CA1158903A - Needle punched papermaking felt and method of manufacturing the same - Google Patents
Needle punched papermaking felt and method of manufacturing the sameInfo
- Publication number
- CA1158903A CA1158903A CA000393805A CA393805A CA1158903A CA 1158903 A CA1158903 A CA 1158903A CA 000393805 A CA000393805 A CA 000393805A CA 393805 A CA393805 A CA 393805A CA 1158903 A CA1158903 A CA 1158903A
- Authority
- CA
- Canada
- Prior art keywords
- foundation
- fabrics
- batts
- fabric
- layers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/024—Woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F7/00—Other details of machines for making continuous webs of paper
- D21F7/08—Felts
- D21F7/083—Multi-layer felts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/14—Mixture of at least two fibres made of different materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2433/00—Closed loop articles
Abstract
Abstract of the Disclosure The invention relates to a needle punched papermaking felt. The felt includes a plurality of layers of relatively easily woven endless foundation fabrics consisting of synthetic filament yarns, synthetic fiber spun yarns, synthetic-natural fiber blended spun yarns or two or more kinds of those yarns.
Batts, consisting of synthetic fibers and/or natural fibers, are laid over one or both sides of the foundation fabric.
In accordance with the invention, the component fibers are caused to be entangled with each other by needle punching.
The invention also relates to a method for making the felt which method includes the steps of weaving a plurality of relatively easily woven endless foundation fabrics, setting up the foundation fabrics to a needle punching machine under tension and supplying and laying batts consisting of syn-thetic fibers and/or natural fibers over the layers of found-ation fabrics while the layers of foundation fabrics are advanced. The combined layers of the foundation fabrics and the batts are then needle punched so that the component fibers are caused to be entangled with each other.
Batts, consisting of synthetic fibers and/or natural fibers, are laid over one or both sides of the foundation fabric.
In accordance with the invention, the component fibers are caused to be entangled with each other by needle punching.
The invention also relates to a method for making the felt which method includes the steps of weaving a plurality of relatively easily woven endless foundation fabrics, setting up the foundation fabrics to a needle punching machine under tension and supplying and laying batts consisting of syn-thetic fibers and/or natural fibers over the layers of found-ation fabrics while the layers of foundation fabrics are advanced. The combined layers of the foundation fabrics and the batts are then needle punched so that the component fibers are caused to be entangled with each other.
Description
~89~3 Because of recent trends in the papermaking indus-try to employ papermaking machines of enlarged size and in-creased operating speed for the purpose of improving paper-making efficiency, there is a requirement for papermaking felts of enlarged size as compared with the conventional papermaking felts~ In addition to the requirement for such enlarged size, needle punched felts which are resistant to yielding to the high nipping pressure applied to the felts by press rollers and which have smooth and soft working sur-faces are required to maintain stabilized size and shape of the felts under high operating speed, to provide good squeezing capability and to avoid marking on papers. Accordingly, strong and relatlvely hard yarns are used for forming the foundation fabrics of the papermaking felts and in most cases, double layer fabrics or multiple layer fabrics are used, since the foundation fabrics must be of sufficient thickness, and they also have a requirement of non-compressibility for the component yarns~ to provide sufficient capacity of dewatering and containing a large quantity of water squeezed out from wet papers. Furthermore, in order to avoid the vibration of the press rollers, the foundation fabric of the felt must be endless as well as seamless, therefore, the foundation fabrics must be woven in the hollow weave construction. However, weaving a multiple layer fabric of the hollow weave construction with strong and relatively hard yarns is extremely difficult and needs advanced skill, and also it is necessary to use a special and heavy loom, since it is extremely difficult to weave such a fabric of stable quality with an ordinary loom for weaving fabrics and production of many faulty fabrics is liable to result.
It is therefore an object of the invention to , ., 11~8~3 provide an improved needle punched papermaking felt.
