Patent ID: 6877449

Claim:
A method of creating and tufting a carpet pattern comprising the steps of: selecting pattern parameters of width, length, a relatively high pile height and a relatively low pile length, for stitches on a computer display; creating a border pattern for at least one border to surround a central image; scanning an image to create a digital image; processing the digital image by a computer to calculate corresponding yarn heights and yarn feed increments for a plurality of colors of yarns in a carpet pattern to create pattern information; inputting the pattern information into a master controller of a multi-needle tufting machine; threading yarn ends of said plurality of colors of yarns from a yarn supply through a yarn drive array to a plurality of laterally spaced needles; reciprocating the plurality of laterally spaced needles threaded with said plurality of yarns through a backing fabric fed longitudinally from front to back through the tufting machine; sending information relative to the position of the plurality of needles to the master controller; the master controller sending information relative to the amount of yarn to be fed for the next stitch to the yarn drive array; operating a looper mechanism in synchronized cooperation with the plurality of needles to seize loops of yarn tufted through the backing fabric; thereby forming a tufted carpet having: a top surface on the backing fabric, a bottom surface and an outer perimeter encompassing a center portion; a first border surrounding the center portion comprising a first plurality of bights on the outer perimeter of the top surface of the backing fabric; wherein the plurality of bights comprising said first border is formed by feeding stitches of yarn in at least three distinct increments of length.