Improvements in Kidderminster, Scotch, or Ingrain Carpets.
Year: 1898

page_text: Improvements in Kidderminster, Scotch, or Ingrain Carpets.
We, THOMAS Fox NAYLOR and ARTHUR NAYLOR, of Green Street, Kidderminster,
in the County of Worcester, Carpet Manufacturers, do hereby declare the nature
of this invention to be as follows: -
Our invention relates to improvements in that class of carpet fabrics known as
Kidderminster, Scotch, or ingrain carpets, the object being to insert a smaller
number of wefts than is usually employed. The present invention is an improve-
ment upon the invention described in the Specification to British Letters Patent,
No. 11692, of 1895, having the same object in view.
The ordinary Kidderminster, Scotch, or ingrain carpet fabric is woven with
two or more plies of weft; that is to say, it has two or more webs or layers of
material thrown or shot by the shuttle, the said webs being bound together by
the interweaving both of the warp threads and the weft material.
But in our improved carpet fabrics, while we also employ two plies of weft
material thrown by the shuttles, one web is composed of only one half of the
number of shots comprised in the other web. The finished fabric is therefore
hereinafter called a one and a half ply carpet, like those referred to in the above
named Specification No. 11692 of 1895. In the set of three shots forming one
fabric, two shots are placed side by side in forming one web, and one shot in
forming the other web. The one shot can change places with either of the two
shots, or with both. We use a stuffer warp running between the two webs of
weft, as in carpets described in John Orr's British Specification, No. 905 of 1855
in this class of carpets the stuffer warp is used mainly as a controlling or guiding
warp, to determine the position of the wefts. In our invention it may guide
two wefts to the top or upper surface of the fabric; and one to the bottom surface,
or vice versa. If two wefts are guided to the top, and one weft guided to the
bottom, and supposing the two top wefts to occupy the space of two eighths
of an inch, then the one bottom weft will only occupy one eighth of an inch,
while the other one eighth occupied is formed by the uncovered stuffer warp.
Or if the reverse be woven, that is, if the stuffer warp guides one weft to the
top, and two wefts side by side to the bottom surface, then one eighth of an inch
of the stuffer warp will remain uncovered and exposed as if on the top surface
of the fabric. Thus, by omitting one weft thread in every four of the wefts as
formerly used, the usual "pairing' or mateing" of wefts does not occur in
our one and a half ply carpet fabrics. It follows also that the colour of the
exposed stuffer warp, in combination with any one of the three wefts used,
produces a colour effect. Thus, if the three shuttles thrown respectively contain
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page_text: wefts coloured olive, scarlet, and cream, and the stuffer warp is black, then
the following combinations of colours may be produced.
Olive and scarlet.
Scarlet and black.
Olive and cream.
Olive and black.
Scarlet and cream.
Cream and black.
Consequently any two of the wefts can be brought to the top surface, side by
side; while any one of the three wefts can also be brought to the surface to
combine in colour effect with the uncovered black stuffer warp.
As the stuffer warp plays the most important part in guiding the wefts to
their allotted places in the fabric, and in itself forms part of the pattern or
design, it is necessary to use a jacquard machine and stamp cards in the usual
way for lifting or lowering the stuffer warp threads. In a simple class of
design, the binder warp threads may be operated by a pair of gears or heddles,
one heddle lifting twice in succession to admit of two wefts, the other heddle
lifting once to admit of one weft. But in more elaborate designs, where more
colour effects are required, it is necessary to use a jacquard machine and to
stamp the cards for lifting the binder warp threads. For example, if a 1088
needle jacquard be fixed on a loom, 544 needles may be used for the stuffer warp,
and 544 needles for the binder warp. It facilitates and simplifies the stamping
if two cards can be worked on the cylinder, one to control the stuffer warp
needles, and the other the binder warp needles; the harness of the loom being
tied up to suit. The drawing of the sley may be such as to produce a straight
rib, such as described in Orr's British Specification, No. 905 of 1855, or to
produce a twilled effect, as described in Naylor's British Specification, No. 14410
of 1888. In the former case two threads of stuffer warp may be controlled by one
needle, as they always lift together, but in the latter each thread of stuffer
warp must be controlled by a separate needle, and 8 by 8 design paper is used
for designs, the usual eight-holes-in-a-row machine being used for stamping;
each punch serving for a single thread of stuffer warp. In the former case,
however, 4 by 8 design paper is used, the eight-holes-in-a-row machine may be
also employed, the punches being used in pairs; but in case two ends of warp
are drawn through one eye in the harness, and controlled by one needle, then
a half sized stamping machine and jacquard machine may be employed. The
designs are painted in the ordinary way, and while stamping, the stamper reads
two lines or lashes at once, which we name
A course will show
all the varied positions of the three wefts used in the set; a card being stamped
for each weft, and therefore, for each pick of the loom. The stamper should
read and stamp all the olive cords first, for example; then all the scarlet cords,
then all the cream; or any other order, indicated in the design, but the whole
of one colour before stamping the next colour, and so on. But the colour of
the stuffer warp must not be stamped, as it is produced automatically in con-
trolling the three wefts; the same principle being followed for stamping for the
binder warps as for the stuffer warp.