It is a further object of the invention to provide a method for making such a felt.
In accordance with the invention, a needle punched papermaking felt comprises a plurality of layers of relatively easily woven endless foundation fabrics consisting of syn-thetic filament yarns, synthetic fiber spun yarns, synthetic-natural fiber blended spun yarns or two or more kinds of those yarns, and batts consisting of synthetic fibers and/or natural fibers and being laid over one or both sides of said found-ation fabric, wherein the component fibers are caused to be entangled with each other by needle punching.
From a different aspect, and in accordance with the invention, a method of manufacturing a needle punched paper-making felt comprises weaving a plurality of relatively easily woven endless foundation fabrics, setting up said foundation fabrics to a needle punching machine under tension, supplying and laying batts consisting of synthetic fibers and/or natural fibers over said layers of foundation fabrics while said layers of foundation fabrics are advanced, and needle punching the combined layers of said foundation fabrics and said hatts so that the component fibers are caused to be entangled with each other.
The invention will be better understood by an examination of the following description, together with the accompanying drawings, in which:
Figure 1 is a fragmentary sectional view of a con-ventional needle punched paperma~ing felt, Figure 2 is a schematic side elevation of a needle punching machine for manufacturing the needle punched felt of Figure 1, 1 ~58~3 Figure 3 is a fragmentary sectional view of a needle punched papermaking felt of the present invention, and Figure 4 is a schematic side elevation of a needle punching machine for manufacturing the needle punched felt of Figure 3.
As shown in Figure 1, the conventional papermaking felt is manufactured by weaving a foundation fabric 1 of a multiple layer construction with a special heavy loom, then laying batts 2 of staple fibers over the foundation fabric 1, and finally needle punching the hybrid layers of the foun-dation fabric 1 and the batts 2 of staple fibers to cause the component fibers to be entangled with each other. In the man-ufacturing process for the conventional felts as shown in Figure 2, an endless foundation fabric 1 of a multiple layer construction is extended between a driving roller 3 and a driven roller 4 with its upper side being set up horizontally and with its lower side being loosened. A batt of staple fibers conveyed by a lattice 5 is wound around the foundation fabric 1 by a required number of turns while the layers of batt 2 is subjected to the needle punchin~ operation of a needle board 6. Such a conventional felt, however, inevit-ably raises the manufacturing cost due to various unfavorable reasons, such as the high cost of equipments due to the nec-essity of using costly special heavy loom, and the necessity of many hours and much expenses for training operators due to requirement of advanced and skilled weaving techniques. This invention was made to overcome those disadvantages. ~ccor-ding to the present invention, relatively easily woven foundation fabrics are wov~n with an ordinary loom for weaving foundation f~bric% without using a special heavy loom, a plurality of those relatively easily woven foundation fabrics are heaped up, batts of fibers are laid over one or both sides of the foundation fabric, and then subjècted to needle punch-ing, thus providing a felt capable of a papermaking perfor-mance the same or exceeding that of the conventional felt easily and at a reduced cost, more particularly, this invention relates to a needle punched papermaking felt, comprising an endless~~foundation fabric consisting of a plurality of layers~
of relatively easily woven foundation fabrics consisting of synthetic filament yarns, synthetic fiber spun yarns, syn-thetic natural fiber blended spun yarns or two or more kindsof those yarns, and batts consisting of synthetic fibers and/or natural fibers and being laid over one or both sides of the foundatibn fabric, wherein the component fibers are caused to be entangled with each other by needle punching, and also relates to a method of manufacturing a needle punched papermaking felt, comprising weaving a plurality of relatively easily woven endless fabrics, subjecting said foundation fabrics to a needle punching machine in layers under tension, supplying and laying batts consisting of synthetic fibers and/or natural fibers over said layers of fabrics while said layers of foundation fabrics are advanced, and needle punching the combined layers of said fabrics and said batts so that the component fibers are caused to be entangled with each other.
