US2967549A

US2967549A - Pile carpets

Info

Publication number: US2967549A
Application number: US738408A
Authority: US
Inventors: Mcknight Stewart
Original assignee: Mohasco Industries Inc
Current assignee: Mohasco Industries Inc
Priority date: 1958-05-28
Filing date: 1958-05-28
Publication date: 1961-01-10
Anticipated expiration: 1978-01-10

Description

Jan. 10, 1961 5, MCKNIGHT 2,967,549

PILE CARPETS Filed May 28, 1958 NTOR.

'wire and the pick.

PILE CARPETS Stewart McKnight, Amsterdam, N.Y., assignor to Mohasco Industries, Inc., Amsterdam, N.Y., a corporation of New York Filed May 28, 1958, Ser. No. 738,468 3 Claims. (Cl. 139-402) This invention relates to pile fabrics for floor covering purposes and resides more particularly in a pile carpeting of novel construction, which can be produced rapidly and at low cost on a standard pile wire loom. The new carpet has a pile made of elements of pile yarn bound beneath picks of filling, and, although the pile contains a relatively small amount of yarn per unit area, the pile elements are so distributed that the pile provides good coverage of the base of the fabric and has an attractive appearance and good wearing qualities.

For a better understanding of the invention, reference may be made to the accompanying drawing, in Which Fig. l is a diagrammatic longitudinal sectional view through one form of the new carpet on the loom;

Fig. 2 is a diagrammatic longitudinal sectional view of the carpet removed from the loom; and

Figs. 3, 4, and are diagrammatic bottom plan views of different forms of the carpet.

The new carpet comprises a base formed of picks of filling 10 lying in a single plane and interlaced with binder warp yarns in two sets under substantially equal tension and represented by the yarns 11 and 12. The fabric contains no stutter warp yarns and the binder yarns are distributed across the fabric in spaced pairs with each pair containing a yarn from each set. The two binder warp yarns of each pair pass on opposite sides of each pick and cross between adjacent picks.

The pile yarns are warp yarns in a plurality of sets and the pile yarns are distributed across the fabric in groups, each of which contains a pile yarn of each set. In all forms of the fabric there are at least three sets of pile yarns with yarns representing those in the sets designated 13, 14, and 15, respectively. Adjacent pile yarns of each group may be separated by one or more pairs of binder yarns, as shown in Figs. 3 and 4, or adjacent groups of pile yarns may be separated by one or more pairs of binder yarns, as shown in Fig. 5.

In the weaving of the fabric, the binder yarns of the two sets are manipulated to lie in different levels in successive sheds for insertion of a pick of filling between them and a pile wire 16 is inserted in every other shed and above both binder yarns. In each shed in which a wire is inserted, the pile yarns of two sets are raised above the wire, while the yarns of the third set lie below both the wire and the pick of filling. In each shed in which no wire is inserted, the pile yarns of two sets pass above the pick of filling and the pile yarns of the third set pass below. Thus, as shown at the left in Fig. l, in the shed, in which the pick of filling 1t! and the wire 16 are inserted, the pile yarns 13 and are raised over the wire, while the pile yarns 14 lie below both the I The binder yarns 11 lie below the pick 10, while thebinder yarns 12 lie between the pick and the wire. In the next shed to the right, a pick ltla of filling is inserted and, in this shed, the binder yarns 11 lie above and the binder yarns 12 lie below the pick, while the pile yarns 13 and 14 lie above the pick and the pile yarns 15 lie below the pick.

In the third shed, a wire 16a and a pick 10b are inserted and, in this shed, the

pile yarns

14 and 15 lie above the wire and the pick and the pile yarns 13 lie below the wire and the pick. Both binder yarns 11 and 12 lie below the wire with the yarns 12 above the pick and the yarns 11 below the pick. In the fourth shed, no wire is inserted and the

pile yarns

13 and 15 lie above the pick and the yarns 14 lie below the pick 10c, while the binder yarns 11 lie above and the binder yarns 12 lie below the pick.

In the fifth shed, both a Wire 16b and a pick 10d of filling are inserted and the

pile yarns

13 and 14 lie above the wire and the pick, while the pile yarns 15 lie below both the wire and the pick. The binder yarns 12 lie below the wire and above the pick and the binder yarns 11 lie below the pick.

In the sixth shed, no wire is inserted and the

pile yarns

14 and 15 lie above and the pile yarns 13 lie below the pick 10c. The binder yarns 11 lie above and the binder yarns 12 lie below the pick. With the completion of the sixth shed, the weaving cycle is completed and, in the seventh shed, the arrangement of the yarns is the same as in the first shed.

