Improvements in the Manufacture of Kidderminster, Scotch, or Ingrain Carpets.
Year: 1888

page_text: Date of Application, 8th Oct., 1888
Complete Specification Left, 8th July, 1889-Accepted, 10th Aug.. 1889
PROVISIONAL SPECIFICATION.
Improvements in the Manufacture of Kidderminster, Scotch, or
Ingrain Carpets.
THOMAS FOX NAYLOR and ARTHUR NAYLOR of Kidderminster Co-partners as Carpet
Manufacturers and FRANCIS BEST FAWCETT of Kidderminster, Commission Agent, do
hereby declare the nature of this invention to be as follows:
Our invention relates to the improvements in Kidderminster Scotch or Ingrain
Carpets & has for its object to make the Carpet solid cloth throughout, thereby im-
proving its durability, increasing the scope of designs & enabling in some cases a
cheaper material being used for warps.
The ordinary earpet has always been woven in two or three separate & distinct
cloths, & only bound together where the warp & weft pass from back to front, or vice
versa, in the formation of the pattern. Consequently if the pattern be open, or free,
or large in style, in other words, not thoroughly broken up, the separate cloths are
baggy & loose, & feel thicker than where bound together, also being of an uneven
surface does not wear as well as those parts that are broken in pattern and bound
together. By our invention we bind the separate cloths together by constant changes
in the warps & make one solid cloth of even surface & thickness irrespective of the
changes of the weft when forming the pattern. We have therefore more scope in
designing and can adopt large plain parts in the design without detracting from the
wearing powers of the Carpet. Also by our invention it is not necessary to have the
warp threads dyed to suit the colours of the weft, because the said warp threads are
constantly passing from front to back, & back to front & are worked very tightly so
that they are almost buried by the weft spreading over them which also enables us to
use a cheaper material than in the ordinary Carpet. This may be carried out in
various ways, one being for the ordinary looms the stamping of double cards for each
lash or row of the design paper, one half being stamped ordinary way, and the other
half the reverse way. The operating of planes and shuttles being made to correspond.
In other cases a single lifter jacquard may be employed and the required changes
stamped for.
Dated this Fourth day of Ontation 1000
THOMAS FOX NAYLOR.
ARTHUR NAYLOR.
FRANCIS BEST FAWCETT.
COMPLETE SPECIFICATION.
Improvements in the Manufacture of Kidderminster, Scotch, or
Ingrain Carpets.
We THOMAS FOX NAYLOR and ARTHUR NAYLOR of Kidderminster, Co-partners as
Carpet Manufacturers, and FRANCIS BEST FAWCETT of Kidderminster, Commission
Agent 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:-
Our invention relates to improvements in the manufacture of Kidderminster, Scotch
or ingrain carpets, and has for its object to make the carpet solid cloth throughout,
thereby improving its durability, increasing the scope of designs, and enabling in some
cases a cheaper material to be used for warp. Hitherto the ordinary Kidderminster
carpet has always been woven in two or three separate and distinct cloths, and been
only bound together where the warp and weft pass from back to front, or vice versa,
n the formation of the pattern; consequently if the pattern be open, free, or large in
1 PR1

page_text: style, in other words not thoroughly broken up, the separate cloths are baggy and
loose and feel thicker than where bound together; also as it is of an uneven surface
it does not wear as well as those parts that are broken in pattern and bound together.
According to our invention we bind the separate cloths together by constant changes
in the warps, and make one solid cloth of even surface and thickness irrespective of the
changes of the weft when forming the pattern.
We have therefore more scope in designing and can adopt large plain parts in the
design without detracting from the wearing powers of the carpet. Also when our
invention is adopted it is not necessary to have the warp threads dyed to suit the
colors of the weft, because the said warp threads are constantly passing from back to
front and front to back and are worked very tightly so that they are almost buried by
the weft spreading over them; this also en ibles us to use a-cheaper material than in
the ordinary carpet.
Our invention may be carried out in various ways, one being for the ordinary looms,
the stamping of double cards for each lash or row of the design paper, one half being
stamped the ordinary way and the other half the reverse way, the operating of the
planes or heddles and shuttles being made to correspond. In other cases a single
lifter, Jacquard may be employed and the required changes stamped for.
