Improvements in the Manufacture of Reversible Three Ply Ingrain Carpets.
Year: 1897

page_text: Date of Application, 28th May, 1897
Complete Specification Left, 23rd Feb., 1898-Accepted, 26th Mar., 1898
PROVISIONAL SPECIFICATION.
Improvements in the Manufacture of Reversible Three Ply Ingrain
Carpets.
We, HENDERSON AND COMPANY LIMITED, of the City of Durham, in the County
of Durham, Carpet Manufacturers, and ROBERT BRITTON, of 3, Wanlass Terrace,
in the same City, Power Loom Tuner, do hereby declare the nature of this inven
tion to be as follows:-
"
The object of our invention is to manufacture a reversible three ply ingrain
carpet fabric without what are termed "pockets," which pockets are a very great
drawback to the fabric, on account of each of the plies forming a separate cloth,
and being separate from each other, and hitherto the existence of these "pockets'
has been considered inevitable in the manufacture of an ordinary three ply ingrain
carpet fabric, and is quite a disadvantage in producing large plain design effects,
on account of the forming of the open piles or separate cloths and the inability to
produce a saleable carpet in these said broad plain design effects, the only place
where the plies are tied together in an ordinary three ply ingrain carpet being
where they change the one for the other; that is to say, where the ply which was
on the face of the carpet is made to take either the middle or under ply, the middle
to take the place of the upper or under ply, and the under ply to take the place of
the middle or upper ply, and so forth.
"
In producing a three ply ingrain carpet according to our present invention we
employ, say, the same number of warp threads as are usually employed.
We will for simplicity's sake term the ground ply "dark," the inner ply "middle"
and the bottom ply "light." For instance when the dark is on the face of the
fabric the middle colour is between the top and bottom ply and the light colour
will be on the underside of the carpet; or when the middle colour is on the face
of the carpet the light will be the inner ply and the dark on the under-
side; or when the light is on the face the dark will be the inner ply and the
middle on the underside. We are also able when the dark is on the face to put
the light in the middle and the middle on the underside; and so forth. When
dark forms the ground of the carpet we utilize the dark warp and the middle warp
to cover and bind it, allowing the dark warp to take its ordinary course and at proper
intervals, at will, by bringing a portion of the middle warp as well as the dark
warp over the "dark" (that is, the dark weft thread) so that say two warps are
used instead of one, which also makes a much better wearing carpet fabric, as well
as binding the plies.
The portion of the middle warp utilized for this purpose is not intended to be
exposed but takes its place or position directly under the dark warp, the said middle
warp being of the same size and covered by the said dark warp, and it must be
clearly understood that either the middle or light warps may be utilized for this
purpose. The middle warp which covers or binds the dark say on odd rows of the
design descends to the underside and covers or binds the light or the
middle to the inner layer or ply on the even rows. When the middle

page_text: weft colour is showing on the face of the fabric we utilize the
light warp as well as the middle warp to bind the face weft or ply; the middle warp
is allowed to take its ordinary course and a portion of the light warp is utilized to
bind the middle color to the inner layer or ply; the portion of the light warp
threads say on odd rows of the design descends to the underside and covers or binds
the bottom layer to the said inner layer on the even rows. When the light colour
is showing on the face of the fabric, we utilize a portion of the dark warp threads
which are now forming the middle ply to bind the upper or light weft threads to
the inner layer or ply. These dark warp threads say on odd rows of the design
descend to the underside and bind the middle coloured weft threads, which are
now on the underside, on even rows. The repitition of the above manipulations
on even rows will produce similar effects in relation to the odd rows.
It must also be understood that we are able by a similar manipulation to tie
what is thus the middle layer to the upper layer without interfering with the
bottom layer; or vice versa.
With reference to the portion of the middle ply warp threads which are utilized
in binding the face of the carpet the corresponding or mate warp thread of the
middle ply warp may be taken to the underside on the same row to bind what is
the under ply. to the inner ply. We do not limit ourselves to any particular number
of warp threads taken from the middle or bottom ply to bind the top ply, or from
the middle or top ply to bind the bottom ply..