Each of the pile wires 16 used in making the fabric illustrated is provided with a knife 17 at the 'end of the wire which trails as the Wire is withdrawn. Accordingly, after all of the wires of the set have been inserted and the first wire is withdrawn for insertion in a new shed, the withdrawal of the wire severs the loops of pile yarns raised over it to produce pairs of tuft legs and the manner, in which the pile yarns were raised over the wires, causes the tuft legs to have different lengths. Thus, upon withdrawal in succession of the

wires

16, 16a, 16b, lids, and 16d, the pile yarn 13 raised over the

wires

16, 16b, and 16c forms long tuft legs bound beneath the pick 10b and short tuft legs bound beneath the pick 102. Similarly, the yarn 14 raised over the

wires

16a, 16b, and 16d forms short tuft legs bound beneath the pick 10c and long tuft legs bound beneath the pick 10 while the yarn 15 raised over the wires 16, 16a, and forms short tuft legs bound beneath the pick 10a and long tuft legs bound beneath the pick 1001. When the raised yarns are cutthe severed lengths of yarn bound beneath individual picks and rising on opposite sides-of each such pick tend to straighten so that the angle between the tuft legs formed by each length of yarn increases. As a re-v sult, the tuft legs, such as those marked 13a, 131 which were produced by cutting the yarn 13 by withdrawal of the wire 16c, tend to overlap and cross each other, as shown in Fig. 2. The effect of such crossing of the tuft legs is to increase their covering and concealment of the back and, since the crossing of the tuft legs is not uniform in extent, the pile has a rough appearance and tex-. ture which is highly desirable.

Different effects are obtainable at the back of the fabric by the manner in which the binder yarns are interlaced with the picks of filling. Thus, in the fabric shown in Fig. 3, adjacent rows of lengths of pile yarn bound beneath picks of filling are separated by pairs of binder yarns consisting of a yarn of each set and the binder yarns lying at opposite sides of a row of pile yarns are from the same set as, for example, from the set 12. Accordingly, these yarns pass. on the same side of each pick of filling and they lie below the pick 10b binding the pile yarn 13c and above the pick 1% binding the pile yarn 13d. The binder yarns 12 passing below the pick 10b tend toprevent the bottom of the pile yarn 13c from spreading laterally but the bottom of the'pile yarn 13d bound beneath the pick 10a, over which the binder yarns 12 pass, is not held against lateral spreading and is thus wider than the bottom of the yarn 130. For the sat ne reasons, the bottoms of the yarns 14a and 15a are not closely confined by binder yarns on opposite sides thereof and tend to spread laterally. The result is that, at the back of the fabric shown in Fig. 3, diagonal rowsof Patented Jan. 10, 1961 the bottoms of pile yarns which have spread laterally are visible, and a diagonal rib efiect is obtained.

In the fabric illustrated in Fig. 4, the rows of pile yarn elements are separated by pairs of 'binderyarns 11, 12 with each pair of made up of a yarn of each setand the arrangement of the binder yarn of the sets is the same in all pairs. As a result, the bottom of each pile yarn is engaged at one side by a binder yarn passing beneath the pick which binds the pile yarn but, at the other side, the adjacent binder yarn passes over the pick, so that the bottom of the pile yarn can spread laterally in one direction. Since the bottoms of all the pile yarns at the back of the fabric are confined below their binding picks at one side only, the portions of the pile yarns visible at the back of the fabric are all of the same size and the diagonal rib effect visible in the fabric shown in Fig. 3 is absent. I

In the fabric shown in Fig. 5, the pile yarns are arranged in groups of three with adjacent groups separated by a pair of binder yarns made up of a yarn of each set. In the actual fabric, the warp yarns lie close together and, since the pile yarns are larger than the binder yarns, there are noticeable lengthwise stripes in the back of the fabric formed by the bottoms of the pile yarns in the several groups.

In the fabric illustrated, the binder warp yarns are distributed across the fabric in pairs made up of a yarn of each set and the pairs of binder yarns are separated by one or more rows of loops of pile yarn bound beneath picks of filling. If desired, other distributions of the binder yarns may be employed, as, for example, the rows of pile yarns may be separated by two pairs of binder yarns with each pair made up of a yarn of each set so that, in such a group of four binder yarns, the first and third are from the same set and the second and fourth are from the other set. In an alternative arrangement, the binder yarns may be inserted in groups of four with the first and second yarns from one set and the third and fourth from the other set. The latter arrangement is similar to that illustrated but with two binder yarns from the same set handled as one.

