US2555159A - Method of and apparatus for weaving relief designs in pile surfaces of textile fabrics - Google Patents

Method of and apparatus for weaving relief designs in pile surfaces of textile fabrics Download PDF

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US2555159A
US2555159A US726330A US72633047A US2555159A US 2555159 A US2555159 A US 2555159A US 726330 A US726330 A US 726330A US 72633047 A US72633047 A US 72633047A US 2555159 A US2555159 A US 2555159A
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pile
wires
loom
fabric
yarns
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US726330A
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Gustav E Schulz
Harold H Fonda
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NYE WAIT Co Inc
NYE-WAIT COMPANY Inc
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NYE WAIT Co Inc
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    • DTEXTILES; PAPER
    • D03WEAVING
    • D03DWOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D39/00Pile-fabric looms

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  • the present invention relates to a; new and. imiproved method. of producing pile surfaces of different or' contrasting heights in textile fabrics, and to ⁇ apparatus for creating relief designs, in one or more colors or combinations thereof,V in the, weaving of textile fabrics such as carpets and'. rugs..
  • the'Vlr primary objectsofthe" present invention are to provide a new nlethod and apparatus'v which overcomes the aforesaid-limitationsv and disadvantages, simplifies the attain ment of embossedor relief designs of practically infinite variation, reduces* the cost off' produc'- ti'onr, is independent of any wetting' treatment, makes it unnecessary tor employ yarns having a hard2 or. excessivetwist, yet isA equally applicable to.: yarns of.' uniform twist or of any' practical range of. variation of twist',-color, and/or combinations thereof, affords maximum coverage and. density, extends the permissible range of variation of. two or more different pile heights inlithe same fabric, andlproduces a construction and embossed effect which is' not'A affectedl by cleaning orwashingcf the fabric'.
  • the method is characterized by weaving ofthe fabricon a Wilton loom equipped with a' JacL dinard or other" pattern control to'. control; in predetermined. order, the raising andi lowering ofi lingoes through which theV pile or surface yarns pass, wherebyto.form pile.' loops on staf?- tionary pile wires of different heights; thel pile loops 1being: ultimately cuta'hd being bound liiito tnefbacking of thefa'bric'during-theweavingi of the stuifers, binders, and filling.
  • nijy'-vf be looped over the low wires which are adjacent t'o the' high wires for these highpile areas; for greaterY coverage or density, if' desired.
  • the' ⁇ siirface yarns of'v the color or colors which are not to appear in these low areas, andthe srfaceyarnsassociated with the adjacent high pile" wires, must be buried exceptE where O'ut' lin'esfare to be formed in the pattern or design.
  • Figure 1 is a more or less diagrammatic view, partly in longitudinal vertical section and partly in elevation, of the forward portion of a loom as set up for the practice of the present invention
  • Figure 1a is a continuation of Figure 1, showing the rear portion of the loom and one of the creeis from which the surface yarns are led into the loom;
  • Figure 2 is an enlarged fragmentary perspective View showing a group of stationary longitudinally extended pile wires, with the pile wires arranged in an alternate high and low wire arrangement transversely of the loom, as in one typical set-up for the practice of the present invention;
  • Figure 3 is a transverse vertical sectional view taken through the pile wires on the line 3-3 of Figure 2, and more clearly showing the alternate high and low arrangement of the Wires;
  • Figure 4 is a fragmentary perspective view showing the relation of the lingoes and heddle frames for controlling one complete set of warps for one split in the reed, it being understood that a separate set of warps is provided for each reed split, and in the three-frame Wilton loom example illustrated, there being two'binder warps, four stuifer warps and three surface yarns of one or more colors, per set, or per split;
  • Figure 5 is a fragmentary diagrammatic perspective View of the jacquard mechanism for controlling the lingoes through which the surface yarns pass;
  • Figure 6 is a fragmentary top plan View of a pile fabric as produced by the present invention, and illustrating the distinctive embossed or relief effect in one typical geometrical or figure design of the many artistic designs which may be produced by the method and apparatus ⁇ of this invention.
  • I generally denotes a, portion of the loom frame at the breast or front end of the loom, and upon which the woven pile fabric 2 is supported and over which the fabric passes to the take-up roll 3 which is provided with pins 4 in the usual manner to positively engage the fabric. From the take-up roll 3, the fabric is guided to the winding roll or shaft 5 on which the fabric is wound as it is woven. At the rearward side of the frame member I is attached a table or shelf 6 which extends transversely across the loom and upon which the fabric is supported at the weaving point.
  • lay-sword 8 Disposed rearwardly of the table or shelf 6 is the lay 'I which is carried by lay-sword 8 having the usual reed 9 at the upper end thereof.
  • the lay 1 and reed 9 may be of conventional form and are movable forwardly and rearwardly towards and away from the rearward edge I0 of the shelf or table 6 in a well-known manner, this motion being imparted to the lay-sword 8 and the lay and reed carried thereby, by suitable operating mechanism (not shown).
  • a pile wire holder generally designated II, said holder including a heavy metal bar which is suitably attached to the frame member I in spaced relation to the latter in order to allow the fabric to pass therebeneath to the take-up roll 3, as the fabric is woven.
  • the pile wire holder For the details of the pile wire holder, reference may be had to our prior Patent No. 2,414,064 hereinabove referred to, and it will suffice to say for the present application that the holder is provided with a plurality of accurately spaced vertically disposed slots in which are received the respective butt ends of the pile wires which are generally indicated at I2 and I3.
  • the pile wires preferably have the general form as more particularly described in our prior patent above referred to, except that the wires are of different heights according to the present invention, the wires designated I2 being illustrated as low wires, and the wires designated I3 being illustrated as high wires.
