An Improved Manufacture of Kidderminster, Scotch, or Ingrain Carpets.
Year: 1895

page_text: Date of Application, 15th June, 1895
Complete Specification Left, 11th Apr., 1896-Accepted, 6th June, 1896
PROVISIONAL SPECIFICATION.
An Improved Manufacture of 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 an improved manufacture of Kidderminster, Scotch, or
ingrain carpets, the object being to use a smaller number of wefts than is usually
employed.
The ordinary carpet of this class is composed of two or more plies of weft, that
is to say having two or more webs or layers of material thrown or shot by the
shuttle, which webs are bound together by the interweaving both of the warp
threads and of the weft material.
When weaving two ply carpets, the shots of weft are placed alternately in the
top web, and in the bottom web; that is to say the first weft is shot into
the bottom web, (for example), and the second weft shot into the top web, the
third weft is then shot into the bottom, the fourth weft into the top, and so on
alternately; the one shot being directly under the next shot, except where they
cross and recross in forming the pattern.
Four shots of different coloured wefts are frequently used in a two ply carpet
fabric, and the pattern or design is produced by various combinations of these
colours in the manner following;
Black may be first shot in the top web.
Olive may be first shot in the bottom web.
Scarlet may be second shot in the top web.
White may be second shot in the bottom web, and then repeat.
The combinations used to give colour effects are ;
Black and scarlet.
Olive and white.
Black and white..
Olive and scarlet, but in some cases black and olive are used as an additional
combination.
Now our invention consists in making a carpet having two webs or layers of
material thrown by the shuttle, but with one web composed of one half the number
of shots of the weft material to that which composes the other web. The web
forming the face or upper side of the carpet has the larger number of weft shots,
and in making the fabric two shots are placed in the top web to one in the bottom
web. In the set of three shots therefore, two shots would be placed side by side in
forming the top web, and one shot in the bottom web, but the bottom web shot is
sometimes passed into the top web to form a part of the pattern, either in place of
the first top shot or in place of the second top shot, while one of the latter takes
its place in the bottom web. This improved carpet fabric is hereinafter called a
one and one half ply carpet.
No. 1 weave. By our invention we are enabled to weave one and one half ply
carpet fabric with the ordinary ingrain warp having four threads of warp in a set,

page_text: as for example, two black ends for ground, and two brown ends for the figure or
pattern all the warp threads being stamped for on the pattern card.
No. 2 weave. We are further enabled to weave one and one half ply carpet fabric
as above, with an additional warp, worked by gears, which passes from bottom to
top, and top to bottom, every three shots of weft, so as to bind the two webs
together and make a solid cloth.
No. 3 weave. We are further enabled to weave one and one half ply carpet
fabric by having only one ply of ordinary warp, which shall continue in the top
web and be what is known as a universal warp throughout ground and figure, and
a stuffer or backing warp of a different material so as to form a substantial back,
which shall work in the bottom web only and not appear in the top web.
No. 4 weave. We further weave one and one half ply carpet fabric in the
manner described for No. 3 weave, but with the additional binding warp described
with reference to No. 2 weave.
No. 5 weave-We-further-weave-one-and-one-half-ply_carpet_fabric_with_a
stuffer warp between the webs as adopted in imitation Brussels carpets in addition
to the warps referred to under all the former weaves of one and one half ply.
No. 6 weave. We further weave one and one half ply carpet fabric with a
stuffer warp between the webs, with the. further addition of binder warp as in
No. 2 weave.
No. 7 weave. We further weave one and one half ply carpet fabric with an
ordinary ingrain warp having four threads in a set, as for example, two black for
ground and two yellow for figure, but we bring the black threads of warp over the
figure as well as the ground, and the yellow threads over the ground as well as the
figure, in order to produce extra or additional colour effect, as described in
J. S. & S. Smith's Specification No. 2964 of 1888, which refers to Specification
No. 4908 of 1881.
No. 8 weave. We further weave one and one half ply carpet fabric in the
manner described above referring to No. 7 weave, with the additional fine binder
warp described with reference to Fig. 2 weave.
No. 9 weave. We further weave one and one half ply carpet fabric in the
manner described above referring to No. 3 weave, with fine universal face (ground
and figure) warp as a binder, and a thick backing warp in addition.
No. 10 weave. We further weave one and one half ply carpet fabric as described
above referring to No. 9 weave, but without the thick backing.
No. 11 weave.-We further weave one and one half ply carpet fabric as last
described for No. 10 weave, but with a stuffer warp in addition.
It is to be understood that we do not confine our invention to the special weaves
above enumerated, as we may combine other weaves with the one and one half ply
wefts herein before mentioned.
Dated this 14th day of June 1895.
FAIRFAX & WETTER,
433 Strand, London, Agents for the Applicants.
COMPLETE
SPECIFICATION.
An Improved Manufacture of Kidderminster, Scotch, or Ingrain
it
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 particularly described and ascertained in and by the following
statement:-
Our invention relates to an improved manufacture of Kidderminster, Scotch, or