In the production of the new fabric, only one pile wire is inserted for each two picks of filling. As a result, the loom has an easy motion and it may be operated at higher speed than an ordinary pile wire loom, in which the necessity of inserting a wire in each shed limits the speed of operation. As each pick of filling binds lengths of pile yarns of a single set only, there are relatively few pile elements per unit of pile area. However, in a cut pile fabric, good coverage of the base is obtained because of the use of high and low tuft legs and, even with a low density pile, excellent durability can be obtained by the use of hard twist pile yarn. The yarns preferred are those having a twist of 60 to 90 turns in a length of and a size varying from 41 to 50 yards per ounce. An excellent yarn for the purpose is one having a size of 41 yards per ounce with a plus or minus tolerance of 10% and 66 turns per 10''. The wires employed in producing the fabric may be of any of the usual heights and the fabric may have a pitch within the commercial range of 180 to 256. The term pitch as used herein means the number of splits in the reed in 27" with each split containing a pair of binder chain yarns and as many pile yarns as are used per pair of binder yarns.

While the new fabric has been illustrated in a form having a cut pile with the pile elements tuft legs, the fabric can also be made with a pile, in which the pile elements are loops of pile yarn. In the production of such a fabric, the pile wires used are of the non-cutting type and, upon their removal, the pile yarns remain as loops. The loops are all of the same height as each one is bound beneath every third pick and passes over the intervening pair of picks. Thus, if the wires shown in Fig. 1 were non-cutting, withdrawal of the wires would leave loops of pile yarns 14 bound beneath the pick- 10, passing over the picks 10a and 10b, and again boundbeneath the pick 100. Similarly, the pile of the fabric would include loops of yarns 15 bound beneath the pick- 10a, passing over the picks 10b and 10c, and bound be neath the pick 10d, and loops of yarns 13 bound beneath the pick 10b, passing over the picks 10c and 10d, and bound beneath the pick 10c. While the wires are in place in the loops, the loops are unsymmetrical and each has a long side and a short side but, upon withdrawal of the wires, the loops assume a natural shape with sides of equal length. In order to obtain proper coverage of a the backing of the fabric, in which the pile is made of loops, the pile yarns used are heavier than those employed in the cut pile version of the fabric, so that the loops of heavy yarn expand and hide the backing.

In the production of the fabric illustrated, the wire used are of uniform height from end to end and, as explained, the tuft legs in the cut pile form of the fabric vary in height, while, if non-cutting wires are used, the pile loops are of uniform height. If desired, the pile wires may be of the wavy type and vary in height from end to end, in which event the pile loops will vary correspondingly in height.

I claim:

1. A pile carpet, which comprises a base formed of binder warp yarns in two sets and picks of filling interlaced therewith, the binder warp yarns being under substantially equal tension and the picks of filling lying substantially in a plane, the binder yarns being distributed across the fabric in spaced pairs with each pair consisting of a yarn of eachset and the yarns of each pair passing on opposite sides of each pick and crossing between adjacent picks, and a pile formed of elements of pile yarns in three sets only with the elements of each yarn lying in a row extending lengthwise of the fabric, the pile elements of each yarn being bound beneath single picks of filling distributed along the base and separated by two other picks of filling only, each element extending above the base between each binding pick and the adjacent picks on opposite sides thereof to form a pile element, the rows of pile elements of the several pile yarns being distributed across the fabric in like groups with each group consisting of a row of elements of a pile yarn of each set, each pick of filling binding elements of pile yarns of a single set only and lying beneath elements of pile yarns of the other sets and successive picks of filling binding elements of pile yarns different from the pile yarns forming the elements bound by adjacent picks of filling on opposite sides of said pick.

2. The pile carpet of claim 1, in which all the pile elements are tuft legs formed by cutting loops and the legs of pile yarns bound beneath alternate picks of filling along the fabric differ in height from the legs of pile yarns bound beneath intermediate picks of filling.

3. The pile carpet of claim 1, in which the pile elements are loops.

References Cited in the file of this patent UNITED STATES PATENTS OTHER REFERENCES G. H. Oelsner: Handbook of Weaves, 1915 edition, The Macmillan Co., New York, New York, page 16, Figure 38. (Copy in Scientific Library.)