  • the actual heights of the respective pile wires may be varied according to the heights of the pile that is to be produced, and the difference in height of the respective sets of high and low wires may also be varied as desired, according to the contrast that is to be made between the high and low pile areas of the finished fabric.
  • the pile wires are stationary and extend longitudinally of the loom in substantially parallel relation to each other and approximately parallel to the warps of the loom.
  • the pile wires are firmly held in vertical positions in accurately spaced relation to each other and do not depend upon each other for support and/or spacing, as in the case of conventional cross-wire looms where the cross-wires float in the fabric during the weaving operations.
  • each wire is provided with a knife I4, when it is ⁇ desired to cut the pile loops formed on the wires so that the pile surfaces will be formed by the cut ends of the pile tufts which will be woven into the fabric.
  • a separator It Between each pair of pile wires, there is disposed a separator It, said sepai rators being suitably supported in a vertical position and arranged in a transverse row coinciding with the transverse row of vertical legs I5 at the rear ends of the pile wires.
  • the pile wires in the loom may be disposed in a predetermined order of alternate high and low wires transversely across the loom, as best shown in Figure 3 of the drawings.
  • the high wire will extend through one split in the reed 9
  • a low wire will extend through the next split in the reed, then another high wire through the next split, a low wire through the next split, and so on, all the way across the loom, until there are suflcient wires as may be required for the width of the fabric that is to be produced on the loom.
  • the wires preferably have the forni of selvage wires, one of which is illustrated in Figure 2 of the drawings, as indicated at Il.
  • the function of these selvage wires is well-known in the art, and hence need not be further described.
  • the set-up as illustrated by way of example in the drawings, three separate sets of lingoes have been shown, and it will be understood that there is one lingo in each row for every split in the reed 9.
  • all of the lingoes of the same row may contain surface yarns of the same color, and the surface yarns may be of different colors for the lingoes of the respective rows, there being a surface yarn of each color in every split of the reed.
  • the surface yarns may be planted so as to have different colors in the same row. To avoid confusion, it may be assumed that in the arrangement as illustrated in the drawings, the respective rows of lingoes designated IS, i9 and 29 contain surface yarns of different colors, said surface yarns being respectively designated 2I, 22 and 23.
  • Each lingo in each row is connected at its upper end to a cord 2t known as a harness, and the cords lead upwardly to the jacquard mechanism shown in Fig- 'ure 5 of the drawings, which will hereinafter be more fully described.
  • the bottom end of each lingo is connected to a weight 25, said weights servingr to hold the lingoes in a vertical position Aand tending to pull the same in a downward direction.
  • heddle frames Behind the lingoes is disposed a plurality of heddle frames, respectively designated 26, 2'I and 28, said heddle frames respectively supporting
  • the number of heddle frames may be varied as desired,
  • the set-up as shown in the drawings corresponds to the usual arrangement for a three-frame Wilton loom.
  • Each of the heddles 129; in the heddle frame 26- carries a binder warp,
  • binder warps being designated 32'.
  • Each Iof the heddles 3D of the heddle frame 2I also carries a binder warp 33.
  • Each of the heddles 3l of the heddle 'frame 23 V carries one or more stuifer warps, said stuffer warps being "designated 34, and in the case illustrated7 there being four stuifer warps per heddle.
  • the stuffer warps 36 lead forwardly through the loom from a stuffer beam 35, or other source of supply, at the back of the loom, and the binder warps 32 and 33 also lead forwardly through the loom from a binder beam 36, lor other suitable source of supply, at the back of the loom.
  • Both the stuffer warps and the binder warps pass lover one or more guide rolls v3'I and lease rods 3B located between the beams and the heddles to guide the warps to the respective heddles and to minimize tangling of the warps.
  • the surface yarns 2l, 22 and 23 are led for'- wardly through the loom from a suitable source of supply at the back of the loom, such as one or more stationary or portable creels.
  • a suitable source of supply at the back of the loom such as one or more stationary or portable creels.
  • Figure la of the drawings there is shown a portable type of creel, designated 39, which forms the subject matter of a prior application Serial No. 607,179, filed July 26, 1945, now Patent No. 2,437,670, issued March 2, 1948.
  • the present invention is not confined to use with creels of this specific type, but when such creels are used, they have the advantage that they can be loaded at a central preparation point and delivered to the 10cm, or quickly moved from one loom to another, all filled, with the yarns threaded through the usual tensions and guides and ready to be tied to the ends in the loom, thereby minimizing time lost in the operation of the loom.
  • the individual yarn packages or spools are loaded in the creel in rows as indicated at '49, and all of the yarn packages or spools of surface yarns may be either of one color in the same creel, or the colors may be planted as preferred.
  • the number of yarn packages, and the number of creels for a given loom set-up may be varied to suit the requirements for the fabric to be woven, there being one yarn package or spool for each surface yarnfor end that is to be led through the loom.
  • , 22 and 23 are led forwardly to the loom and passed through an inverted open reed II at the back of the loom. From the open reed s! the surface yarns may be passed over idler rolls, generally designated at IIE. Freni the idler rolls d2, the surface yarns pass forwardly to the lingoes I3, I9 and 253 which are movable in an upward and downward direction under the control of a suitable pattern control mechanism or jacquard as illustrated in Figure 5 of the drawings.
  • the jacquard may be of any' suitable type, and it is to be understood that the construction shown in Figure 5 is largely diagrammatic and illustrative of one conventional construction which is well-known in the art, and which may be briefly described as follows. rthe upper end of each cord or harness 26 for the lingoes IS, is and 29, is connected tor the lower end of a wire @3 which terminates at its upper end in the form of a hook fill. The hooks Alvi of the Wires i3 which are connectedl to the lingoes I8, are normally engaged over a bar t5 of a frame 46 which is movable in an upward and downward direction by any suitable motion transmitting mechanism.
