‘Oct. 14, 1930. ' w. s. NUTTER 1,778,196 " PILE FABRIC'AND'METHOD OF MAKING THE SAME

Filed Jan. 1'7, I929 '

' lnvén’ror. ' William SNuITer . ATTys. Patented Oct. 14, 1930 1,778,196

UNITED" STATES PATENT oFiuca

WILLIAM S. NUTTER, OF SANFORD, MAINE, ASSIGNOR TO GOODALL WORSTED COMPANY, OF SANFORD‘, MAINE, A CORPORATION OF MAINE ‘

PILE FABRIC AND METHOD OF MAKING THE SAME Application ?led January 17, 1929. Serial No. 333,081. This invention relates to the Weaving of a case of the V weave fabric where each pile warp pile fabric and especially a plush fabric loop 1s simply looped about a single ?lling of the so-called’ V weave type in which the thread. This extra length of the expensive pile warp threads are of mohair or a like slip plle warp threads which is involved in mak 5 pery ?ber. ' - ing the pile loops in the W weave pile fab 55 Pile fabrics such as plushes, velvets, etc. r1c adds very materially to the cost of pro may be divided into two classes which are duction. commonly referred to as the W weavetype But while less of the expensive yarn is and the V weave type. In the W weave each used 1n the weaving of a V weave pile fabric 10 pile loop is looped about three or more ?lling yet the weaving of this fabric involves some 60 threads, each loop passing from the pile face di?iculties not present in the weaving of the of the fabric under one ?lling thread and then W weave fabric. Since in the V weave fabric over one or more ?lling threads and then each pile loop is looped abouta single ?lling under another ?lling thread and back to the thread only, said loops are not so securely an 15 pile face of the fabric. This gives each loop chored in the body of the fabric as in the 65 a shape somewhat like the letter W; hence the case of the W weave fabric, and in order to designation W-weave. In the V weave fabric hold the pile loops in the V weave fabric _.each pile loop is looped about a single ?lling it has been necessary to employ an extra thread, that is, each loop passes from the pile warp separate from and in addition to the 20 face into the body of the fabric around a warp comprising the regular warp threads. 70 single thread and then back to the pile face This extra warp is carried on a beam which of the fabric again, and thus has the shape is separate from that carrying the regular of' the letter V; hence the designation V warp.

weave. _ y The threads of the regular warp are dur 75 25 In the -W weave fabric each pile loop is ing the weaving operation under tension securely anchored or tied into the body of the while the threads of the extra warp may fabric because of the fact that it loops about have little or no tension and during the a plurality of ?lling threads, while in the V weaving operation these extra warp threads weave fabric the pile loops are much less become crowded into the body of the fabric securely anchored because each pile loop and thus assist in holding the V-shaped pile 80 loops about a single ?lling thread only. loops in place. Various terms are used to There is less ex en? involved in making designate this extra warp such‘ as “slack a V weave pile fabric than a W weave pile warp”. “binding warp,” “extra warp,” etc. fabric, part-1y due to the difference in the cost ‘While this extra warp has been regarded of the‘ material going to make up the fabric. as necessary in the making of a V weave 85 In these warp pile plush fabrics the pile loops plush in order to assist in binding the pile ~ are formed from pile warp threads, which loops into the fabric yet there are certain during the weaving operation, are inter disadvantages that result from its use. looped with the ?lling threads. Usually the One is that the presence of this extra or 40 material from which the pile warp threads slack warp produces a crowding of the warp are made is considerably more expensive than threads in the reed and harnesses of the that from which the other warp threads and loom. In weaving many plush fabrics it is ?lling threads are made, for example, the pile more or less common to employ a reed hav warp threads may be of mohair yarn while ing eighteen to twenty-two dents to the inch 45 the other warp threads and the ?lling may be and in threading up a loom for weaving a cotton. *1 double plush fabric of the V weave type In the case of a W weave fabric where there will be in each'dent two pairs of reg each pile loop is looped about a plurality ular or ground warp threads, two pairs of of ?lling threads each loop will contain a the warp threads of the extra or slack warp 50 much greater length of yarn than in the besides a pile warp thread. In other words 2 1,778,196

