wilton carpet

BY: Hemant GhanGhor & Patanjal Kumar

Wilton Carpet Weaving

• High tuft density produces a durable carpet

• Up to five color (frames) per pattern is produced

• One yarn forms the row of tufts while the remaining yarn is buried in the pile

• Strongly constructed foundation

Materials and structure of Wilton carpets

Wilton Carpet

Strongly constructed foundation

Chain warp

Stuffer Warp

Dead Pile

Material and structure of wilton carpet

1.Chain Warp:- Chain warp with the weft inserted form the basic backing of the fabric e.g. Cotton , polyester , Cotton/polyester , PP etc.

2.Stuffer Warp:- Held straight during weaving to provide dimensional stability in warp direction e.g. cotton , PP , Jute etc.

3.Dead Piles :- Intermittent length of pile yarn working as dead i.e. not being utilized on the surface to form the part of the pattern. Dead pile contribute cushioning of the carpet . Its presence contributes significantly to the cost of the product

Terms commonly used

•Pitch: Number of piles present in a 100 mm length across the width of carpet.

•Shot: Number of weft inserted per inch across the carpet.

•Pile mass: Weight of the piles per square meter of the carpet.

Identification of Wilton carpets

Examine a cut edge

Note the buried yarns that alternate with the surface colors

In addition , the pile will be denser and the carpet is tighter than other carpet construction

Wilton carpet

fig.1.1

Principle 1.principle is similar to plain weave weaving but the operation is more complicated2.Both pile and ground fabric are woven simultaneously3.Three healds are required (two for chain warp and one for stuffer warp)4.Separate healds are used for pile yarns5.Pile loops are formed over wires,inserted (weft wise during weaving ) and withdrawn later

Weaving cycleFirst weaving cycle:-•Shed is formed during first revolution of weaving cycle(formation of backing).•Weft shot is introduced in the open shed to beaten by sley or reed.

Second weaving cycle:-•movement of heald has alternated the portion of chain and stuffer warps•One row of pile yarn is raised to create a double shed.•The weft is shot in such a way that it is above the chain warp but under the stuffer and pile warps.•A wire is thrown above the backing warp and all the pile warps except the selected once.•After beat up the weft shot becomes located at the base of backing and the wire plus selected pile loops are on the surface.•After cutting pile wire is withdrawn from a pile row and is returned to the insertion mechanism.

First weaving cyclefig.1.2

Second weaving cyclefig.1.3

pitch Shot(rows/inch

Pile length(in mm)

jute count

Warp count

backingmaterial(cotton)(gsm)

Total weight after latexing

7 9 25.4 1/18’s1/16’s

3/9’s 191 2440

7 8.5 21.4 1/18’s1/16’s

3/9’s 191 2161

7 6.5 21.4 1/12’s2/10’s

3/9’s 191 1896

7 6 49.2 1/16’s 3/9’s 191 1579