  • the other rows of lingoes designated I9 and 20 are likewise connected to additional wires having hooks at their upper ends which normally engage over bars 41 and 48 respectively, also carried by the frame 46.
  • Extending forwardly from each wire 43 is a pin 49 which projects through an opening 56 in a board 5l, said board serving to hold the pins in uniform position.
  • Associated with the board I is a series of cards 52 having holes 53 punched therein in a predetermined position to form the pattern of the fabric. Each of the cards 52 determines the pattern for one weaving cycle, and the cards are successively moved into alignment with the board 5I and pressed against the board as the weaving operations progress.
  • FIG. 4 of the drawings there is shown one complete unit or set of warps which all pass through one split in the reed 9, said split containing either a high pile wire i3 o1' a low pile wire I2, as the case may be.
  • a brief description of one complete weaving cycle will now be given.
  • one binder designated 33 is in the extreme raised position, and the other binder 32 is in the extreme lowered position.
  • the stuffers 34 (which may be one or more in number) have just started to rise.
  • the position of the binders and stuiers just referred to is determined by the upward and downward movement of the heddle frames 26, 21 and 28, each of which is suitably connected to a harness (not shown), ,I
  • One of the surface yarns 2l is also shown in a raised position to cross over the top of the pile wire for the purpose of forming a pile loop on said wire, this crossing over being controlled by a transversely reciprocatable comb 54 (see Fig. 1) which is located at the back of the pile wires, between the pile wires and the lingoes.
  • the function of this comb 54 is more particularly described in our prior patent hereinbefore referred to.
  • the raised binder 33 Immediately following the crossing of the filling shot, the lingo I8 which controls the raised surface yarn 2
  • the binders 32 and 33 again exchange positions, the stuffers 34 are lowered, and one of the lingoes which is selected by the jacquard raises one of the surface yarns 22 or 23, whereupon the filling shot is made and one Weaving cycle is completed, with the warps in a position to start another weaving cycle which is simply a repetition of the cycle just described.
  • the binders 32 and 33 move upwardly and downwardly to exchange positions in regular step with the filling shots, and serve to bind the various components into the woven fabric.
  • the lingoes select the desired surface yarn which is to appear at the surface of the fabric, according to the pattern determined by the jacquard, and the surface yarn raises to a position to form the pile loop over the pile wire at the correct time in relation to the movement of the other component parts of the loom.
  • the stuifers 34 are raised and lowered periodically so that the filling shots will pass over and under them in an alternate fashion.
  • the surface yarns in the same reed split may be of different colors, and that color or those colors which are not to appear on the surface of the fabric may be buried in the back of the fabric, along with the stuffers, leaving only a single color or any desired combination of colors to appear on the pile surface.
  • the same colors of surface yarns may either be repeated for each split of the reed, or an entirely different set of surface yarn colors may be employed for each different height of wires used, thus multiplying the color selection that is possible.
  • the selectivity may be still further increased by planting the colors in a predetermined order in the creels 39.
  • the foregoing method and apparatus may be adapted to the production of an iniinite number of different patterns or designs, one typical example of which is illustrated in Figure 6 of the drawings, wherein the dark stippled areas 55 represent the high pile areas, and the lighter stippled areas 56 represent the low pile areas.
  • the surface yarns at the low pile wires which may happen to fall within these areas may be so manipulated as to all be buried in the back of the fabric, along with the stuifers, but if preferred, these surface yarns may be looped over the low pile wires to form low pile tufts which are interspersed with the high pile tufts sc as to give a better density.
  • this is not essential, as the density can be equally well controlled by suitable selection of yarns,
  • the surface yarns associated with the high pile wires must be buried in the back of the fabric, except where outlines may be desired.
  • the method of producing embossed or relief designs in pile fabrics with Wilton looms having a stationary pile wire in every split of the reed and the wires being of at least two different heights and arranged in a predetermined order of alternate high and low wires transversely across the loom which comprises passing binder, stuffer and surface warps longitudinally through the loom and through every split in the reed, selectively manipulating the warps aforesaid in an upward and downward direction in timed relation to each other and selectively looping the surface warps over the high and low pile Wires to form high and low pile loops in a predetermined order in each transverse row across the loom, and passing filling shots in timed relation to the motion of the binder, stuffer and surface warps, transversely across the loom .to bind together the component warps of the fabric into a backing having the surface yarns presented on one face thereof in the form of high and low pile areas I arranged in a predetermined pattern according to the selective
  • a pile fabric loom for weaving embossed or relief designs in pile fabrics comprising a lay, a reed carried by said lay and having a plurality of splits arranged in spaced relation to each other transversely acrossthe loom for receiving binder,
  • stuifer and surface warps adapted to be passed longitudinally through each reed split, a stationary pileY wire longitudinally extended through each reed split in substantially parallel relation to the warps aforesaid, said pile wires being of,l at least two dilerent heights and arranged in a predetermined order of alternate high and low wires transversely across the loom, means for selectively looping in successive transverse rows the surface warps on selected pile wires according to a 'predetermined pattern, and means for weaving said binder and stuffer warps into a backing fabric and for binding the surface warp loops into the backing fabric as the latter is woven, withthe surface warps extending from one face of the backing fabric in the form of pile areas of different heights and pattern as aforesaid.