a course."
A further development of the one and a half ply fabric is to use two stuffer
warps of two different colours, as for example, 544 warp threads of black, and
544 warp threads of white; two threads of black being controlled by one needle,
and two threads of white by one needle. The binder warps to work and operate
the same as previously described in connection with the single stuffer warp.
In this way an increased number of colour combinations can be made, as the
black stuffer warp can be brought up to combine with either of the three wefts
and the white stuffer warps likewise. In order to keep the white stuffer separated
from the black when the black is required to appear on the upper surface, the
white stuffer must drop to the back entirely, under the bottom weft of every
alternate course, and must rise over the bottom weft of every alternate course thus
forming a heavy twilled back. This is effected by a slight alteration in the

page_text: stamping, which a practical manufacturer would understand. The same order
is maintained when the white stuffer warp must appear on the upper surface,
always bearing in mind that the reverse colour must be thrown to the bottom,
so as to form the heavy twill back. When there are not sufficient needles to
operate two stuffer warps and a binder warp, then the binder warp must be
worked by heddles. But if heddles be used, the number of combinations of colour
will be slightly reduced in number.
FAIRFAX & WETTER,
37 and 39, Essex Street, Strand, London,
Agents for the Applicants.
Improvements in Kidderminster, Scotch, or Ingrain Carpets.
We, THOMAS Fox NAYLOR and ARTHUR NAYLOR, of Green Street, Kidderminster,
in the County of Worcester, Carpet Manufacturers, do hereby declare the nature
of this invention and in what manner the same is to be performed, to be particu-
larly described and ascertained in and by the following statement:-
Our invention relates to improvements in that class of carpet fabrics known as
Kidderminster, Scotch, or ingrain carpets, the object being to insert a smaller
number of wefts than is usually employed. The present invention is an improve-
ment upon the invention described in the Specification to British Letters Patent
No. 11692, of 1895, having the same object in view.
In the further description of this invention, reference is made to the accompany-
ing drawings, which represent longitudinal sections taken along the improved
fabrics in the direction in which they are woven. In these drawings, Fig. 1
shows a carpet fabric having a black stuffer warp marked B, and built upon
it in the manner fully described hereinafter are top and bottom plies of weft,
the shots of which are respectively indicated by a, and c, arranged in various
positions. The letters D and E indicate the binding warps, which are either
stamped for in order to be worked by the jacquard or harness, or they may be
operated by two heddles or gears as their movement is in a regular order;
The digits 1,
1 always lifting twice to E lifting once in this formation of fabric.
2, 3 and 4, placed at the top of the fig. each indicate a short length of the fabric
to show various combinations of wefts on the face, as in 1, the wefts a and c are
brought up side by side on the face or upper surface of the fabric; in 2, b and c
are brought up side by side; in 3, the weft a and the uncovered stuffer warp B
show together on the upper surface; while in 4, the weft b and the uncovered
stuffer warp B show side by side on the face of the carpet. This is a simple
form of our improved fabric, giving four combinations of colours on the face
of the carpet, with opposite colours on the back, and is therefore a reversible
fabric.
Fig. 2 shows a more elaborate design and weave, in which six combinations
of colour effect are produced. The letters a, b and c, the digits 1, 2, 3, 4, 5 and 6,
and the letter B, all have the same significance as the like references in Fig. 1:
but in this order of weaving the binder warps D and E must be stamped for,
to admit of the various changes shown of the three wefts a, b and c.