page_text: ingrain carpets; the object being to use smaller number of wefts than is usually
employed.
The ordinary carpet of this class is composed of two or more plies of weft, that
s to say, having two or more webs or layers of material thrown or shot by the
shuttle, which webs are bound together by the interweaving both of the warp
threads and of the weft material.
When weaving two ply carpets (of the class above named) the shots of weft are
placed alternately in the top web, and in the bottom web; that is, the first weft is
shot into the bottom web (for example) and the second weft is shot into the top
web; the third weft is then shot into the bottom, the fourth weft into the top, and
so on, alternately; the one shot (or odd shots) being directly under the next shot
(or even shots, in the order just named) except where they cross and recross by
interweaving in forming the pattern.
Four shots of different coloured wefts are frequently used in the ordinary
two ply carpet fabric of the aforesaid class, and the pattern or design thereof is
produced by various combinations of the colours employed. Adverting to the
aforesaid order of placing the odd numbers of the shots under the even numbers,
and assuming the colours to be black, olive, scarlet and white, they may be
combined in the manner following
Black may be first shot in the bottom web.
Olive may be first shot in the top web.
Scarlet may be second shot in the bottom web.
White may be second shot in the top web, and then repeat.
The combinations used to give colour effects are ;-
Black and scarlet.
Olive and white.
Black and white.
Olive and scarlet; but in some cases black and olive are used as an additional
combination.
Now our invention consists in making a Kidderminster, Scotch, or ingrain carpet
having two webs or layers of material thrown by the shuttle, but with one web
composed of one half the number of shots of the weft material to that which
composes the other web. The web forming the face or upper side of the carpet
has the larger number of weft shots, and in making the fabric two shots are placed
in the top web to one in the bottom web. In the set of three shots, therefore, two
shots would be placed side by side in forming the top web, and one shot in the
bottom web; but the bottom web shot is sometimes passed into the top web to form
a part of the pattern, either in place of the first top shot, or in place of the second
top shot, while one of the latter takes its place in the bottom web. Our improved
manufacture of Kidderminster, Scotch, or ingrain carpet fabric is hereinafter called
a one and one half ply carpet.
In further description of our invention, reference is made to the accompanying
drawings, in which longitudinal sections of the various weaves of our said one and
one half ply carpets are given, the warp threads being shown in an extended
manner, while the top and bottom shots of weft are shown by circles indicating
their transverse position in the fabric.
In Fig. 1 is shown a one and one half ply carpet fabric woven with ordinary
ingrain warp having four threads of warp in a set, as for example, two black
ends 1, 2, for ground, and two brown ends, 3, 4, for the figure or pattern; all the
warp threads being stamped for on the pattern card, so that they may change with
the wefts and help to form pattern. The weft shots are denoted by a for scarlet,
olive, and c black. The wefts a and c are first used with 6 beneath them; a
change is made in the colour combination by raising b to the top and lowering a
while a third colour effect is produced by returning a to the top beside band
placing c below them. The upper and the lower layers are bound together in this