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Description

May 29, 1951 G. E. scHuLz E-r AL 2,555,159
METHOD oP AND APPARATUS EDR wEAvING RELIEF DESIGNS IN PILE suRFAcEs oP TEXTILE FABRICS May 29, 1951 G. E. scHuLz Er AL- 2,555,159
METHOD OF AND APPARATUS FOR WEAVING RELIEF DESIGNS IN PILE SURFACES 0F TEXTILE FABRICS Filed Feb. 4, 1947 4 Sheets-Sheet 2 May 29, 1951 G. E. SCHULZ ET AL N25,555,159
4 Sheets-Sheet 3 METHOD 0FI AND APPARATUS FOR WEAVING RELIEF DESIG v IN PILE SURFACES 0F TEXTILE FABRICS Filed Feb. 4, 1947 vi. 4Z. y
May 29, 1951 G. E. scHuLz ET Al. 2,555,159
METHOD OF AND APPARATUS FOR WEAVING RELIEF DESIGNS I IN PILE SURFACES 0F TEXTILE FABRICS 4 sheets-sheet 4 Filed Feb. 4, 1947 film mmv@ Patentec May 29,1951
UNITED STATES PATE-NT FFIC-E METHOD or' ANDnPrAnATUs Fon WEAV- INo RELIEF DESIGNS IN PILE sURrAoEs or TEXTILE FABRICS York Appt-manon February 4, 1941,seriarNe. 726,330 2 ciaims.- (o1. 139-47) The present invention: relates to a; new and. imiproved method. of producing pile surfaces of different or' contrasting heights in textile fabrics, and to` apparatus for creating relief designs, in one or more colors or combinations thereof,V in the, weaving of textile fabrics such as carpets and'. rugs..
In: Patent; No.. 2,121,909, granted J une y 28, 1938, to: Harold H. Fonda, there was disclosed ahemb'o'ssed or relief pile fabric of the' general. type to: which the present inventionI relates, and wherein. theV embossedl or relief effect was attainedl by the' use of two or more sets of pile yarnsnhaving different degrees of twist, an'dfpar'- tially releasing the twist of the harder' twisted yarns-by'subjecting the yarns to a wetting treat'- ment, so as` to cause the pile tuftsf to' elongate and! rise above; the tufts formed by the lesser twisted yarns. While this method and' the fab'- rics produced! thereby are entirely practical and feasible and have been. extensivelyusled with-very favorable results,` the prior method' is inherently subject tocertain limitationsv and disadvantages asf to range of designs, permissible number' of color` combinations, physical characteristicsV of tlie'- p'il'e' yarns, relatively highcost ofprodu'otion; etc.
Accordingly; the'Vlr primary objectsofthe" present invention are to provide a new nlethod and apparatus'v which overcomes the aforesaid-limitationsv and disadvantages, simplifies the attain ment of embossedor relief designs of practically infinite variation, reduces* the cost off' produc'- ti'onr, is independent of any wetting' treatment, makes it unnecessary tor employ yarns having a hard2 or. excessivetwist, yet isA equally applicable to.: yarns of.' uniform twist or of any' practical range of. variation of twist',-color, and/or combinations thereof, affords maximum coverage and. density, extends the permissible range of variation of. two or more different pile heights inlithe same fabric, andlproduces a construction and embossed effect which is' not'A affectedl by cleaning orwashingcf the fabric'.
Inv carryingout thev objects of the invention, the method is characterized by weaving ofthe fabricon a Wilton loom equipped with a' JacL dinard or other" pattern control to'. control; in predetermined. order, the raising andi lowering ofi lingoes through which theV pile or surface yarns pass, wherebyto.form pile.' loops on staf?- tionary pile wires of different heights; thel pile loops 1being: ultimately cuta'hd being bound liiito tnefbacking of thefa'bric'during-theweavingi of the stuifers, binders, and filling.
To permit the practice of this method,v there is provided in the loom a setof heddles, lingoes, stuifer warps, binder warps and surface yarns for" every split in the reed',v as' well asaf stationany' pile wire which extends longitudinally' of the loom through each split, thefpile wires being arrangedV a predetermined' order of alternate highland low Wires, or other regular'sequence of high and low wire's, transverselyacross thev loom. As the reed moves back and forth, the' surface yarns-, binders andi stuffer's are manipulated? up and down by theY jacquard and heddle frames u'I-l'iic'hf are so' timed with relation to eac'li other andi` the' fill-ing shots' as to' complete a weaving cycle. With the selectivity that is attainable with a jacquard mechanism forcoritrolling' the surface' yarns, the pilefsurface of the fabric niay be: woven'- so' toi produce high and low" pile ar'eas'? in beautiful and exquisite l'nat'terrlis,` one or'm'o'z'fe` colors or combinations thereof, all with"- outthe"V ai'd of solcallecl planted frames; al'- thcu'gh planted frames may be employed,` if desired, as'inA the'co'nventional Wilton weave. In the' highl pile areas',- the surface yarns o'f-` the coloroii colors f which4 are not to app-ear ini tlles' a'r'easmay? be'A buried inl the backing with the stuliiers, by not raising these other yarns" t'o" forni loops-vr' the pile w're's,A altlfi'ollg-h7 they: nijy'-vf be looped over the low wires which are adjacent t'o the' high wires for these highpile areas; for greaterY coverage or density, if' desired. On the other' hand'glin' the" case of the low pile areas, the'` siirface= yarns of'v the color or colors which are not to appear in these low areas, andthe srfaceyarnsassociated with the adjacent high pile" wires, must be buried exceptE where O'ut' lin'esfare to be formed in the pattern or design.
