Improvements in the Manufacture of Piled Carpets and Fabrics.
Year: 1894

page_text: Date of Application, 4th Aug., 1894
Complete Specification Left, 13th Apr., 1895-Accepted. 24th May. 1895
PROVISIONAL SPECIFICATION.
Improvements in the Manufacture of Piled Carpets and Fabrics.
ALBERT WEBB Carpet Manufacturer St. Mary's Terrace, London Road
Worcester, GEORGE MATTHIAS WHITTALL Carpet Manufacturer Spring Bank
Wribbenhall near Bewdley Kidderminster, FRANCIS BEST FAWCETT Commission
Agent 44 Comberton Road Kidderminster, do hereby declare the nature of this
invention to be as follows:-
Our invention has reference more particularly to Brussels and tapestry fabrics
when manufactured in cut pile or velvet carpets.
In this make they are generally woven with a 3 shot. weave or stitch binding one
wire or row of pile, in order to make the pile fast.
We use an improved 4 shot weave or stitch binding two wires or rows of pile
together with a fast bind, by which an increased production may be obtained, and
in some cases a saving of material as well.
:
For the stitch and process of weaving which we prefer, (though there may be
some modifications therein) we make the motion of the dead-warp to rise once in
4 shots, viz. for the back weft and to remain down for the other 3 shots or wefts.
And instead of the ordinary binder-warp, we employ two binder-warps, one a
through warp as it passes through the fabric to and fro between the surface and
the back thereof and binds the wefts on both sides, the other is a surface warp as
it only moves above and below the upper wefts.
The process of weaving may then be as follows: We will begin at the point
where one stitch is completed and another stitch commenced, for which purpose the
through binder-warp is lowered, and the dead warp is raised, the figure-warp is
also raised above the dead-warp, thus opening a double shed as it is technically
called, a wire is then inserted into the upper shed, and at the same time the back
weft is thrown into the lower shed, the figure and dead warps are then lowered, and
the two binder-warps are raised and a weft is inserted to bind the pile; the figure-
warp is now again raised for another wire to be inserted, and the surface-binder
is lowered, leaving the through binder-warp raised and forming another double
shed, a weft is then thrown in simultaneously with the said wire, the surface
binder-warp is now raised so that both binder-warps are up together again, and
the figure-warp being lowered a weft to bind the pile is then thrown in this
brings us to where we commenced, (viz. : " the through binder-warp is lowered &c.”)
and the process is repeated.
Dated this 3rd day of August 1891
Improvements in the Manufacture of Piled Carpets and Fabrics.
We, ALBERT WEBB, of Saint Mary's Terrace, London Road and of Copenhagen
Street both in Worcester, Carpet Manufacturer, GEORGE MATTHIAS WHITTALL,
of Spring Bauk, Wribbenball, near Bewdley, Worcestershire, and of Caldwell Carpet

page_text: Mill, Kidderminster, in the County of Worcester, aforesaid Carpet Manufacturer,
and FRANCIS BEST FAWCETT, of 44, Comberton Road, Kidderminster, aforesaid,
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 :-
This invention has reference more particularly to Brussels and tapestry fabrics
when manufactured as cut pile or velvet carpets, but is also applicable to other
classes of piled fabrics. Such carpets and other piled fabrics are generally woven
with three shots of the weft to bind one wire or row of pile tufts in order to make
the pile fast. By this invention we are enabled to firmly bind each wire or row of
tufts with two shots of the weft instead of three shots, the cycle of the process
being completed in two rows of tufts making four weft shots in all for the two
rows. By this means an increased production is obtained with a saving of one-
third of the weft and a reduction in the cost of the weaving.
We will describe this invention by referring to the accompanying drawings on
which
Figs. 1, 2 and 3 illustrate our method of weaving as hereinafter described;
Fig. 4 is a longitudinal section through a portion of our improved fabric drawn
on an enlarged scale and with spaces between the warp and weft threads so as to
shew their arrangement more clearly;
Fig. 5 shews how we arrange the cams which lift the dead warp threads;
Figs. 6, 7, 8 and 9 are face views of the other cams separately;
Fig. 10 is a face view of one of the lifting cams shewn in Fig. 5; and
Fig. 11 shews how the beams or rolls for carrying the two binding warps
which we use may be arranged.
The same letters of reference indicate the same or corresponding parts in all the
figures.