In carrying out our invention and in order better to adapt the designs for the
stamping or cutting of the cards for the Jacquard as above described, also for the
present looms we prefer having them drawn with the lash double width or two rows
unlike across the width, so that one row may be stamped the ordinary way, and the
other the reverse way. The pitch or count of the designs may be as usual, viz. :-half
the pitch or count of the warp. The cards having been thus stamped may be laced
together in either of two ways for working on the Jacquard. One way is to have the
cards of the two kinds of stamping alternated with preferably one stamped in the
ordinary way placed to go first on the Jacquard cylinder in the process of weaving.
The other way is to lace the cards in alternate pairs,-i.e., two stamped in the ordinary
way together and two stamped in the reverse way together, care being taken that the
cards of each two rows alike of the design come together: as for instance calling the
ordinary stamping O and the reverse stamping R, coupled with the numbers of
the cards, they would be laced together as follows:-Nos. 10, 1 R, 2 R, 20, 30, 3 R
and so on.
We will call the first mode of lacing with the necessary adjustments or alterations
in the loom and process of weaving No. 1 combination, and the second mode of lacing
with its alterations No. 2 combination.
The adjustments required in the loom and the process of weaving for working the
No. 1 combination are to make the heddles or planes, and the sequence of inserting
the wefts work in accordance with the new arrangement of the pattern cards, but in
other respects the usual arrangements may be preserved.
The planes which in the ordinary looms work in the following order,-1, 3, 2, 4,-
are now made to work in repetitions as follows,-1, 3, 1, 3, 2, 4, 2, 4. The ordinary
mechanism can easily be adapted to this change, or it may be operated by the Jacquard
with an eight-sided cylinder as any loom tuner will readily understand."
As regards the wefts which for the sake of simplicity we will call "Ground" and
2 Figure," and which are gencrally inserted in this rotation, viz. :-Ground, Figure,
Ground, Figure, they are now caused to operate in repetitions, each going in twice
successively. In commencing to weave, however, it may be necessary to put in a
single weft say of Ground first, and then follow on with the pairs ad libitum; as for
instance, starting with No. 1 card, with No. 1 plane and the first lifter of Jacquard
both raised a Ground weft may be inserted, then with No. 3 plane and the other
Jacquard lifter both raised a Figure we't may be inserted. The card is now changed
to No. 1 R and No. 1-plane and the first lifter both rise again and another Figure
weft is thrown in (as required by the reverse stamping) then No. 3 plane with the
other lifter again rises and a Ground weft finishes the first round of changes for the
first two rows alike of the design. The second round begins on No. 20 card with a
Ground weft (making up the pair with the preceding weft) and is a repetition of the

page_text: former process, except that Nos. 2 and 4 planes take the place of Nos. 1 and 3, viz.,
2 for 1 and 4 for 3 after which Nos. 1 and 3 begin again and so on; the cards of
course going straight on through the pattern. The above order of insertion of wefts
may be got in several ways, one way, for power looms with four shuttle-boxes on each
side, arranged one above the other, and dropping down to change from bottom to top,
is to place two shuttles for each (Ground and Figure) in the boxes to follow in the
required order.
The adjustments required in the loom and process of weaving for working
No. 2 combination will be the same as for No. 1 as regards the heddles or planes, but
the order of inserting the wefts is changed to suit the different new arrangement of
the cards.
Starting with No. 10 card and Nos. 1 and 3 planes with their respective Jacquard
lifters rising in turn as before, the wefts would be put in first Ground, then Figure;
then with No. 1 R card and Nos. 1 and 3 planes with their lifters rising in turn as
before, the wefts would be first Figure, then Ground.
With the next two cards and
four wefts a reverse order obtains, viz. -with 2 R card, and Nos. 2 and 4 planes with
their respective Jacquard lifters rising in turn, the wefts would be Figure then Ground,
and with No. 20 card they would Ground then Figure. They thus alternate every
four wefts. It may be varied and perhaps more easily arranged for working the shuttles
by starting to weave with R cards, and O cards would of course follow next.