In Fig. 3 all the letters and digits have likewise the significance above stated,
but an additional stuffer warp W, indicated by a broken line, is introduced:
and if, for example, it is white in colour, while the aforesaid stuffer warp B,

page_text: indicated by a heavy black line'is black in colour, then it is possible to produce
nine combinations of colour effect. It may be expedient not to use all these
combinations of colour, but it gives a greater range for selection; and it will
be seen that the additional stuffer warp W is shown as meandering under and
over the alternate back or bottom weft, and sometimes reverses position with
the black stuffer warp B.
The ordinary Kidderminster, Scotch, or ingrain carpet fabric is woven with
two or more plies of weft; that is to say, it has two or more webs. or layers of
material thrown or shot by the shuttle, the said webs being bound together by
the interweaving both of the warp threads and the weft material.
In our improved carpet fabrics, we also employ two plies or webs of weft
material thrown by the shuttle,' one web being composed of only one half of the
number of shots comprised in the other web; but it is to be noted that in some
parts of the fabric there is but one weft in the top layer, and two wefts in the
bottom layer, while in other parts there are two wefts in the top, and one in
the bottom, in accordance with the design. The finished fabric is therefore herein-
after called a one and a half ply carpet, like those referred to in the above
named Specification No. 11692 of 1895. In the set of three shots forming a
fabric, two shots are placed side by side in forming one web, and one shot in
forming the other web. The one shot can change places with either of the two
shots, or with both. We use a stuffer warp running between the two webs of
weft, as in carpets described in John Orr's British Specification No. 905 of 1855.
In this class of carpets the stuffer warp is used mainly as a controlling or
guiding warp, to determine the position of the wefts. In our invention it may
guide two wefts to the top or upper surface of the fabric, and one to the bottom
surface, or vice versa. If two wefts are guided to the top, and one weft guided
to the bottom, and supposing the two top wefts to occupy the space of two eighths
of an inch, then the one bottom weft will only occupy one eighth of an inch,
while the other one eighth occupied is formed by the uncovered stuffer warp.
Or if the reverse be woven, that is, if the stuffer warp guides one weft to the
top, and two wefts side by side to the bottom surface, then one eighth of an inch
of the stuffer warp will remain uncovered and exposed as if on the top surface
of the fabric. Thus, by omitting one weft thread in every four of the wefts as
used in ordinary two ply, the usual "pairing" or mateing" of wefts does not
occur in our one and a half ply carpet fabrics. It follows also, that the colour
of the exposed stuffer warp, in combination with any one of the three .wefts
used, produces a colour effect. Thus, if the three shuttles thrown respectively
contain wefts coloured olive, scarlet and cream, and the stuffer warp is black,
then the following combinations of colours may be produced.
Olive and scarlet.
Olive and cream.
Scarlet and black.
.Olive and black.
Scarlet and cream.
Cream and black.
Consequently any two of the wefts can be brought to the top surface, side by
side; while any one of the three wefts can also be brought to the surface to
combine in colour effect with the uncovered black stuffer warp.
As the stuffer warp plays the most important part in guiding the wefts to
their allotted places in the fabric, and in itself forms part of the pattern or
design, it is necessary to use a jacquard machine and stamp cards in the usual
way for lifting or lowering the stuffer warp threads. In a simple class of
design, the binder warp threads may be operated by a pair of gears or heddles,
But in more
one heddle lifting twice in succession to admit of one weft.
elaborate designs, where more colour effects are required, it is necessary to use
a jacquard machine and to stamp the cards for lifting the binder warp threads.
For example, if a 1088 needle jacquard be fixed on a loom, 544 needles may
It facilitates
be used for the stuffer warp, and 544 needles for the binder warp.

page_text: and simplifies the stamping if two cards can be worked on the cylinder, one to
control. the stuffer warp needles, and the other the binder warp needles; the
harness of the loom being tied up to suit. The drawing of the sley may be such
as to produce a straight rib, such as described in Orr's British Specification,
No. 905 of 1855, or to produce a twilled effect, as described in Naylor's British
Specification, No. 14410 of 1888. In the former case two threads of stuffer
warp may be controlled by one needle, as they always lift together, but in the
latter, each thread of stuffer warp must be controlled by a separate needle, and
8.by 8 design paper is used for designs the usual eight-holes-in-a-row machine
being used in stamping; each punch serving for a single thread of stuffer warp.
In the former case, however, by 8 design paper is used the eight-holes-in-a-row
machine may be also employed, the punches being used in pairs; but in case
two ends. of warp are drawn through one eye in the harness, and controlled by
one needle, then a half sized stamping machine and jacquard machine should
be employed. The designs are painted in the ordinary way, and while stamping,
the stamper reads two lines or lashes at once, which we
66
name
a course.