To' offset anyI lo'ss in density which mayJ1 re'- s'ult from the use1 of high and' lowpile wires", when the surface. yarns are buried, it' is possible toi increase' the llihgl shots per inchv to :ai-point that" the bulk o'f' materials alone Will priit', and'. by' decreasing? the 'size' of the filling, the sii facezyarns can' be beaten' up' to? a point o'fl eX'- treme density'l without any congestionf b'eirg offered.' byf the stationary pile wires which are disposed' in" th'ef loom? in' substantially parallel relation' to"t thev surfacel yarn ends; Since the stationary wire's are" firmly'r held in an upright position" without" having' any' w'iie dp'end upon ario'ther'for' any' support, as" distinguished' from the. arrangement conventional cross-'wire loom, where thecrosswires heatin' the'fabric depend upon each other for support and therefore limit the density to which the yarns may be beaten up because of the thickness of the wires themselves, wires of extremely different heights may be employed for practicing the present invention, resulting in a practically unlimited variation in pile heights between the highest and lowest tufts, and making it possible to obtain more than two pile heights, if desired, and relatively less difficult to obtain either a soft or firm, high pile.
Other and further objects and advantages of the invention will be hereinafter described and the novel features thereof defined in the appended claims.
In the drawings:
Figure 1 is a more or less diagrammatic view, partly in longitudinal vertical section and partly in elevation, of the forward portion of a loom as set up for the practice of the present invention;
Figure 1a is a continuation of Figure 1, showing the rear portion of the loom and one of the creeis from which the surface yarns are led into the loom; Figure 2 is an enlarged fragmentary perspective View showing a group of stationary longitudinally extended pile wires, with the pile wires arranged in an alternate high and low wire arrangement transversely of the loom, as in one typical set-up for the practice of the present invention;
Figure 3 is a transverse vertical sectional view taken through the pile wires on the line 3-3 of Figure 2, and more clearly showing the alternate high and low arrangement of the Wires;
Figure 4 is a fragmentary perspective view showing the relation of the lingoes and heddle frames for controlling one complete set of warps for one split in the reed, it being understood that a separate set of warps is provided for each reed split, and in the three-frame Wilton loom example illustrated, there being two'binder warps, four stuifer warps and three surface yarns of one or more colors, per set, or per split;
Figure 5 is a fragmentary diagrammatic perspective View of the jacquard mechanism for controlling the lingoes through which the surface yarns pass; and
Figure 6 is a fragmentary top plan View of a pile fabric as produced by the present invention, and illustrating the distinctive embossed or relief effect in one typical geometrical or figure design of the many artistic designs which may be produced by the method and apparatus `of this invention.
Like reference characters designate corresponding parts in the several figures of the drawings which show only the essential parts of that much of the loom as are sufficient to enable those skilled in the art to understand the construction and operation of the same, and the practice of the method which forms a part of the present invention. The apparatus is illustrated more or less diagrammatically, and, in general, conforms to that of the well-known type of Wilton loom as more particularly described in our prior Patent No. 2,414,064, granted January 7, 1947, except that the stationary pile wires are c1" two or more heights, and, in addition to the heddle frames, the loom is provided with lingoes through which the pile or surface yarns pass and which are manipulated in an upward and downward direction under the control of a jacquard or other suitable pattern control.
According to the drawings which form a part hereof, I generally denotes a, portion of the loom frame at the breast or front end of the loom, and upon which the woven pile fabric 2 is supported and over which the fabric passes to the take-up roll 3 which is provided with pins 4 in the usual manner to positively engage the fabric. From the take-up roll 3, the fabric is guided to the winding roll or shaft 5 on which the fabric is wound as it is woven. At the rearward side of the frame member I is attached a table or shelf 6 which extends transversely across the loom and upon which the fabric is supported at the weaving point.
Disposed rearwardly of the table or shelf 6 is the lay 'I which is carried by lay-sword 8 having the usual reed 9 at the upper end thereof. The lay 1 and reed 9 may be of conventional form and are movable forwardly and rearwardly towards and away from the rearward edge I0 of the shelf or table 6 in a well-known manner, this motion being imparted to the lay-sword 8 and the lay and reed carried thereby, by suitable operating mechanism (not shown).
At the front or breast end of the loom, and extending transversely across the loom is a pile wire holder generally designated II, said holder including a heavy metal bar which is suitably attached to the frame member I in spaced relation to the latter in order to allow the fabric to pass therebeneath to the take-up roll 3, as the fabric is woven. For the details of the pile wire holder, reference may be had to our prior Patent No. 2,414,064 hereinabove referred to, and it will suffice to say for the present application that the holder is provided with a plurality of accurately spaced vertically disposed slots in which are received the respective butt ends of the pile wires which are generally indicated at I2 and I3. The pile wires preferably have the general form as more particularly described in our prior patent above referred to, except that the wires are of different heights according to the present invention, the wires designated I2 being illustrated as low wires, and the wires designated I3 being illustrated as high wires. The actual heights of the respective pile wires may be varied according to the heights of the pile that is to be produced, and the difference in height of the respective sets of high and low wires may also be varied as desired, according to the contrast that is to be made between the high and low pile areas of the finished fabric. While we have shown only two sets of pile wires, that is, a set of high pile wires and a set of low pile wires, it is to be understood that more than two heights may be employed in the same loom to produce pile surfaces of more than two different heights, when desired. In order to avoid confusion and undue complication of the descriptionherein, the method and apparatus of this invention will be primarily confined to the arrangement employing only two different heights of pile wires, for illustrative purposes.
It will be understood from reference to the drawings that the pile wires are stationary and extend longitudinally of the loom in substantially parallel relation to each other and approximately parallel to the warps of the loom. By the use of the special holder II, previously referred to, the pile wires are firmly held in vertical positions in accurately spaced relation to each other and do not depend upon each other for support and/or spacing, as in the case of conventional cross-wire looms where the cross-wires float in the fabric during the weaving operations.
Near the forward or butt ends of the respecvthe heddles designated 29, 3i) and 3|.