The order of wefts would then be,-Figure, Ground, Figure Ground; then Ground,
Figure, Ground, Figure, and so on. To that whichever starting place is adopted, the
sequence of the wefts will alternate every four wefts. In those power looms in which
the Jacquard indicates the shuttle to be picked across, this rotation may easily be
obtained as is well understood.
The arrangement of warp threads in the reed or slay would require a little change
from that of No. 1 combination to produce the same alternate effect on the surface,
which any loom tuner will readily understand.
In both the above combinations a cheaper material than worsted or woollen; such as
cotton, or threads of any other suitable vegetable fibre may be employed for the warp ;
and as each of the warp threads is liable to come in contact with and bind any or all
of the weft colors, we prefer to have them fewer in number, so that they may be less
visible, and to have them all of one color, of some neutral shade that would answer the
purpose. The pitch or count we find most advantageous for the warp is 544 threads
to the yard in width, being half the usual pitch, and No. 12 three fold cotton is a
suitable material, though we do not confine ourselves to these details. This wider
pitch of the warp, together with the stamping of double cards for each row of the
design or the two on of the lash, enables broad and massive effects to be produced in
the designs, and renders these combinations well adapted for making thicker carpets
(by using thicker wefts) than the ordinary kinds, though these latter may be equally
as well produced.
The number of lashes in all the designs should be divisible by four, to correspond
with the routine of changes in the process of weaving. The usual reed or slay of
272 pitch may be employed.
The effect or stitch produced by the No. 1 combination is such as to bind the plain
parts of the pattern (which in the ordinary carpet would be separate cloths) into one
solid cloth in the following manner, and as indicated in the diagram Figure 1, which
represents a piece of the carpet cut longitudinally. Two warp threads cross each other
from back to front and front to back after every alternate series or pairs (or after every
three wefts if adapted to 3 ply), the threads of Nos. 2 and 3 planes at one time, an I
the threads of Nos. 1 and 4 planes at the other time; then 2 an 13 begin again and so
On. Thus these crossings pro luce the solid cloth, and the alternate spaces between
are bound by the warp threads passing from the middle of the cloth to front and to
lack, and vice versa. For greater clearness the warp threads 1 and 2 are shown in
dotted lines and 3 and 4 in full lines; the figures 1-3, 2-4 at top indicate the
planes; one weft is shown in full circles and the other in dotted circles.
But when changes in the design occur another stitch of a more uniform character

page_text: comes into operation. This may be described as follows: Each of the warp threads
as they are operated in turn, after having hound a weft either on front or on back,
passes to the opposite position on the alternate series of wefts, and thus binds into solid
cloth the broken up and changing portions of the design in a more gradual and
uniform manner than the above. in the diagram indicate the places of change.
Both stitches have a tendency to bury the warp threads by causing the wefts to spread
over them; this improves the appearance of the carpets.
No. 2 combination reproduces both the above two stitches but in the reverse
positions, as the more uniform stitch binds the plain parts of the pattern and the stitch
with the abrupt crossings from front to back and back to front, comes into operation
in the changing parts, see diagram Figure 2 which indicates the effect or stitch
produced by No. 2 combination.
-
:
.
We will now proceed to describe a combination which we will call No. 3, and which
has the effect of producing the more uniform stitch by itself, and keeping it intact
through all the phases of the designs and this enables the finer cloth and varied
effects of pick and pick or shot and shot combinations to be produced with the advan-
tage of solid cloth, as well as the thicker cloth and massive and broad effects for which
the two former combinations are more particularly adapted. There are several ways
in which this may be done by adjusting the 2 ply Jacquards, but we prefer to employ
a Jacquard with a single lifting board and cards to change every lift, such as are used
in weaving Brussels carpets and other fabrics; and the four heddles or planes may be
operated by the Jacquard or in any other convenient manner as is well known. With
these arrangements either 3 ply or 2 ply carpets may be woven. In drawing the
designs for 3 ply the pitch or count should be one fourth the number of warp threads,
as four threads are required to make the changes in each cord or longitudinal division;
but for 2 ply they may be drawn the same as for the other combinations. The number
of lashes or rows across the width may be determined by the length of design and
quality required, but they should be divisible by four, and each lash may differ from
the others as in ordinary qualities. This applies to both 3 ply and 2 ply
manufacture.