To produce our improved fabric in a Jacquard Brussels carpet loom, it is first
necessary to arrange that the dead warp threads shall rise only once in four shots
or wefts, ria. -for the back weft, and to remain down for the cther three shots or
wefts. In a Brussels carpet loom the dead warp sometinies consists of two kinds,
firstly those portions of the figure warp which are not at the time being used to
produce the figure, but lie dormant in the body or back of the fabric, and secondly
an extra warp of cotton jute or other material for the purpose of backing or filling
and which takes no part in producing the figure. The first named threads will
hereinafter be described as the "dead warp," and the second or backing warp will
be described as the "stuffer." The first named threads thus having the double
capacity of figure warp and dead warp are entered in the eyes of the Jacquard
healds or harness, and those selected for producing the figure are lifted by the
jacquard, and the remainder as dead warps are lifted by a lower board called the
comber-board. And as regards the stuffer threads, they are entered in a heald
which may be attached to the said comber-board (and fixed immediately behind
the Jacquard healds in the ordinary manner) so as to partake of the same motion
as the other dead warp indicated in Figures 1, 2 and 3 as hereinafter described.
To accomplish the desired movement of the dead warp threads is. :-to make
the dead warp threads rise for the back weft and to remain down for the other
three shots or wefts, we take off the lifting cams ordinarily affixed to the picking
cams F
(see Fig. 5) on the bottom shaft G of the loom, used for lifting the
comber-board which raises the dead warp and stuffer healds. For these we
substitute two cams H H running loose on the shaft G each having a toothed
wheel of say 30 teeth of a coarse pitch attached to its inner face. These
cams H H are kept in their places by collars i, i secured to the shaft G by set
screws. Between the two cams H H is fixed a toothed wheel J having say
20 teeth which gears with another spur wheel K of 40 teeth fixed on the counter-
shaft L and on this counter-shaft there are fixed two other spur wheels M M
each 30 teeth gearing with the wheels h, h so to cause the cams H H to revolve
once for two revolutions of the shaft G. This counter-shaft L can be carried by

page_text: the two brackets 1, 1 fixed to the cross framing N of the loom. As the speed of
the shaft G is one revolution to two shots or wefts, it will be seen that this
arrangement of gearing reduces the speed of the counter-shaft L and also that of
the cams H H to one revolution in four shots or wefts as described. The exact
shape of the lifting cams H H will depend on whether a quick or slow lift is
desired, but as regards the duration of its highest lift, it may be generally described
as being one half that of the ordinary cams as its speed is reduced one half. The
approximate shape for these cams H H is shewn in Fig. 10.
The lifting levers ordinarily employed in Brussels looms have the stud and bowl
which runs on the cam upon that side of the lever nearest to the outside of the
loom and where this is the case the stud must be removed and put on the other side
of the lever so that it may work in between the cams H and Fin Fig. 5.
The arrangement of mechanism above described provides for the raising of the
dead warp and stuffer once only in four shots or wefts; but it will be evident that
other arrangements of mechanism nay be used to obtain a like result without
departing from the nature of our invention. The figure warp is raised in the
ordinary manner by the jacquard at every alternative shot.
Instead of putting the ordinary binding warp or ground chain on one beam or
roll we employ two of these, putting half the usual number of threads on each
bean or roll; one of these warps (marked a) we call the "through" warp because
it passes to and fro through the whole thickness of the fabric and the other
(marked ) we call the "surface" warp because it only moves above and below the
upper wefts and never passes through to the back of the fabric.
"
These two binding warps are placed, as regards the "through warp" beam, in
the usual position occupied by the ground chain in an ordinary Brussels, tapestry
or Wilton carpet loom, and as regards the "surface warp beam in a pair of
brackets OO attached to the. loom frame at the back in any convenient inanner
but preferably as indicated in Fig. 11. It is not necessary that this warp should
have any let off motion but may be allowed to pull off as required, a firm tension
being created by any of the means commonly employed to put a drag upon the
warp beams.
A method for this is shewn in Fig. 11 where a drum P is attached
to the shaft p carrying the beam p³ and a rope p³ is passed twice around it. One
end of this rope is secured to a stud in the frame O and the other end to the
lever having a weight pupon it.
The stuffer beam is placed inside the loom in the usual position.
Referring to Fig. I it will be seen that the threads of the "through
" warp
which are marked a are entered in the heald numbered 1 and the "surface" warp
which is marked is entered in the number 2 heald; and the stuffer warp which
is marked c is entered in the number 3 heald.