D
1 1 .adul 1
100%
WM. BROOKES & SON,
55 and 56, Chancery Lane, London, Agents for the Applicants.
Improvements in the Manufacture of Reversible Three Ply Ingrain
Carpets.
We, HENDERSON AND COMPANY LIMITED, of the City of Durham, in the County
of Durham, Carpet Manufacturers, and ROBERT BRITTON, of 3, Wanlass Terrace,
in the same City, Power Loom Tuner, do hereby declare the nature of this inven-
tion and in what manner the same is to be performed, to be particularly described
and ascertained in and by the following statement:―
"
The object of our invention is to manufacture a reversible three ply ingrain
carpet fabric without what are termed "pockets," which pockets are a very great
drawback to the fabric, on account of each of the plies forming a separate cloth,
and being separate from each other, and hitherto the existence of these "pockets"
has been considered inevitable in the manufacture of an ordinary three ply ingrain
carpet fabric, and is quite a disadvantage in producing large plain design effects,
on account of the forming of the open piles or separate cloths and the inability to
produce a saleable carpet in these said broad plain design effects, the only place
where the plies are tied together in an ordinary three ply ingrain carpet being
where they change the one for the other; that is to say, where the ply which was
on the face of the carpet is made to take either the middle or under ply, the middle
to take the place of the upper or under ply, and the under ply to take the place of
the middle or upper ply, and so forth. In producing a three ply ingrain carpet
according to our present invention we employ, say, the same number of warp threads
as are usually employed.
We will for simplicity's sake term the ground ply "dark," the inner ply "middle"
and the bottom ply "light." For instance when the dark is on the face of the
fabric the middle colour is between the top and bottom ply and the light colour

page_text: will be on the underside of the carpet; or when the middle colour is
on the face of the carpet the light will be the inner ply and the dark on the under-
side; or when the light is on the face the dark will be the inner ply and the
middle on the underside. We are also able when the dark is on the face to put
the light in the middle and the middle on the underside and so forth. When
dark forms the ground of the carpet we utilize the dark warp and the middle warp
to cover and bind it, allowing the dark warp to take its ordinary course and at proper
intervals, at will, by bringing a portion of the middle warp as well as the dark
warp over the "dark" (that is, the dark weft thread) so that (say) two warps are
used instead of one, which also makes a much better wearing carpet fabric, as well
as binding the plies.
The portion of the middle warp utilized for this purpose is not intended to be
exposed but takes its place or position directly under the dark warp, the said middle
warp being of the same size and covered by the said dark warp, and it must be
clearly understood that either the middle or light warps may be utilized for this
purpose. The middle warp which covers or binds the dark, say, on odd rows of the
design descends to the underside and covers or binds the light or the
middle to the inner layer or ply on the even rows.
When the middle weft colour is showing on the face of the fabric we utilize the
light warp as well as the middle warp to bind the face weft or ply; the middle warp
is allowed to take its ordinary course and a portion of the light warp is utilized to
bind the middle colour to the inner layer or ply; the portion of the light warp
threads say on odd rows of the design descends to the underside and covers or binds
the bottom layer to the said inner layer on the even rows. When the light colour
is showing on the face of the fabric, we utilize a portion of the dark warp threads
which are now forming, the middle ply to bind the upper or light weft threads to
the inner layer or ply. These dark warp threads-say on odd rows of the design-
descend to the underside and bind the middle coloured weft threads, which are
now on the underside, on even rows. The repetition of the above manipulations
on even rows will produce similar effects in relation to the odd rows.
It must also be understood that we are able by a similar manipulation to tie
what is thus the middle layer to the upper layer without interfering with the
bottom layer; or vice versa.
With reference to the portion of the middle ply warp threads which are utilized
in binding the face of the carpet the corresponding or mate warp thread of the
middle ply warp may be taken to the underside on the same row to bind what is
the under ply, to the inner ply. We do not limit ourselves to any particular number
of warp threads taken from the middle or bottom ply to bind the top ply or from
the middle or top ply to bind the bottom ply.