S tive pile wires, each wire is provided with a knife I4, when it is `desired to cut the pile loops formed on the wires so that the pile surfaces will be formed by the cut ends of the pile tufts which will be woven into the fabric. In any event, there is one pile wire for each split in the reed 9 or pitch count of the fabric, the wires extending rearwardly from the holder II through the respective splits in the reed SI, and each terminating in a vertical leg i5. Between each pair of pile wires, there is disposed a separator It, said sepai rators being suitably supported in a vertical position and arranged in a transverse row coinciding with the transverse row of vertical legs I5 at the rear ends of the pile wires.
In arranging the pile wires in the loom, they may be disposed in a predetermined order of alternate high and low wires transversely across the loom, as best shown in Figure 3 of the drawings. In such a case, starting with a high wire, the high wire will extend through one split in the reed 9, a low wire will extend through the next split in the reed, then another high wire through the next split, a low wire through the next split, and so on, all the way across the loom, until there are suflcient wires as may be required for the width of the fabric that is to be produced on the loom. At the extreme opposite sides of the loom, the wires preferably have the forni of selvage wires, one of which is illustrated in Figure 2 of the drawings, as indicated at Il. The function of these selvage wires is well-known in the art, and hence need not be further described.
In back of the pile wires and suitably spaced therefrom is a plurality of lingoes respectively designated I8, is and 29, said lingoes each having an eye therein through which the surface yarns are passed, and the lingoes being preferably arranged in one or more transverse rows across the loom. In the set-up, as illustrated by way of example in the drawings, three separate sets of lingoes have been shown, and it will be understood that there is one lingo in each row for every split in the reed 9. If desired, all of the lingoes of the same row may contain surface yarns of the same color, and the surface yarns may be of different colors for the lingoes of the respective rows, there being a surface yarn of each color in every split of the reed. On the other hand, if preferred, the surface yarns may be planted so as to have different colors in the same row. To avoid confusion, it may be assumed that in the arrangement as illustrated in the drawings, the respective rows of lingoes designated IS, i9 and 29 contain surface yarns of different colors, said surface yarns being respectively designated 2I, 22 and 23. Each lingo in each row is connected at its upper end to a cord 2t known as a harness, and the cords lead upwardly to the jacquard mechanism shown in Fig- 'ure 5 of the drawings, which will hereinafter be more fully described. The bottom end of each lingo is connected to a weight 25, said weights servingr to hold the lingoes in a vertical position Aand tending to pull the same in a downward direction.
Behind the lingoes is disposed a plurality of heddle frames, respectively designated 26, 2'I and 28, said heddle frames respectively supporting The number of heddle frames may be varied as desired,
Abut for purposes of illustration of the present invention, the set-up as shown in the drawings corresponds to the usual arrangement for a three-frame Wilton loom. Each of the heddles 129; in the heddle frame 26- carries a binder warp,
said binder warps being designated 32'. Each Iof the heddles 3D of the heddle frame 2I also carries a binder warp 33. Each of the heddles 3l of the heddle 'frame 23 Vcarries one or more stuifer warps, said stuffer warps being "designated 34, and in the case illustrated7 there being four stuifer warps per heddle.
As best shown in Figure la lof the drawings, the stuffer warps 36 lead forwardly through the loom from a stuffer beam 35, or other source of supply, at the back of the loom, and the binder warps 32 and 33 also lead forwardly through the loom from a binder beam 36, lor other suitable source of supply, at the back of the loom. Both the stuffer warps and the binder warps pass lover one or more guide rolls v3'I and lease rods 3B located between the beams and the heddles to guide the warps to the respective heddles and to minimize tangling of the warps.
The surface yarns 2l, 22 and 23 are led for'- wardly through the loom from a suitable source of supply at the back of the loom, such as one or more stationary or portable creels. In Figure la of the drawings, there is shown a portable type of creel, designated 39, which forms the subject matter of a prior application Serial No. 607,179, filed July 26, 1945, now Patent No. 2,437,670, issued March 2, 1948. It is to be understood, however, that the present invention is not confined to use with creels of this specific type, but when such creels are used, they have the advantage that they can be loaded at a central preparation point and delivered to the 10cm, or quickly moved from one loom to another, all filled, with the yarns threaded through the usual tensions and guides and ready to be tied to the ends in the loom, thereby minimizing time lost in the operation of the loom. The individual yarn packages or spools are loaded in the creel in rows as indicated at '49, and all of the yarn packages or spools of surface yarns may be either of one color in the same creel, or the colors may be planted as preferred. The number of yarn packages, and the number of creels for a given loom set-up may be varied to suit the requirements for the fabric to be woven, there being one yarn package or spool for each surface yarnfor end that is to be led through the loom.
From the creel 3', the surface yarns or ends 2|, 22 and 23 are led forwardly to the loom and passed through an inverted open reed II at the back of the loom. From the open reed s! the surface yarns may be passed over idler rolls, generally designated at IIE. Freni the idler rolls d2, the surface yarns pass forwardly to the lingoes I3, I9 and 253 which are movable in an upward and downward direction under the control of a suitable pattern control mechanism or jacquard as illustrated in Figure 5 of the drawings.