Referring to Figure 3 illustrating a needle punched papermaking felt of the present invention, an outside found-ation fabric 7 and an inside foundation fabric 8 each woven in endless forms are laid one over the other batts 2 consisting of synthetic fibers and/or natural fibers are laid over one or both sides of the foundation fabrics. The component fibers of the warps and wefts consisting the foundation fabric and ~1~89~3 the component fibers of the batts are firmly entangled with each other to form a felt construction. This felt construc-tion is subjected to finishing processes such as a chemical treatment or singeing when necessary. In the foundation fabric as shown in Figure 3, all of the foundation fabric are of the single layer fabrics in many cases, however, some of them may be of multiple layer fabrics which can relatively easily be woven and the rest of them may be of single layer fabrics, for example, the foundation fabric may be woven with one fabric of a single layer fabric and one fabric of a double layer fabric instead of a fabric of a triple layer fabric which is used in the conventional practice. The res-pective weave constructions, component yarns, yarn densities, length ratio and width ratio of the component fabrics are selectively determined so that the properties and performance of the foundation fabric can meet the requirements of the papermaking conditions to which the foundation fabric is sub-jected, namely, the dewatering ability, pickup performance, dimensional stability, marking preventing capability, resis-tance to tension and wear resistance, and also so that thesuperposed foundation fabrics are heaped up perfectly to each other without stretching and slackening even if the contraction or elongation of the foundation fabrics are caused by the needle punching process. Generally, it is preferable to form the outside foundation fabric 7 with yarns of superior elasticity in a dense construction to provide a surface capable of preventing the marking, whereas it is preferable to form the inside foundation fabric 8 with non-compressible yarns in a relatively coarse construction to provide the inside found-ation fabric 8 with a capability of maintaining space underhigh compressive force and good dewatering ability. Synthetic 1 ~8~3 spun yarns, synthetic-natural fiber blended spun yarns, synthetic multifilament yarns or synthetic monofilament yarns are used as to component yarns of the fabrics. Single synthetic monofilament yarns or twisted synthetic monofilament yarns are preferable particularly for the needle punched felts used under high speed and high nipping pressure. These yarns are used individually or in combination of different types~
Synthetic fibers of the polyamide system, polyester system, polyacrylonitrile system, polyolefin system and polypropylene system are used. Wool is used in most cases as the material for the natural fiber, however, cotton and flax may be used.
Epoxy resin, phenol resin, melamine resin, formaldehyde resin, polyamide resin, polyvinyl resin and polyurethane resin are used for the resin treatment of the felts. Batts are formed in one bo ten layers and are needled with foundation fabrics while the layer of batts are being laid over the surface of the foundation fabric, or further are needled several re-quired times after the laying of batts has been completed to cause the component fibers to be firmly entangled with each other. A thin layer of the batt can be interposed between the adjacent component fabrics. Such provision of a thin layer of the batt contributes to enhancing the binding between the component foundation fabrics as well as increasing the elastic-ity of the felt. Synthetic fibers and natural fibers used for forming the batts are staple fibers of the same kind of the above mentioned yarns.