there will be nine threads to the dent, and ?lm-like coating of pyroxylin is such that with twenty-two dents to the inch this would it ties the ‘V-shaped pile loops into the fabric means one hundred and ninety-eight threads more ?rmly than is done by the loose or slack to the inch. warp threads ‘of the extra warp which have The handling of this large number of heretofore been used in the V weave fabric. warp threads complicates weaving condi The absence of the threads of this extra warp tions as the crowding of the threads in the (four threads to the dent in the weaving of dentsvof the reed and in the harnesses inter a double plush fabric) greatly facilitates the feres with the proper formation of the weaving operation, partly because it relieves sheds, especially since some of the threads the dents of the reed and the harnesses from in each‘dent are those of the extra warp the “crowded conditionwhich obtains when which are more or less slack. Moreover, the extra warp is used and thus eliminates where the threads are so crowded in the loom the disadvantageous weaving conditions there is more danger-of broken warp threads, above referred to. In fact, with a reed hav 15 and each broken warp thread involves the ing twenty-two dents to the inch the elimina 80 stoppage of the loom to have the damage re tion of‘ the extra warp will remove from the paired. Hence the presence of the extra reed and harnesses something over ?ve thou slack warp threads, which has been deemed sand threads in a sixty inch reed space. necessary in the weaving of the‘V weave fab This diminution in the number of threads 20 rics, results in slowing down production due in the dents allows the threadsin each dent 85 to more frequent stoppage of the loom for to freely pass each other during the making repairing broken warp threads. ‘of the shed and it produces a condition which Furthermore, since thethreads of the ex reduces greatly the possibility of the threads tra warp‘ are more or less slack the actual , becoming fouled or tangles or broken through 25 tension of the individual extra warp threads the presence of a knot in any thread. More will'vary’more or less as the weaving pro over, since all the warp threads of the fabric, ceeds, thus establishing a condition‘ which that is, the pile warp threads and the regular tends to produce an unevenness in the pile warp threads, are under a controlled tension surface of the fabric which detracts from its the result is that the pile face of the fabric 30 appearance. Hence while it has been deemed will present an-even uniform appearance free

necessary to use the extra or slack warp in the from P its or “crowfeet” or other‘im erfec?. production of V weave fabrics, yet the pres tions which are apt to develop when the extra ence of this extra warp produces various dis warp is used. _ _ advantages which it is highly desirable to The weaving of the fabric in accordance as overcome. ' _ . with my invention by omitting the slack warp It is one of the objects of my present in threads and substituting the ?exible bind vention to provide an improved method of ing material does not of itself involve any making a V weave pile fabric by which such change in the number of pile V’s per unit of a fabric can be made without the use of the area, In other words, a fabric embodying -40 additionalor extra warp and which fabric my invention has as many pile V’s per unit lu.) when completed has all the desirable charac of area as a corresponding fabric woven with teristics of a high-grade plush as well as some the usual slack warp threads for binding the additional desirable characteristics. pile V’s in the fabric. If then the number of In carrying out my invention I weave a picks be the same in both types of fabric the 45 V-weave warp pile fabric with the usual num quality of the pile face will be same but the H0 ber of picks per inch but with-simply the pile appearance of my fabric is better for the rea >' warp and the ordinary tensioned or ground sons above set forth. ' warp, the extra or slack warp which caused The pyroxylin or other binding material the above recited disadvantageous conditions which is applied to the back face of the fabric 50 being eliminated. ‘In other words the fabric is not only of such nature that it will not is initially woven with a subnormal number obscure the texture of the fabric but it is not of warpthreads requisite to bind the pile a?ected by nor does it affect the operation of V’s into the fabric occasioned by the omission dyeing, scouring, washing or otherwise treat of the slack warp threads heretofore em ing the fabric and, therefore, the plush fabric .55 ployed for that purpose. ‘After the fabric thus made from interweaving the threads of with the pyroxylin-coated back may be dyed, the pile warp and the regular tensioned warp scoured, or otherwise treated during the with ?lling threads is taken from the loom ?nishing operations in the same manner as I appl to the back vface'of said fabric a thin a fabric without the, backing. In fact, the 60 ?lm-1i e coating of pyroxylin or some other presence of the pyroxylin coating on the back 125 similarbinding material which serves to bind of the V weave plush fabric from which the together the portions of the threads exposed extra or “slack” warp threads are omitted on the back face without, however, appre is‘ highly advantageous during the dyeing, ciabl obscurin the texture of the fabric. scouring, washing or other ?nishing opera '65 I nd that tie binding effect of this thin tion as it holds the fabric in shape and pre I30 1,77s,1ee I 3