The healds numbered 1 and 2 being required to fall for one shot only and to
remain up for three shots will require two cams to operate them similar to those
shewn respectively by Figs. 6 and 7 and marked R and S these two cams being
fixed in opposition to each other in the ordinary treadle box on the shaft G in the
usual manner so as to revolve at half the speed of the shaft G and so arranged
that when the cam R operating number 1 heald is drawing down that heald the
other cam S is in the middle of its highest lift and the cams H H in Fig. 5 should
also be in the middle of their highest point. The heald number 3 is attached to
the comber-board which raises the dead warp in the usual manner and therefore
rises and falls with it.
The process of weaving will now be as follows, and as indicated in Figs. 1, 2
and 3.
First, the "through" binding warp marked a (see Fig. 1) is drawn down and
the "surface" warp with the dead warp d and the stuffer c is raised. The figure
warp e is still further raised above the binding dead and stuffer warps by the
jacquard thus forming a double shed or opening as shewn in Fig. 1. A wire Q' to
form the pile is then inserted into the upper shed and at the same time a weft
number 1 is shot through the lower shed and the whole is beaten up by the slay.

page_text: Second, the figure warp e the dead warp d and the stuffer c are then drawn down
as shewn in Fig. 2 and the "through" warp a is raised to the same level as the
** surface warp which remains steady. A shot number 2 is thrown across and
beaten up, thus binding the first row of pile tufts.
Third, the "through" warp a remains raised and the figure warpe is raised 5
above it by the jacquard as in the first operation to form a double shed. The
"surface warp b is drawn down and the dead warp d and stuffer remain down at
A
The position is shewn in Fig. 2.
the same position as in the second movement.
wire is inserted in the upper shed and then a shot number 3 in the lower shed
and beaten up by the slay as before.
Fourth, this movement is the same in its effect as the second above described,
the figure warpe being drawn down to the same position as c and d in the second
and third movements and the surface warp & being raised to the same level as a
which remains steady. The throwing in of the fourth shot (marked 4 in Figure 4)
and beating up by the slay complete the cycle.
The effect of this method of weaving is sbewn in Fig. 4. The fastness of the
bind is secured by the gripping together of the three upper wefts 2, 3 and 4 by
the "through" warp a.
In the case of tapestry looms, in which there is no jacquard employed as the
figure warp has the pattern printed on it, there are no figure warp threads to lie
dormant or dead in the body of the fabric, the stuffer being sufficient for the
purpose. The Jacquard healds marked 4 in Figs. 1, 2 and 3, are replaced by a
single heald for the figure warp which is actuated by a cam from the treadle box
in the usual manner, the cam being made to raise and draw down with each
alternate weft shot. The shape of this cam is shewn in Fig. 9 which is the same
as the ordinary figure warp cans of a tapestry loom. The stuffer heald marked 3
in Fig. 1 is required to rise only once in four weft shots as in the Brussels loom,
but the gearing and cams herein before described with reference to Fig. 5 are not
necessary for this purpose as the stuffer heald may be operated by a cam in the
treadle box, constructed just the reverse of the binding warp cams viz. :-to rise
once in four weft shots and remain down for three other weft shots. This cam is
shewn by Figure 8. The two binding warps a and b and the cams FF for
actuating them, also the process of weaving may all be the same as for the Brussels
loom hereinbefore described, except that in reading the description of the process
be discarded.
and referring to the figs. all reference to the dead figure warp
may
The relative positions of the four cams in the treadle box as required to produce
the conditions shewn in Fig. 1 is given by Figs. 6, 7, 8 and 9 their vertical
lines X X coinciding. From this the other three positions of the cycle will follow
as the cams revolve.
Having now described the nature of this invention and in what manner th
same is to be performed we declare that what we claim is :-
1. In weaving piled carpets and other piled fabrics the herein described improved
order and method of operating the figure warp threads and dead warp threads and
stuffer warp threads in conjunction with the two binding warp threads a and b an
the wefts whereby we obtain a fast bind for the pile with four wefts for every tw
rows of tufts as hereinbefore set forth, instead of using three wefts for one ro
of tufts.
2. Piled carpets and other piled fabrics woven in the manner substantiall
as hereinbefore described and illustrated by Fig. 4 of the accompanying drawing
thin 10th day of Avril 1895.
CHARLES BOSWORTH KETLEY,
Agent for the Applicants.