Needle punched papermaking felts according to the present invention are manufactured by using a needle punching machine as illustrated in Figure 4~ A plurality of foundation fabrics woven by taking into consideration the weave con-struction, component yarns, yarn density, length ratio and width ratio as described hereinbefore, are laid one over the ~ 158903 other and extended over the rollers of the needle punching machine. The layers of the foundation fabrics are tightened with a stretching roller 9 so that the outside foundation fabric 7 and the inside foundation fabric 8 are tightened and made to adhere to each other, and then turned slowly by a driving roller 3 and a driven roller 4 along the guide rollers 10. A batt of fibers is supplied continuously over the surface of the foundation fabric 7 from a feed lattice in required number of layers while the foundation fabrics 7 and 8 and the layers of the batt are subjected to needling operation of a needle board 6. After a required number of layers of the batt has been form~d over the surface of the foundation fabric 7, the batt supply is interrupted. The foundation fabrics and the layers of the batt are subjected to further needling when required. Thus the component fibers are caused to be entangled firmly with each other. When the - -felt is required to be provided with a batt on the opposite side of the foundation fabric, it is only necessary to turn inside out and to repeat the same batt supplying and needling procedure. When the felt is required to be provided with thin layers of batts between the adjacen~ foundation fabrics, the following process is put into the above mentioned process that is first a single foundation fabric is subjected to the batt supplying and needling process, then the batt supply is interrupted after a thin layer of batt has been supplied over the surface of the foundation fabric, then the first hybrid layer of said first foundation fabric and said first thin layer of batts is loosened and a second foundation fabric îs laid over the first thin layer of batt formed over the sur-face of the fir~t foundation fabric, then the foundationfabrics are tightened, and then the second thin layer of batt and needling procedure is repeated. After the needling ~ 7 -~ 15~a03 process, the felt is subjected to the conventional finishing processes, such as chemical treatment and singeing, according to the purpose.
It is obvious from what has been described herein-before that, since the foundation fabric of the needle punched papermaking felt of the present invention is formed by laying a plurality of relatively easily woven foundation fabrics one over the other, various foundation fabrics of different weave constructions, component yarns and yarn densities can be selectively combined to provide the foundation fabric with papermaking properties according to the purpose. Accordingly, the papermaking properties, such as dewatering ability, dimen-sional stability, marking preventing property and wear resis-tance, are the same with or superior to those of the convent-ional papermaking felts. Furthermore, according to the present invention, the cost of equipment is remarkably reduced, only a reduced floor space for installing the machines is necessary, and the training time is saved as the operators of ordinary skill can meet the operating requirements, since the founda-tion fabrics of the present invention can be woven with anordinary loom for weaving them without using special heavy loom which is necessary for the conventional methods and only the provision of a stretching roller for the needle punching machine is necessary. When some special heavy loom have already been installed, the weaving efficiency will be improved when those special heavy loom are used for weaving relatively easily woven foundation fabrics. Still further, even if increased installation of loom is necessary for the purpose of increasing the production, it is only necessary to install ordinary loom for papermaking felt. Thus the present invention is capable of remarkably reducing the manufacturing cost.
~ ~8903 Embodiment 1:
An outside foundation fabric was woven in an end-less form with an ordinary loom by using polyamide staple fiber/wool blended spun yarns of 5's in a construction of a warp density: 60 ends/5 cm, weft density: 54 picks/5 cm, length ratio: 103% and weave construction: 1/3 broken twill.
An inside foundation fabric was woven also in an endless form with an ordinary loom ~y using polyamide monofilament yarns of 1800 denier in a construction of a warp density: 50 ends/
5 cm, weft density: 42 picks/5 cm length ratio: 100% and plain weave construction. I`he outside foundation fabric and the inside foundation fabric were laid one over the other and extended tightly on a needle punching machine as shown in Figure 4. The foundation fabric and the layers of batts of polyamide staple fiber/wool blended fibers were subjected to needling while the batt was supplied over the surface of the foundation fabric in five layers to form a felt. The felt was subjected to five cycles of needling after the supply of the batt had been interrupted, and then the felt was sub-jected to the conventional drying process and singeing process.Thus a needle punched papermaking felt was obtained. The respective water contents of wet papers after squeezing with the needle punched felt of this embodiment and the conventional needle punched felt comprising a single sheet of double layer fabric of 1/3 broken twill weave outside and plain weave inside were 56% and 5~O~ which verified the superiority of the felt of the present invention to the conventional felt in the dewatering ability. No mark was observed over the surface of the s~ueezed paper. Furthermore the cost of equip-ment was reduced remarkably, since the installation of anyspecial heavy loom was unnecessary.
