Weaving Ingrain Carpet Fabric.
Year: 1890

page_text: Date of Application, 3rd May, 1890-Accepted, 7th June, 1890
COMPLETE SPECIFICATION.
Weaving Ingrain Carpet Fabric.
I, WILLIAM B. KEEFER a citizen of the United States residing in the city and
county of Philadelphia, and State of Pennsylvania, United States, Carpet manu-
facturer, do hereby declare the nature of this invention and in what manner the same
is to be performed to be particularly described and ascertained in and by the following
statement:-
My invention belongs to a class of carpets known to the trade as "ingrains."
The old method of weaving a two-ply ingrain carpet requires four figuring and
binding woft-threads and four warp throads in a set or weave. In a three-ply six
figuring and binding weft threads and six warp-threads are required to a set or weave.
All two-ply and three-ply ingrains are woven by the jacquard, two-ply ingrains being
woven with four rising and falling journals, and one card being used for each two
shots of weft, while in the weaving of a three-ply six journals and one card for each
shot of weft are employed.
My invention consists in a fabric of the improved construction hereinafter fully
described it resembling in appearance a three-ply ingrain carpet but having six weft
threads and four warp threads in a set, and although containing one-third less warp
threads and made at much less cost, being nearly if not quite as good as a three-ply
carpet made in the ordinary way.
In the accompanying drawings; making a part of this specification ;-
Fig. 1 is a diagram showing a combination of nine shots of weft-threads or one
complete set of weft threads and half of a second set and four warp threads.
Figs. 2 and 3 are diagrams showing the same number of shots, but with the weft
and warp threads placed in different positions.
Fig. 4 shows a combination of forty-two shots of weft threads and four warp
threads.
Similar letters and numbers refer to similar threads in the several figures.
The colors of the weft threads shown in the drawings may be supposed to be as
follows;W, white; S, scarlet; B, blue. The warp threads may be supposed to be
of the following colors;-1, white; 2, scarlet; and 3 and 4 blue. It is to be
understood that the colors of the weft and warp threads can be varied in sets to
produce the shading desired in the design and that since each set of wefts is
composed of six weft-threads any number of colors of wefts up to six may be
employed in each set.
In the drawings I have represented each set of wefts as composed of two white
wefts, two scarlet wefts, and two blue wefts the object in using two of each color
being to secure solid color effects. In practice five different colors have been
employed by me with good results-as for instance white, olive, red, olive and gold
twisted together, (olive twist) and black, the white heing introduced twice. It is
to be understood therefore, that the colors of wefts illustrated have been merely
arbitrarily selected and it is so also with the colors of the warp threads the colors
assigned thereto herein having been selected for convenience of explanation and
because they agree with the colors of the wefts. Obviously there need not be the
two blue warp-threads or two of any other color, unless desired, for instead one of
the said two may be replaced by a warp-thread of a different color.
In arranging the warp in the loom-barness I prefer a loom with four journals
which is the same as a "comber-board" divided into four parts. The warp is
divided into four parts one part being composed of the white threads and placed
under the control of the harness-cords passing through one journal another part being
composed of the scarlet and being placed under the control of the cords passing

page_text: through a second journal and the other two parts being composed of the blue warp
threads and being placed under the control of the cords in the remaining two
journals.
The design to be woven is cut on the cards one card being used to each shot of
woft. The journals do not move but are stationary serving morely as guides for the
harness-cords and the warp threads are moved solely by the jacquard as controlled
by the cards. In the various diagrams in the drawings the shots of weft on the
left-hand side are supposed to be put in first. If a hand-loom be used or a power-
loom that will "call" any pick at will the shots of woft may be thrown in regular
succession.
Fig. 1 shows a combination of threads in which three white wefts W appear in
the upper plane hound by white and scarlet warp threads 1 and 2 alternately,
three scarlet wetts S in the middle plane and three blue wefts B in the bottom plane
bound by the blue warp threads 3 and 4 alternately.
Fig. 2 shows a combination of threads in which three scarlet wefts S appear in
the upper plane bound by blue and scarlet warp threads 2 and 3 alternately three
white wefts W in the middle plane and three blue wefts B in the bottom plane bound
by white and blue warp threads 1 and alternately.
Fig. 3 shows a combination of threads in which three blue wefts B appear in the
upper plane bound by blue warp threads 3 and 4 alternately three scarlet wefts S in
the middle plane, and three white wefts W in the bottom plane bound by white and
scarlet warp threads 1 and 2 alternately.
Those three diagrams illustrate portions of fabric in which the same color of weft
appears consecutively for a number of picks in the same plane and are intended to
display clearly the manner in which the respective wefts are combined with the
respective warp threads in the different positions which the wefts occupy in the
fabric.
It will be seen that in Fig. 1 on the face of the fabric the first white weft is
bound by the white warp thread and the second is hound by the scarlot warp, the
latter harmonizing with the said second weft more closely than the blue warps while
on the back thereof the first blue weft is bound by one blue warp thread and the
second blue weft is bound by the other blue warp thread. In fig. 2 on the face of
the fabric the first scarlet weft is bound by blue warp thread 3 and the second
scarlet weft is bound by the scarlet warp throad, and on the back the first blue weft
is bound by the white warp thread while the second blue weft is bound by the blue
warp thread 4 and in Fig. 3 on the face of the fabric the first blue weft is bound
by blue warp thread 3 and the second by blue warp thread 4, while on the back the
first white thread is bound by the white warp thread and the second white weft is
bound by the scarlet warp thread. In other words every color of woft where it
appears on either face is bound by a warp-thread of the same color or else by that
color most fully harmonizing therewith.
Fig. 4 is a diagram intended to illustrate the manner in which the wefts and warp
threads may be varied in position in the fabric in producing a pattern and it can
readily be traced to ascertain what wefts and warp threads are on top what wefts and
warp threads are in the middle and what wefts and warp threads are on the
bottom.
It will be understood by skilled weavers that by the aid of the jacquard machine
and a pick-and-pick loom that will "call" any shuttle or weft at will the weft
and warp threads may be interwoven to produce shading effects. Thio wefts
not wanted on either the face or the back of the fabric are thrown to the
middle thereof.
The wefts are introduced in sets of six oach, as above referred to for the reason that
the introduction of six wefts is necessary to complete each round in the interweaving
and to secure proper binding of the wefts into a solid and homogeneous fabric. Thus in
Fig. 1 the first shot of white weft in the top plane is bound by the whire warp thread 1, !
the first shot of blue weft in the bottom plane is bound by the bluo warp thread 3,