page_text: case, and in Figs. 3 and 5, only where the wefts pass from the top to the bottom,
or bottom to top.
Fig. 2 indicates a one and one half ply carpet fabric woven as above, but with
two additional warp threads, 5 and 6, worked by gears or heddles in the usual
manner; this warp passes from bottom to top, and top to bottom every three shots
of weft, so as to bind the two webs together and make a solid cloth of this said
one and one half ply. It will be seen therefore, that the same shed of the binding
warp opens three times in succession to receive the three shots of wefts a, b and c,
when they cross and reverse for the next three wefts; thus binding the two webs
together, as aforesaid.
Fig. 3.-This shows a one and one half ply carpet fabric with only one ply of
ordinary warp 1, 2, which continues in the top web and is known as a universal
warp throughout-ground-and-figure. The thick lines 7 and 8 denote a stuffer and
backing warp of a different material to form a substantial back which shall-work
in the bottom web only, and not appear in the top web. The wefts are the same
as in the former cases, and, like Figs. 1 and 5, the two webs are only bound or tied
together where the wefts change their relative positions from front to back, and
'back to front.
In Fig. 4, the one and one half ply fabric is shown as woven in the same manner
as in Fig. 3; 1 and 2 being thin universal warp threads for the face, with 7 and 8
as thick backing warps; but the additional binding warp threads 5 and 6 are
introduced to bind the front and back webs together by crossing at intervals of
three shots of weft, as described above-in reference to Fig. 2.
In Fig. 5 we show a one and one half ply carpet fabric with a straight stuffer
warp 9 introduced between the webs (as adopted in imitation Brussels carpets,
known as Istakbr and pro-Brussels, and similar fabrics) in addition to the above
named warps 1, 2, 3, and 4, as in Fig. 1; and 1, 2, 7 and 8, as in Fig. 3. The
wefts are as above stated; and the straight stuffer warp is worked into the middle
to give bulk and weight.
Fig. 6 shows a one and one half ply carpet fabric also with the straight stuffer
warp 9, combined with the binding warp 5 and 6 of Fig. 2, in addition to
the warps 1, 2, 3 and 4 of. Fig. 1. This weave is therefore compounded of
Figs. 2 and 5.
In Fig. 7, the one and one half ply carpet fabric is woven with the ordinary
ingrain warp having four threads in a set, as for example, two black threads for
ground and two yellow for the figure or pattern, but we bring the black threads of
warp over the figure as well as the ground, and the yellow threads over the ground
as well as the figure, in order to produce by the combination additional colour
effect as described in J. S. & S. Smith's Specification No. 2964 of 1888, which
refers to Specification No. 4908 of 1881.
Fig. 8 indicates that we further weave one and one half ply fabric in the manner
above described in reference to Fig. 7, but with the additional fine binder warp
threads 5, 6, which cross after each three shots of weft, as described in reference
to Fig. 2.
Fig. 9 denotes a one and one half ply fabric woven in the manner described for
Fig. 3, but with the fine universal warp 1, 2, stamped for to bind together the two
webs by passing round the bottom wefts to make a solid cloth; the thick warp
threads 7 and 8 being used in the combination for a backing, as in Fig. 3.
Fig. 10 indicates a one and one half ply fabric woven with the fine universal
warp threads 1, 2, in the manner just above described with reference to Fig. 9, but
with a coloured warp 10 in addition, say of yellow colour, which sometimes acts as
a stuffer warp between the upper and lower wefts, and at other times is brought
over any of the upper wefts to produce a change of colour, as for instance, if
brought over blue a shade of green results, or over red, a shade of orange; and so
The figure also shows the backing warp 7 and 8.
on.
In Fig. 11 the wefts and the binding warp 1, 2, are as shown in Fig. 9, but the
one and one half ply fabric is woven with a straight stuffer warp 9, instead of with

page_text: the thick backing warp 7 and 8; while in Fig. 12 the same arrangement is followed
with the addition of an extra warp 10 which is brought to the top surface occasionally
from. its middle position, to give colour effect to the wefts, as already described.
Fig. 13 shows the further development of weaving one and one half ply carpet
fabric by combining the weave shown in Fig. 2 with that shown by Fig. 10. In
this example the warps 5, 6, are crossed to bind both webs together after every
three shots of weft, the thick backing warps 7, 8, are used for the bottom web, and
the coloured warp 10 is brought over some of the wefts to produce a change of
colour, as aforesaid.
".
It is to be noted that any of the above named binder warps, that is, warps used
for binding the upper and the lower webs together, may he slayed so as to run two
ends of warp in one reed close together so as to give a straight line or ribbed
appearance as in the case of the Pro-Brussels " or "Istakhr" carpets; or the
binder warps may be split so as to produce an alternate or twilled appearance as
seen in the carpets known in the trade as "Super Kidder," or "Roman."
Furthermore, the latter named carpet ("Roman") is made by us in accordance
with the Specification to Letters Patent No. 14410 of 1888, in which we describe.
and claim certain improvements whereby the upper and lower webs of Kidderminster,
Scotch, and ingrain carpets are bound together and made "solid cloth" throughout.
This term "solid cloth is used above in combination with the herein described
one and one half ply fabrics, and it is to be understood that the term is used in.
this restricted sense; and further, that we restrict our claims to the special class of
carpets herein before described.
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 Kidderminster, Scotch and ingrain carpets the herein described manufacture.
of one and one half ply carpet fabric, substantially as and for the purpose specified
and shown by the drawings.
2. In Kidderminster, Scotch and ingrain carpets the herein described manufacture.
of a carpet fabric consisting of two layers or webs of weft, in which two shots of
weft are used in the upper web, or face, to each shot of weft in the lower web, or
back, and the several wefts are made to exchange their relative positions in.
weaving the figure or pattern, substantially as and for the purpose specified and.
shown by the drawings.
Dated this 9th day of April 1896.
FAIRFAX & WETTER,
433 Strand, London, Agents for the Applicants..