The drawing of the warp threads into the Jacquard harness and the division into
four heddles or planes may be done in several ways; perhaps the most convenient way
when the Jacquard has perpendicular rows of eight needles (which is a usual con-
struction) would be to make the top needle at the weaver's left side of the loom,
operate the left edge thread of warp, then to proceed straight on down the row of
eight needles and begin at the top of the next row, and so on, with the result that the
bottom needle at the right of loom would operate the right edge thread of the
warp.
It will be convenient to consider these rows of eight needles simply as two fours ;
then the top needle of each four all across the Jacquard or width of loom, or rather
the warp threads operated by them, would make one division for a heddle which may
be called No. 1 plane, all the second needles down would make No. 2 plane, all the
third needles down would make No. 3 plane, and all the fourth needles would make
No. 4 plane. Thus the needles, planes and warp threads may all be identified by the
Nos. 1, 2, 3 and 4. We prefer to have the warp as in Nos. 1 and 2 combinations all
of one color and the same pitch, viz.,-544 threads to the yard in width. A reed or
slay of the usual 272 pitch may be used, and in drawing the warp threads through it
from the harness we prefer to put the edge thread in a dent by itself, and then put
two threads in each dent until the other edge is reached, when that thread may be
put into a dent by itself; though these details may obviously be varied. In other
respects the loom may be arranged in the ordinary manner, except as regards the
working of the planes and the stamping or cutting of the cards, which we will
now proceed to describe.
In describing the stamping or cutting of the Jacquard cards for 3 ply and 2 ply
we will call, the warp threads to be operated by the Jacquard by the aforesaid Nos. 1,
2, 3, 4, so that when we say either or any combination of these four numbers is to be
raised we mean that the card must. be so dealt with as to cause these threads to be

page_text: raised; it may be by leaving the card uncut, or by cutting holes, which any stamper
will understand according to the construction of the Jacquard.
As there will be three wefts in 3 ply weaving for each lash or row across the design,
they may be distinguished by the letters A, B, C, and the cards may be numbered
thus, 1A, 1B, 1C, 2 A, 2 B, 2C and so on, and be laced together so that the A cards
should go first on the cylinder of the Jacquard in the process of weaving. The same
order may be observed in 2 ply cards, only that as there are only two wefts in the
series A and B will be sufficient, and cards can be numbered 1A, 1B, 2A, 2B, and
so on, and laced for A's to go first as above. In weaving 3 ply the beddles or planes
will require to be each in its turn raised three times successively, which may be done
by the Jacquard with a twelve-sided cylinder. In 2 ply they will rise twice succes-
sively as before mentioned. The rotation we prefer for both is,-1, 3, 4 and 2.
We will now describe the stamping of the cards for the 3 ply, but must first explain
that each weft as it is inserted is liable by the exigencies of the design to go into three
different positions in the cloth, see diagram Figure 3 in which one weft is shown in
full circles, another in dotted circles and the third in black or solid circles. Part of
each weft may be required on the front, part to go out of sight into the middle of the
cloth, and part to go on the back, where it would be visible when the carpet was turned
over.
As explained before the Nos. 1, 2, 3 and 4 by which we shall describe the threads
to be raised apply also to the needles in the Jacquard which operate them, and which
have corresponding holes in the stamping plates, in which punches are either placed or
left out according to the effect desired to be produced. The A, B and C on the cards
also indicate the three different colored wefts to be employed and the order of inserting
them.
The following formula shows how the stamping may be done for the above arrange
ment of loom, but would require modifying for any change in harness or slay. It is
to be understood that the cords of No. 1 plane are raised by the ordinary mechanism
and that the cords Nos. 2 and 3 are raised by the Jacquard action.

page_text: It will be observed that the numbers of the planes are repeated in the two latter
divisions, that is only to show that the threads of each plane are raised all across the
loom by the plane, and consequently being up, only the additional numbers have to be
raised by the Jacquard and provided for in the stamping.