, vents the pile loops from becoming loosened which embodies in its construction the slack or pushed through the back of the fabric. warp threads. ' In order to give a better understanding of The omission of the extra or “slack” warp the invention I have illustrated in the draw threads not only removes the crowded con , ings diagrammatically a V weave plush fabric dition of the threads in the dents of the reed 70 embodying my invention. and harness which is present when the extra Fig. 1 illustrates diagrammatically the V warp is used, but it enables production to be weave with the extra warp omitted in accord speeded up. In weaving the V-weave warp ance with my present invention; pile fabric having the “slack” warp threads -10 Fig. 2 is a perspective view illustrating there are three separate warps used, each 75 more or less diagrammatically a fabric em wound on its'own beam, to wit, the pile warp, bodying my invention as it is initially woven. the regular tensioned warp and the extra or Fig. 3 is a fragmentary perspective view of slack warp, each of which has to be drawn the completed fabric. ‘ into the loom separately. When during the 15 As stated above it has heretofore been cus weaving any one of the warps runs out it 80 tomary in the weaving of V-weave warp pile becomes necessary to tie in a new warp. This fabrics to employ a set of slack or stuifer warp tying-in operation is necessaril a slow and threads in addition to the set of ground warp ' tedious one and involves stopping the loom threads, this set of slack warp threads being for approximately a day. The omission of 20 for the purpose of binding the pile V’s into. the extra warp eliminates the necessity of the fabric. In weaving. a double warp pile drawing into the loom the ?ve thousand or fabric having the slack or stuffer warp more threads composing this warp and also threads it has been customary to place in eliminates the necessity of stopping the loom ' each dent of the reed two pairs of the ten for a day or so at various intervals in order 25 sioned or ground warp threads, one ‘for each to tie in a new extra or “slack” warp. Fur fabric, two pairs of the slack or stuffer warp thermore, where the “slack” warp is omitted threads, one pair for each fabric, and a pile and there is less crowding of the warp threads warp thread which passes alternately from ‘in the reed and harness the danger of break one fabric to the other. This makes nine age of warp threads is much reduced 'so that 30 threads in each dent thereby producing the in weaving the fabric shown in Fig. 1 the 95 crowded condition of the warp threads above stopping of the loom to piece up a broken referred to. - ~ thread is much less frequent than in weaving In weaving a V-weave pile fabric in ac the V-weave warp pile fabric having the cordance with my invention the extra or “slack” warp threads. Furthermore, where “slack” warp is omitted thereby removing the extra or “slack” warp is omitted it is pos 100 from each dent four “slack” warp threads sible to divide the tensioned warp on to two when a double pile fabric is being woven. beams, one of which will be located in the This will leave in the fabric only the tensioned loom‘in the position usually occupied by the warp threads and the pile warp threads to beam carrying the extra or ‘éslack” warp. By gether with the ?lling threads, and in the case thus dividing the tensioned warp between two 105 of a double pile fabric each dent will carry warp beams it is, possible to use a warp of only the two pairs of tensioned warp threads double the length that can be used where the together with one pile warp thread. This is entire tensioned warp is wound on a single shown in Fig. 1 which illustrates in full lines beam and this will reduce the stoppage time the warp threads which are in each dent of required for tying in a new warp. In fact, ‘110 the reed. This includes the tensioned or in weaving a fabric such as shown in Fig. 1 ground warp threads 2 and 3 in the upper the stoppage time of the loom may be reduced fabric, the tensioned or ground warp threads as much as ?fty percent over what it is in 4 and 5 in the lower fabric, and the pile warp weaving a V-weave warp pile fabric having thread 10 which passes from one fabric to the the “slack” warp threads. 