Embodiment 2:
An outside foundation fabric was woven in an end---less form with an ordinary loom by using polyamide staple fiber spun yarns of 6's in a construction of a warp density:
56 ends f 5 cm, weft density: 50 picks / 5 cm, length ratio:
101% and plain weave construction. An inside foundation fabric was woven in an endless form also with an ordinary loom by using the twisted yarns consisting of two 840 denier polyester monofilament yarns in a construction of a warp density: 48 ends/ 5 cm, weft density: 40 picks/ 5 cm, length ratio: 100% and plain weave construction. The outside found-ation fabric and the inside foundation fabric were laid one over the other and extended tightly on a needle punching machine in the manner the same with that of Embodiment 1.
The foundation fabric and the layers of batt of polyamide staple fibers were subjected to needling while the b~tt was supplied over the surface of the foundation fabric in four layers to form a felt. The felt was subjected to five cycles of needling after the supply of the batt had been interrupted.
Thus a needle punched felt was obtainedO The dimensional stability of this felt was extremely excellent, while the dewatering ability was superior. The use of an ordinary loom provided the same advantageous effect with that of Embodiment 1.
Embodiment 3:
An outside foundation fabric was woven in an end-less form with an ordinary loom by using the twisted yarns consisting of two 420 denier polyacrylonitrile multifilament yarns as warps and polyester staple fibers/wool blended spun yarns of 5's as wefts in a construction of warp density:
62 ends/5 cm, weft density: 56 picks/S cm, length ratio:
1 15~03 102% and weft backed weave construction which is a weave construction that can ~e relatively easily formed as for multiple layer fabric. An inside foundation fabric was woven by using 1800 denier polyester monofilament yarns in a con-struction of warp density: 48 ends/ 5 cm, weft density: 40 picks/5cm, length ratio: 101% and plain weave construction in ; an endless form. The outside foundation fabric and the inside foundation fabric were extended tightly on a needle punching machine in the same manner a~ described hereinbefore. The foundation fabric and the layers of batts of polyester staple fibers/wool blended fibers were subjected to needling while the batt was supplied over the surface of the foundation fabric in four layers, and then the foundation fabric was turned inside out, then subjected to needling while a layer of the batt was supplied over the inside surface of the oun-dation fabric. The outside surface and the inside surface of felt were subjected to additional two cycles of needling respectively after the supply of the batt had been interr-upted to cause the component fibers to be entangled firmly with each other. The needle punched papermaking felt was finished by melamine resin treatment. The water content of a wet paper squeezed by this felt was 55%, which was smaller by 2% as compared with that of a paper squeezed by a conven-tional papermaking felt of the same specification except that the foundation fabric of the felt was of a triple layer fabric woven with a special heavy loom. The felt of this embodiment was superior in the dewatering ability, excellent in the dimensional stability and marking preventing property. This embodiment also reduced the cost of equipment remarkably, 30 since the foundation fabric could be woven with an ordinary loom.
~ 1589~3 Embodiment 4:
An outside foundation fabric was woven in an end-less form with an existing special heavy loom by using epoxy resin treated polyamide staple fiber/polyester staple fiber blended spun yarns of 6's in a construction of warp density:
58 ends/5 cm, weft density: 54 picks/5cm, length ratio: 102%
and weft backed weave construction. An inside foundation fabric was woven in an endless form with an ordinary loom by using epoxy resin treated 1800 denier single twisted poly-amide multifilament yarns in a construction of warp density:48 ends/5 cm, weft density: 40 picks/5 cm, length ratio:
100% and plain weave construction. First the inside found-ation fabric was extended tightly on a nee~le punching machine and subjected to needling while a thin layer of a batt of polyester staple fiber/wool fibers was supplied, then loosened and the outside foundation fabric was laid over the inside foundation fabric carrying a thin layer of needle punched batt, and then the foundation fabrics were retightened.