In order to simplify the process of reading off the design in the process of stamping,
it may be useful to first arrange how the three wefts' colors shall be placed in the
cloth with regard to each other, and to identify the portions of weft which have to go
into the middle and back of the cloth with the colors of the other two wefts; as for
instance: When A weft is being inserted (with No. 1 plane threads raised) and it
has to go into the middle it may be identified with weft color, and No. 3 threads
raised, and when it has to go on the back it may be identified with B weft color and
Nos. 2 and 3 threads raised. The only way in which the design can show when a
weft is to go below is by another color appearing in the line or lash, and so it may be
used in the stamping for that purpose. See the following example ;-
weft color
or for
1and 3 threads raised
or for A weft color
1 and 3 threads raised
or for B weft color
1 and 3 threads raised i
weft color
or for
Band threads raised
or for A weft color
3 and 4 threads raised
or for B weft color
3 and 4 threads raised
or for C weft color
4 and 2 threads raised
or for A weft color
Hand 2 threads raised
or for B weft color
4and 2 threads raised,
or for C weft color
2 and 1 threads raised
or for A weft color
2 and 1 threads raised
or for B weft color
2 and 1 threads raised
for for B weft color
1, 2, 3 threads raised
or for C weft color
1, 2, 3 threads raised
for for A weft color
1, 2, 3 threads raised
for for B weft color
3, 1, 4 threads raised
or for C weft color
3, 1, 4 threads raised
for for A weft color
3, 1, 4 threads raised
or for B weft color
4, 2, 3 threads raised
for for C weft color
4, 2, 3 threads raised
or for A weft color
4, 2, 3 threads raised
or for B weft color
2, 1, 4 threads raised
for for C weft color
2, 1, 4 threads raised
for for A weft color
12, 1, 4 threads raised

page_text: Jacquard with an eight-sided cylinder, but in the same rotation as the 3 ply, viz.,
1, 3, 4, 2. The cards are stamped in twos instead of threes and the shuttles have to
pick in accordance therewith, which happens to be an ordinary manner of working
them. In other respects the loom may remain as for 3 ply weaving.
In describing the stamping or cutting of the cards for 2 ply, wo would remark that
it is much more simple than 3 ply, as there are only two wefts in the series; when
one is on the front the other is on the back and vice versa.
The following formula shows the stamping for 2 ply weaving on the loom as above
arranged, but any change in harness or slay would require modifying accordingly,—
The threads of each plane are raised all across the loom as in the 3 ply.
The planes being arranged to work as described the weaving of 2 ply carpet with
the cards stamped as above is simply a succession of pairs of wefts in the order of A, B,
as put on the cards.
Figure 3 diagram represents the two ply carpet made according to No. 3
combination except that the planes should be repeated twice and not three times, and
that there will be no wefts or portions of wefts in the middle of the cloth.
Thus with the slight change of the Jacquard cylinder for working the planes and
the exchange of pattern cards the loom with the same warp can weave either 2 ply
ply carpets. This is a great advantage over the ordinary 2 ply and 3 ply looms
which require different Jacquards and warps, and are not interchangeable.
or
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 manufacture of Kidderminster, Scotch or ingrain carpets, the employment
for the purpose of producing a solid cloth, of what is hereinbefore called No. 1
combination, substantially as described.
2. In the manufacture of Kidderminster, Scotch or ingrain carpets, the employment
for the purpose of producing a solid cloth of whit is hereinbefore called No. 2
combination substantially as described.
3. In the manufacture of Kidderminster, Scotch or ingrain carpets the employment
for the purpose of producing a solid cloth of what is herein before called No. 3
combination, and which, with the modifications or changes herein before explained,
allows of either a 3 ply or a 2 ply carpet being produced as may be desired in the
same loom and with the same warp, substantially as described.

page_text: 4. In the manufacture of Kidderminster, Scotch or ingrain carpets, the two stitches
such as are obtained by both Nos. 1 and 2 combinations which bind the cloth
respectively in the plain parts and in the broken up and changing parts of the design,
whereby a solid cloth is produced, as set forth.
5. In the manufacture of Kidderminster, Scotch or ingrain carpets, the stitch such
as is obtained by No. 3 combination which binds the cloth in all the parts of the
design, whereby a solid cloth is produced, as set forth.
6. The manufacture of Kidderminster, Scotch or ingrain carpets as hereinbefore
described.
011
J. C. MEWBURN,
55 & 56, Chancery Lane, London, Patent Agent.
J. C. MEWBURN,
55 & 56, Chancery Lane, London, Patent Agent.