page_text: the second shot of white weft in the top plane is bound by the scarlet warp thread 2.
and the second shot of blue weft in the bottom plane is bound by the blue warp 4.
Now while the first pick of white weft and first pick of blue wert are bound by warp
threads 1 and 3 passing above and below the same respectively the warp threads 2
and pass on opposite sides of the first shot of scarlet weft. Also while binding the
second shot of white weft in the top plane and the second shot of blue weft in the
bottom plane by warp threads 2 and 4 respectively, the warp threads and 3 are
passed to the middle of the fabric and around the second scarlet weft in opposite
directions, as shown. The positions for the succeeding six wefts will be repetitions of
these just described. It will be apparent that the same thing is true when applied to
Figs. 2 and 3 respectively.
The particular arrangements of threads represented in Figs. 1 2 and 3 are of course
not visible throughout the fabric inasmuch as the varied disposition of the wefts both
transversely and longitudinally of the fabric made necessary by the various pattern
effects to be produced, involves altered arrangements of the warp threads, but the
principle of construction remains the same throughout owing to the requirement of an
effectual binding of the face or back wefts into the fabric structure.
In Fig. 4 the arrangement of the warp threads and the wefts in the first set begin-
ning at the left is the same as that represented in Fig. 1. The arrangement in the
second set will be seen to be that represented in Fig. 2, and the arrangement in the
third set will be seen to correspond with that represented in Fig. 3 while the remain-
ing sets 4, 5, 6, and 7 are represented various combinations producing shot-about
effects.
In each of Figs. 1, 2 and 3 wefts of the same color appear on the same surface of
the fabric for a number of shots and consequently the consecutive shots of weft on each
surface are bound by the same pair of warp threads the latter appearing on the said
surface alternately. In the said figures the top and bottom wefts are bound to the
middle weft by the passage of the warp threads in opposite directions around the said
middle weft and the fabric has its different planes of weft closely bound together and
is without pockets.
In fig. 4 in changing from the arrangement of fig. 1 to that of fig. 2 or otherwise
from one of the simple arrangements represented in figs. 1, 2 and 3 to another thereof
the respective warp threads instead of passing from the cutside of one weft on one
surface of the fabric to and around the middle weft and back to the same surface,
continue across to the other surface where they appear outside the outermost weft.
This results from the transfer of the different wefts respectively from one position in
the fabric to another and from the necessity of binding each weft particularly when it
appears on the upper face of the fabric, by warp-thread of the same or a harmonizing
color. In Fig. 4 the fabric is still without pockets. I thus arrange the warp threads
so as to extend from the two surfaces of the fabric in opposite directions around the
middle wefts as in Figs. 1, 2 and 3 and also from one surface of the fabric to the
other with approximate directness so as to bind the three planes of wefts closely and
compactly together whatever may be the character of the figure or pattern appearing
on the faces of the fabric. This result will be secured even though in one or two
sets at intervals instead of carrying the warp threads from the surfaces in opposite
directions to and around the middle weft-threads the warp threads being disposed as
in set 4 of fig. 4 although in practice I shall adopt the arrangement of the said set
only in exceptional cases if at all.
It is to be distinctly understood that the colors mentioned in referring to the
threads in the foregoing description have been selected arbitrarily and for the purpose
of facilitating the explanation of the invention. In practice any desired variety of
colors may he employed.
Having now particularly described and ascertained the nature of my said inven-
tion and in what manner the same is to be performed I declare that what 1
claim is ;-
An ingrain-carpet fabric having three weft-planes, and composed of warp-threads

page_text: and figuring wefts in sets, each comprising six figuring wefts and four warp threads,
and having the warp threads passed from the two sides of the fabric in opposite
directions to and around said middle wofts and also from one surface to the other
throughout substantially the whole extent of the fabric, to bind the threads securely
into a homogeneous fabric without pockets, substantially as described.
B
AA
W. P. THOMPSON & BOULT.
Agents for the Applicant.