115 other. This pile warp thread passes around ' Then again, less power is consumed in alternate ?lling threads 12 in each fabric as weaving the fabric shown in Fig. l/“than in is usual in V-weave warp pile fabrics and the 'weaving a V-weave warp pile fabri‘c having adjacent warp pile threads have a staggered the “slack” warp threads, and the 100m can relation as indicated by the full and dotted be run faster. The cost of production of the 120 V weave fabric shown in Fig. 1 is thus con line warp pile threads 10 and 11 in Fig. 1, it siderably less than‘ that of the V-weave being understood that’ these represent the warp pile fabric having the “slack” warp warp pile threads in adjacent dents. This re threads and some factors which contribute to duction in the number of threads in each dent this reduction in cost'may. be summarized as 125 greatly simpli?es the weaving operation and “follows : eliminates therefrom the various difficulties 7 A reduction inpstoppage time ofté the loom and complications above referred to and. required for drawing 1n and/or tying in the which have heretofore accompanied the warps; _ wea ing of a double pile V-weave fabric A. reduction in the cost of the material used 4 1,778,196 since the omission of the extra warp elimi-_ per unit of area, nor in their relative arrange-, nates four out of every nine war threads ment and hence the pile face of- the fabric em heretofore used in weaving a dou le plush , bodying this invention is in no way inferior fabric or about ?ve thousand threads in a to that of a V-weave warp pile fabric in sixty‘ inch reed space, and the cost of the which the slack or stutter warp threads are 70 pyroxylin coating is considerably less than used. In fact, the quality is improved as the saving in yarn; the omission of the “slack” wa threads Faster operation of the loom; eliminates the crowded condition 0 the warp {fess weaving time lost in piecing up broken threads in the dents and in the harnesses of 10 en s. - the loom which frequently resulted in pro 75 After the fabric has been woven as shown ducing a somewhat uneven appearance in the in Fig. 1 it is cut into the two fabrics in pile surface and such elimination results in a usual manner thereby producing the V-pile better and more even pile surface. loops 14 in each fabric, and then the coating A V-‘weave plush fabric may be considered 15 15 of pyroxylin or other binding material is as having rows of V-shaped pile loops run applied to the back face. This coating‘ will ning lengthwise of the fabric, each row com preferably be a thin‘ ?lm-like coating which prising the loops formed from a single'pile does not appreciably-obscure the texture of warp thread and each loop being looped the back face of the fabric.‘ It does, how-~ about a single ?lling thread. In my im ever, bind together the threads which are ex! proved fabric wherein the extra warp is 85 posed on the back face and thereby acts as a omitted there will be ‘one such row of pile ' substitute for the omit-ted slack warp; threads loops for each two warp threads‘ in the fabric, in binding the pile loops into the fabric. each row of pile loops being thus separated The completed fabric with the pyroxylin by two warp threads only. 25 coating on the back face is one in'which the Furthermore, as stated above the pyroxy-. 90 pile loops are anchored in the fabric more se lin coatin is not affected by nor doesit affect curely if anything than could be done with the ?nishing'operations to which the fabric _ the use of the extra or “slack” warp threads is subjected after’it is woven, such for in and since the fabric is woven without the stance as scouring, dyeing, washing, etc. The so extra or “slack” warp threads and hence pyroxylin has no affect upon the dye liquor 95 without the disadvantages resulting from nor is it affected by the dye liquor and being the use of them, the pile face of the fabric on the back face of the fabric it does not affect " has a better and more even appearance than in any way any of the ?nish-ingoperations usu is posslble to produce where the extra warp ally performed on the pile‘ face of the fabric. 