The jacquard may be of any' suitable type, and it is to be understood that the construction shown in Figure 5 is largely diagrammatic and illustrative of one conventional construction which is well-known in the art, and which may be briefly described as follows. rthe upper end of each cord or harness 26 for the lingoes IS, is and 29, is connected tor the lower end of a wire @3 which terminates at its upper end in the form of a hook fill. The hooks Alvi of the Wires i3 which are connectedl to the lingoes I8, are normally engaged over a bar t5 of a frame 46 which is movable in an upward and downward direction by any suitable motion transmitting mechanism. In a similar manner, the other rows of lingoes designated I9 and 20 are likewise connected to additional wires having hooks at their upper ends which normally engage over bars 41 and 48 respectively, also carried by the frame 46. Extending forwardly from each wire 43 is a pin 49 which projects through an opening 56 in a board 5l, said board serving to hold the pins in uniform position. Associated with the board I is a series of cards 52 having holes 53 punched therein in a predetermined position to form the pattern of the fabric. Each of the cards 52 determines the pattern for one weaving cycle, and the cards are successively moved into alignment with the board 5I and pressed against the board as the weaving operations progress. When a card 52 is pressed against the board 5l, the pins 49 which pass through holes 53 in the card allow the wires 43 to remain in a position with their hooks 44 engaged with the bar 45 of the upwardly and downwardly movable frame 46, so that the lingoes connected with these wires will be raised when the frame 46 is moved upward. Those pins which do not pass through any hole in the card 52, as where the holes are omitted from the card, will be pressed rearwardly, and the corresponding wires 43 will be moved rearwardly to disengage the hooks 44 from the bar 45 of the frame 46, allowing these particular wires 43 and their lingoes to remain stationary when the frame 44 moves upward.
Referring now to Figure 4 of the drawings, there is shown one complete unit or set of warps which all pass through one split in the reed 9, said split containing either a high pile wire i3 o1' a low pile wire I2, as the case may be. A brief description of one complete weaving cycle will now be given. As shown, one binder designated 33 is in the extreme raised position, and the other binder 32 is in the extreme lowered position. The stuffers 34 (which may be one or more in number) have just started to rise. The position of the binders and stuiers just referred to is determined by the upward and downward movement of the heddle frames 26, 21 and 28, each of which is suitably connected to a harness (not shown), ,I
which is actuated by suitable cams or other driving mechanism (not shown) in a Well-known manner to impart motion to the heddle frames in timed relation to each other and to the other elements of the loom. One of the surface yarns 2l is also shown in a raised position to cross over the top of the pile wire for the purpose of forming a pile loop on said wire, this crossing over being controlled by a transversely reciprocatable comb 54 (see Fig. 1) which is located at the back of the pile wires, between the pile wires and the lingoes. The function of this comb 54 is more particularly described in our prior patent hereinbefore referred to.
Continuing with reference to Figure 4, it will be seen that the other two surface yarns designated 22 and 23 are being held down in their extreme lowered position so as to be buried in the back of the fabric as dead frames along with the stuifers 34. When the warps are all in the respective positions just described, a filling shot is thrown across the loom by means of a shuttle (not shown). This filling shot passes under the raised binder 33 and surface yarn 2l, and over the lowered binder 32, stufers 34 and lowered surface yarns 22 and 23. Immediately following the crossing of the filling shot, the lingo I8 which controls the raised surface yarn 2| lowers to above midway position, under the control of the jacquard, the raised binder 33 also lowers to its extreme A'low position,^the lowered binder 32 raises to its extreme upper position, the surface yarns 22 and 23 both are raised to above midway position, and the stuiers 34 to above midway position. 'Ihe lling shot is then returned across the loom, and the filling travels under the surface yarns 2l, 22 and 23 and also under the raised binder 32 and the stuffers 34, but it passes over the lowered binder 33. On the third shot of filling, the binders 32 and 33 again exchange positions, the stuffers 34 are lowered, and one of the lingoes which is selected by the jacquard raises one of the surface yarns 22 or 23, whereupon the filling shot is made and one Weaving cycle is completed, with the warps in a position to start another weaving cycle which is simply a repetition of the cycle just described.
It will be noted that the binders 32 and 33 move upwardly and downwardly to exchange positions in regular step with the filling shots, and serve to bind the various components into the woven fabric. The lingoes select the desired surface yarn which is to appear at the surface of the fabric, according to the pattern determined by the jacquard, and the surface yarn raises to a position to form the pile loop over the pile wire at the correct time in relation to the movement of the other component parts of the loom. The stuifers 34 are raised and lowered periodically so that the filling shots will pass over and under them in an alternate fashion.
The arrangement as above described is repeated for each split of the reed 9, with the reed splits also containing alternate high and low pile wires, or such other regular order or sequence of high and low wires transversely across the loom. As previously mentioned, the surface yarns in the same reed split may be of different colors, and that color or those colors which are not to appear on the surface of the fabric may be buried in the back of the fabric, along with the stuffers, leaving only a single color or any desired combination of colors to appear on the pile surface. The same colors of surface yarns may either be repeated for each split of the reed, or an entirely different set of surface yarn colors may be employed for each different height of wires used, thus multiplying the color selection that is possible. The selectivity may be still further increased by planting the colors in a predetermined order in the creels 39.
The foregoing method and apparatus may be adapted to the production of an iniinite number of different patterns or designs, one typical example of which is illustrated in Figure 6 of the drawings, wherein the dark stippled areas 55 represent the high pile areas, and the lighter stippled areas 56 represent the low pile areas. In producing the high pile areas, the surface yarns at the low pile wires which may happen to fall within these areas may be so manipulated as to all be buried in the back of the fabric, along with the stuifers, but if preferred, these surface yarns may be looped over the low pile wires to form low pile tufts which are interspersed with the high pile tufts sc as to give a better density. However, this is not essential, as the density can be equally well controlled by suitable selection of yarns,
size of filling shots, and the extent to which the fabric is beaten up by the reed. In the low pile areas, on the other hand, the surface yarns associated with the high pile wires must be buried in the back of the fabric, except where outlines may be desired.
The selectivity and quality which is attainable by the method and apparatus herein described, far exceeds anything which has heretofore been possible by any prior methods or apparatus. The improvements and advantages of the present invention are especially pronounced when compared with the limitations of conventional cross-wire looms and the methods of weaving fabric on such looms.
