Needle assembly for tufting machines

Abstract

A replaceable needle module assembly for tufting machines includes a series of needle modules mounted in spaced series along a needle or gauge bar. Each needle module includes a module body having a series of needle receiving passages formed therethrough. The needles are received within and extend through each of the needle receiving passages, with the upper ends of the needles being received and engaged within corresponding recesses formed along an underside surface of the needle bar when the needle modules are mounted thereto. As a result, the needles can be securely and accurately located at a desired elevation along the needle bar.

1 . A needle assembly for a tufting machine, comprising:
 at least one needle bar; and   at least one needle module configured to engage and be mounted along the at least one needle bar, the at least one needle module comprising:
 a module body; 
 a series of needle receiving passages defined through the module body; and 
 a series of needles, each needle having a distal end received within one of the needle receiving passages; 
   wherein the at least one needle bar includes a series of recesses configured to receive the distal ends of the needles received within the needle receiving passages of the module body of the at least one needle module.   
     
     
         2 . The needle assembly of  claim 1 , wherein the needles each comprise a shank having a non-cylindrical configuration. 
     
     
         3 . The needle assembly of  claim 1 , wherein the recesses formed along the at least one needle bar are each aligned with a corresponding needle receiving passage of the module body. 
     
     
         4 . The needle assembly of  claim 1 , wherein the recesses formed along the at least one needle bar are formed at a predetermined depth for locating the needles at a desired elevation. 
     
     
         5 . The needle assembly of  claim 1 , wherein the at least one needle bar is slidably mounted within the tufting machine to enable shifting of the needles. 
     
     
         6 . The needle assembly of  claim 1 , wherein the at least one needle bar comprises an upper body portion having a bottom surface along which the recesses are formed, and a front portion projecting downwardly from the upper body portion, and wherein a module receiving area is defined between the upper body portion and front portion. 
     
     
         7 . The needle assembly of  claim 6 , wherein the front portion of the at least one needle bar comprises a series of fastener openings through which fasteners are received for engaging and mounting the at least one needle module to the at least one needle bar. 
     
     
         8 . In a tufting machine for forming a series of yarns in a backing material, the improvement comprising:
 at least one gauge bar having a ledge defined therealong and having a plurality of receiving sites located in spaced series adjacent said ledge; and   a plurality of gauge modules each comprising a body configured to engage said ledge of said gauge bar and having a front side, rear side, top and bottom portions, and a series of passages extending through said body from said bottom to said top portion thereof, and at least one fastener opening formed along said front side of each gauge module and adapted to receive a fastener therein for mounting said gauge module along said gauge bar; and   a series of gauge parts received within and extending through said passages of said gauge modules, each of said gauge parts having a distal portion projecting from said passages at said top portion of said gauge modules and each received within one of said receiving sites of said gauge bar.   
     
     
         9 . In a tufting machine according to  claim 8 , wherein said needles each comprise a shank having a non-cylindrical configuration. 
     
     
         10 . In a tufting machine according to  claim 8 , wherein said receiving sites formed along said at least one gauge bar are formed at a predetermined depth for locating the needles at a desired elevation. 
     
     
         11 . In a tufting machine according to  claim 8 , wherein said receiving sites formed along said at least one needle bar are each aligned with a corresponding one of said passages extending through said body of each of said gauge modules.