needles of said first series of needles and pick loops of yarns therefrom, and a series of knives each aligned with one of said hooks for engaging and cutting the loops picked by cut pile hooks to form cut pile tufts in the backing material;
• wherein said cut pile hooks are located at an elevation corresponding to said first penetration depth of said first group of needles, and said loopers are located at a different elevation, vertically spaced from said cut pile hooks and corresponding to said second penetration depth of said second group of needles so as to form cut pile tufts and loop pile tufts of synthetic grass yarns at different pile heights sufficient to provide a desired density to enable the artificial/synthetic grass turf products to be formed in a single pass therethrough.