35 threads are used. The weaving of the fab In fact, the presence of this'pyroxylin back 100 ric with the slack warp threads omitted does ing is an advantage during such operations as not involve any change in the number of it securely ties the pile loops into the fabric. picks per inch nor in the number or spacing and thus revents their becoming loosened. ‘of the pile V’s. .In other‘words the fabric While have herein referred to the inven-v 40 may be woven in accordance with this inven tion as applied to a plush fabric yet it will be tion with the same number of pile V’s per unit obvious that the principle involved in the area as when the slack warp threads. are used invention is also applicable to other pile fab to bind the pile V’s in the fabric. ‘ rics than those which are commercially The invention, therefore, may be con- known as “plush fabrics.” 45 sidered as a V-weavewarp pile fabric initial ' I claim. . no 1y woven with a subnormal number of warp 1. A V-weave warp pile fabric having threads requisite to bind the pile V’s into the ground warp threads, ?lling threads and pile fabric occasioned by the omission of the slack V’s, each pile V being looped about a single . warp threads heretofore used for this pur ?lling thread, said fabric being initially 5o‘ pose, this de?ciency of warp threads being" woven with the ?lling threads'around which 115 made good by the application of a thin ?lm the pile V’s are looped in substantially the like coating of pyroxylin to the back face of same close arrangement as in the usual V the fabric after it is woven. The fabric as weave warp pile fabric but with a subnormal shown in Fig. 1 will naturally be of lighter number of warp’ threads occasioned by the 55 weight as it comes from the loom than the omission of the slack warp threads-which are \ V-weave warp pile fabric having the'“slack” employed in, said usual V-weave warp pile. 'warp threads incorporated therein because it fabric to bind the pile-V’s into the fabric, contains so many less warp threads but this said fabric having applied to its back face lightness in weight is made up by the coating a coating of ?exible binding material that 60 of pyroxylin applied to the bee of the fab binds the pile V’s into the fabric and thus 125 ric. The,l hange in the weave or fabric‘ makes good the de?ciency caused by the ~ Ystructur'e of the V-weave warp pile fabric omission of the slack warp threads. . which is the result of omitting the “slack” 2. The method of makin *a V-we'ave warp or stuffer warp threads does not result in pile fabric which consists 1n initially weav-_ 65 any change in the number of the pile loops 14 ing the fabric with a subnormal number of 136 1,778,196 warp threads for the use to which the fabric is to be put resulting from the omission of the slack warp threads usually employed to bind the pile V’s in the fabric, and in so doing vlooping each pile V about a single ?lling thread, beating upthe ?lling threads to give them substantially the same spacing as exists in the usual V-weave warp pile fabric having the slack warp threads to bind the pile V’s , [1o in the fabric, and then applying to the back face of the fabric a coating of ?exible binding material that ties or binds the pile V’s into the fabric and thus makes good the de?ciency caused by the "omission ‘of the slack warp 15 threads. ‘ I 3. A V-weave warp pile fabric having ground warp threads, ?lling threads and pile V’s, each pile V being looped about a single ?lling thread, which fabric is initially woven 20 with a subnormal number of warp threads requisite to bind the pile V’s into the fabric occasioned by the omission of the slack Warp threads heretofore employed for that pur pose but without any reduction in the number 25 of filling threads or pile V’s due to such omis sion, and which fabric so initially woven has applied‘to its back a coating of ?exible bind ' mg material that binds the pile V’s'into the fabric and thus makes good the de?ciency 30 caused by the omission of the slack warp threads. ' 4. The method of making a V-weave warp - ‘ pile fabric which consists in initially weaving the fabric with a subnormal number of warp 35 threads requisite to bind the pile V’s into the fabric occasioned by the omission of the slack warp threads heretofore employed for that purpose but without any‘ reduction in the number of ?lling threads or pile V’s due 40 to such omission, and then applying to the back face of the fabric a coating of ?exible binding material that ties or binds the pile V’s into the fabric and thus makes good the de?ciency caused by the omission of the slack 45 warp threads. ‘ a 4 In testimony whereof, I have signed my name to this speci?cation. ' WM.‘ s, NUTTER. 50

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