A course will show all the varied positions of the three wefts used in the. set;
à card being stamped for each weit, and therefore, for each pick of the loom.
The stamper should read and stamp all the olive cords first, for example; then
all the scarlet cords, then all the cream; or any other order, indicated in the
design, but the whole of one colour before stamping the next colour, and so on.
But the colour of the stuffer warp must not be stamped, as it is produced auto-
matically in controlling the three wefts; the same principle being followed for
stamping for the binder warps as for the stuffer warp.
A further development of the one and a half ply fabric is to use two stuffer
warps of two different colours, as for example, 544 warp threads of black, and
544 warp threads of white; two threads of black being controlled by one needle,
and two threads of white by one needle. The binder warps to work and operate
the same as previously described in connection with the single stuffer warp.
In this way an increased number of colour combinations can be made, as the
black stuffer warp can be brought up to combine with either of the three wefts,
and the white stuffer warps likewise. In order to keep the white stuffer separate
from the black, when the black is required to appear on the upper surface, the
white stuffer must drop to the back entirely, under the bottom weft of every
alternate course, and must rise over the bottom weft of every other alternate course,
thus forming a heavy twilled back. This is effected by a slight alteration in the
stamping, which a practical manufacturer would understand. The same order
is maintained when the white stuffer warp must appear on the upper surface,
always bearing in mind that the reverse colour must be thrown to the bottom,
so as to form the heavy twill back. When there are not sufficient needles to
operate two stuffer warps and a binder warp, then the binder warp must be
worked by heddles. But if heddles be used, the combinations of colour will be
slightly reduced in number.
Having now particularly described and ascertained the nature of our said
invention, and in what manner the same is to be performed, we declare that what
we claim is:
:-
1. In the class of carpet as herein specified, a fabric woven with two plies
of weft material, one ply being composed of one half only of the number of weft
shots in the other ply, some parts thereof having but one weft in the top layer
and two wefts in the bottom layer, while in other parts thereof there are two
wefts in the top and one in the bottom layer, and having a stuffer warp B between
the said plies which is occasionally left uncovered to appear as if on the surface
of the fabric to produce its colour effect, substantially as and for the purpose
herein described.
2. In the class of carpet as herein specified, a fabric woven with two plies of

page_text: weft material, one ply being composed of one half only of the number of weft
shots in the other ply some parts thereof having but one weft in the top layer
and two wefts in the bottom layer, while in other parts thereof there are two
wefts in the top and one in the bottom layer, and having a stuffer warp B and
a stuffer warp W of diverse colours, each being occasionally left uncovered to
appear as if on the surface of the fabric to produce its colour effect, substantially
as and for the purpose herein described.
3. In the class of carpet as herein specified, a reversible fabric woven with
two plies of weft material, one ply being composed of one half only of the
number of weft shots in the other ply, some parts thereof having but one weft
in the top layer and two wefts in the bottom layer, while in other parts thereof
there are two wefts in the top and one in the bottom layer, and having a stuffer
warp B between the said plies which is occasionally left uncovered to appear as
if on a surface of the fabric to produce its colour effect, substantially as and
for the purpose herein described.
.
4. In the class of carpet as herein specified, a fabric woven with two plies
of weft material, one ply being composed of one half only of the number of weft
shots in the other ply, some parts thereof having but one weft in the top layer
and two wefts in the bottom layer, while in other parts thereof there are two
wefts in the top and one in the bottom layer, and having a stuffer warp B and
a stuffer warp W of different colours between the said plies each being occasion-
ally left uncovered to appear as if on the surface of the fabric to produce their
diverse colour effects, and worked on the other surface or back to form a twill,
substantially as and for the purpose herein described.
5. In the class of carpet as herein specified, a fabric woven in a series of
courses or sets of three weft threads in a set to form two plies of weft material,
one ply being composed of one half only of the number of shots in the other ply,
some parts thereof having but one weft in the top layer and two wefts in the
bottom layer, while in other parts thereof there are two wefts in the top and
one in the bottom layer, combined with a stuffer warp between the said plies
which stuffer warp is left uncovered to appear as if on the surface of the fabric
to produce its colour effect, substantially as and for the purpose herein described.
Dated this 12th day of December 1898.
.
FAIRFAX & WETTER,
37 and 39, Essex Street, Strand, London,
Agents for the Applicants.