While the specific details have been herein shown and described, the invention is not confined thereto as changes and alterations may be made without departing from the spirit thereof as dened by the appended claims.
We claim:
l. The method of producing embossed or relief designs in pile fabrics with Wilton looms having a stationary pile wire in every split of the reed and the wires being of at least two different heights and arranged in a predetermined order of alternate high and low wires transversely across the loom, which comprises passing binder, stuffer and surface warps longitudinally through the loom and through every split in the reed, selectively manipulating the warps aforesaid in an upward and downward direction in timed relation to each other and selectively looping the surface warps over the high and low pile Wires to form high and low pile loops in a predetermined order in each transverse row across the loom, and passing filling shots in timed relation to the motion of the binder, stuffer and surface warps, transversely across the loom .to bind together the component warps of the fabric into a backing having the surface yarns presented on one face thereof in the form of high and low pile areas I arranged in a predetermined pattern according to the selective looping of the surface warps over the pile wires.
2. A pile fabric loom for weaving embossed or relief designs in pile fabrics-comprising a lay, a reed carried by said lay and having a plurality of splits arranged in spaced relation to each other transversely acrossthe loom for receiving binder,
stuifer and surface warps adapted to be passed longitudinally through each reed split, a stationary pileY wire longitudinally extended through each reed split in substantially parallel relation to the warps aforesaid, said pile wires being of,l at least two dilerent heights and arranged in a predetermined order of alternate high and low wires transversely across the loom, means for selectively looping in successive transverse rows the surface warps on selected pile wires according to a 'predetermined pattern, and means for weaving said binder and stuffer warps into a backing fabric and for binding the surface warp loops into the backing fabric as the latter is woven, withthe surface warps extending from one face of the backing fabric in the form of pile areas of different heights and pattern as aforesaid.
GUsTAv E. SCHULZ. I HAROLD H. HONDA REFERENCES CITED The following references are of record in the file of this patent:
UNITED STATES PATENTS Number Name Date 1,191,487 Warner July 18, 1916 2,067,574 Lowrie Jan. 12, 1937 2,141,152 Kaufman Dec. 20, 1938 2,164,090 Shuttleworth June 27, 1939 2,225,452 Jacobsen Dec. 17, 1940 2,293,010 Rice Aug. 11, 1942 2,318,080 Keen May 4, 1943 2,355,789 Faber Aug. 15, 1944 2,410,764 Uihlen NOV. 5, 1946 2,414,064 Schulz Jan. 7, 1947v 2,430,559 Dacey Nov. 1,1, 1947 2,477,249 Harding July 26, 1949 FOREIGN PATENTS Number Country Date 273,409 i Great Britain July 6, 1927
US726330A 1947-02-04 1947-02-04 Method of and apparatus for weaving relief designs in pile surfaces of textile fabrics Expired - Lifetime US2555159A (en)

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US2860666A (en) * 1956-12-19 1958-11-18 New York Trust Company Method of weaving and composite pile wire for looms
EP1057911A1 (en) * 1999-05-28 2000-12-06 Griffith Textile Machines Limited Pile loop forming assembly
US6192943B1 (en) * 1999-01-21 2001-02-27 Griffithtextile Machines Limited Carpet loom for weaving warp pile fabric
US20040040611A1 (en) * 2000-05-24 2004-03-04 Griffith John D. Carpet loom

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US2067574A (en) * 1935-05-06 1937-01-12 Lowrie John Pile loom construction
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US2410764A (en) * 1946-03-08 1946-11-05 M J Whittal Associates Inc Three tone fabric and method for making same
US2414064A (en) * 1945-07-26 1947-01-07 Nye Wait Company Inc Pile fabric loom and pile wire therefor
US2430559A (en) * 1945-11-30 1947-11-11 A & M Karagheusian Inc Pile fabric
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US1191487A (en) * 1915-05-19 1916-07-18 Frank Warner Figured velvet fabric.
GB273409A (en) * 1926-04-06 1927-07-06 James Graham Lambert An improvement in and relating to looms for weaving pile fabrics
US2067574A (en) * 1935-05-06 1937-01-12 Lowrie John Pile loom construction
US2141152A (en) * 1938-01-21 1938-12-20 Collins & Aikman Corp Apparatus and method for the manufacture of pile fabrics
US2225452A (en) * 1938-07-08 1940-12-17 Sidney Blumenthal & Co Inc Method and apparatus for making a pile fabric
US2164090A (en) * 1939-02-23 1939-06-27 Mohawk Carpet Mills Inc Pile fabric and method of making same
US2293010A (en) * 1941-02-24 1942-08-11 Firth Carpet Company Inc Pile fabric
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US2355789A (en) * 1941-12-30 1944-08-15 Benjamin S Faber Method of making fabric
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US2430559A (en) * 1945-11-30 1947-11-11 A & M Karagheusian Inc Pile fabric
US2410764A (en) * 1946-03-08 1946-11-05 M J Whittal Associates Inc Three tone fabric and method for making same
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Publication number Priority date Publication date Assignee Title
US2860666A (en) * 1956-12-19 1958-11-18 New York Trust Company Method of weaving and composite pile wire for looms
US6192943B1 (en) * 1999-01-21 2001-02-27 Griffithtextile Machines Limited Carpet loom for weaving warp pile fabric
EP1057911A1 (en) * 1999-05-28 2000-12-06 Griffith Textile Machines Limited Pile loop forming assembly
US20040040611A1 (en) * 2000-05-24 2004-03-04 Griffith John D. Carpet loom
US6926041B2 (en) * 2000-05-24 2005-08-09 Griffith Textile Machines Limited Carpet loom

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