DESCRIPTION OF THE DRAWINGS.
The same letters are used for each section of fabric shown in the accompanying
figures.
Fig. 1 shows a side section of an ordinary three ply carpet fabric such as was
commonly used prior to our present invention and which is here shown only to
facilitate explanation. AA denote dark coloured warp threads, BB the middle
ecloured warp threads, CC light coloured warp threads, D dark coloured wefr
threads, E middle coloured weft threads, and F light coloured weft threads. From G
to H represent, say, dark colour in the face ply, middle colour in the middle ply
and light colour in the under ply; H to I middle colour in the face, light colour in
the middle and dark colour in the underside, I to J, light colour in the face, dark
colour in the middle and middle colour in the underside.
It will be seen on looking at Fig. 1, that if any breadth of plain colour effect is
equired, either dark, middle or light, each of the plies, although manufactured at
he same time, are distinctly separate from each other; that is, what are termed
pockets" are produced, each of the separate plies being independent of each other;
which is the cause of the fabric being very loose and slackly manufactured and

page_text: causes it to "pucker." Hitherto the scope of the designers art has been very much
limited on account of this defect in the manufacture.
On referring to Figs. 2 and 3, it will be observed that we utilize the warp threads
of the middle ply to tie down in as many places as we think necessary the face and
under ply to the said middle ply, and if any one of the warp threads is traced along
the section shown it will be found that at K, Fig. 2, two warp threads cover the
dark weft at that particular part and the greater tension being applied on the
middle colour warp threads will cause it to press into the weft very much further
than the dark warp, so that the dark warp will float above and immediately over it.
This said middle coloured warp thread descends before the formation of the next set
of weft threads and this time it will cover or tie down a light weft thread, allowing
the light warp thread to float over it. Exactly the same thing takes place at N
and O, but with another warp thread of the same colour.
The part of section shown from P to Q has got the light warp threads going
through the middle of the fabric, also the light weft threads and exactly the same
operation takes place at R, S, as took place at K, M, but with the light warp threads;
and the same operation takes place at T, U, that took place at R, S, the dark warps
and wefts being in the middle of the fabric this time, therefore the said dark warp
will tie the light weft at T and the middle weft at U.
We do not limit ourselves as to number of times we utilize the warp threads which
are in the middle of the fabric to tie down the other two plies. Very much broader
design effects can be produced and the life of the fabric prolonged it being tied
down and bound together by the additional warp forming the middle ply.
Fig. 3 shows an alternative way of binding the piles together. In this case wher-
ever one of the middle warps binds the face to the middle ply, its mate warp thread
also binds the bottom ply to the middle ply; this is clearly shown at W,X, six warp
threads being used for each set in Figs. 1, 2 and 3.
Having now particularly described and ascertained the nature of our said inven-
tion, and in what manner the same is to be performed, we declare that what we
claim is:-
1. In the manufacture of reversible three ply ingrain carpets, the method of
weaving the three plies of threads forming the warp with the corresponding weft
threads so that the warp threads are passed to and fro and around the
wefts and so as to cover and bind each other into the fabric, so as
to prevent the formation of "pockets" and facilitate the production
of large plain colour effects or designs in the manner and for the purpose set forth
in Figs. 2 and 3.
2. In the manufacture of reversible three ply ingrain carpets, the method of
weaving the "top ply," the "middle ply" and the "bottom ply" respectively
together, as and for the purpose set forth and shown by the drawings Figs. 2 and 3,
so as to facilitate the employment of large plain colour effects or designs and avoid
the production of what are technically called "pockets or inconvenient separa-
tions of the cloths.
3. In the manufacture of reversible three ply ingrain carpets, the use of a
middle ply of warp thread so as to effect the binding of the " top" ply and
"bottom" ply of weft to the "middle ply" in the manner and for the purpose
set forth and shown by the drawings Figs. 2 and 3.
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0211hmom 1900
WM. BROOKES & SON,
55 and 56, Chancery Lane, London, Agents for the Applicants.