The fabrics thus combined were subjected to needling while
It is therefore an object of the invention to , ., 11~8~3 provide an improved needle punched papermaking felt.
It is a further object of the invention to provide a method for making such a felt.
In accordance with the invention, a needle punched papermaking felt comprises a plurality of layers of relatively easily woven endless foundation fabrics consisting of syn-thetic filament yarns, synthetic fiber spun yarns, synthetic-natural fiber blended spun yarns or two or more kinds of those yarns, and batts consisting of synthetic fibers and/or natural fibers and being laid over one or both sides of said found-ation fabric, wherein the component fibers are caused to be entangled with each other by needle punching.
From a different aspect, and in accordance with the invention, a method of manufacturing a needle punched paper-making felt comprises weaving a plurality of relatively easily woven endless foundation fabrics, setting up said foundation fabrics to a needle punching machine under tension, supplying and laying batts consisting of synthetic fibers and/or natural fibers over said layers of foundation fabrics while said layers of foundation fabrics are advanced, and needle punching the combined layers of said foundation fabrics and said hatts so that the component fibers are caused to be entangled with each other.
The invention will be better understood by an examination of the following description, together with the accompanying drawings, in which:
Figure 1 is a fragmentary sectional view of a con-ventional needle punched paperma~ing felt, Figure 2 is a schematic side elevation of a needle punching machine for manufacturing the needle punched felt of Figure 1, 1 ~58~3 Figure 3 is a fragmentary sectional view of a needle punched papermaking felt of the present invention, and Figure 4 is a schematic side elevation of a needle punching machine for manufacturing the needle punched felt of Figure 3.
As shown in Figure 1, the conventional papermaking felt is manufactured by weaving a foundation fabric 1 of a multiple layer construction with a special heavy loom, then laying batts 2 of staple fibers over the foundation fabric 1, and finally needle punching the hybrid layers of the foun-dation fabric 1 and the batts 2 of staple fibers to cause the component fibers to be entangled with each other. In the man-ufacturing process for the conventional felts as shown in Figure 2, an endless foundation fabric 1 of a multiple layer construction is extended between a driving roller 3 and a driven roller 4 with its upper side being set up horizontally and with its lower side being loosened. A batt of staple fibers conveyed by a lattice 5 is wound around the foundation fabric 1 by a required number of turns while the layers of batt 2 is subjected to the needle punchin~ operation of a needle board 6. Such a conventional felt, however, inevit-ably raises the manufacturing cost due to various unfavorable reasons, such as the high cost of equipments due to the nec-essity of using costly special heavy loom, and the necessity of many hours and much expenses for training operators due to requirement of advanced and skilled weaving techniques. This invention was made to overcome those disadvantages. ~ccor-ding to the present invention, relatively easily woven foundation fabrics are wov~n with an ordinary loom for weaving foundation f~bric% without using a special heavy loom, a plurality of those relatively easily woven foundation fabrics are heaped up, batts of fibers are laid over one or both sides of the foundation fabric, and then subjècted to needle punch-ing, thus providing a felt capable of a papermaking perfor-mance the same or exceeding that of the conventional felt easily and at a reduced cost, more particularly, this invention relates to a needle punched papermaking felt, comprising an endless~~foundation fabric consisting of a plurality of layers~
of relatively easily woven foundation fabrics consisting of synthetic filament yarns, synthetic fiber spun yarns, syn-thetic natural fiber blended spun yarns or two or more kindsof those yarns, and batts consisting of synthetic fibers and/or natural fibers and being laid over one or both sides of the foundatibn fabric, wherein the component fibers are caused to be entangled with each other by needle punching, and also relates to a method of manufacturing a needle punched papermaking felt, comprising weaving a plurality of relatively easily woven endless fabrics, subjecting said foundation fabrics to a needle punching machine in layers under tension, supplying and laying batts consisting of synthetic fibers and/or natural fibers over said layers of fabrics while said layers of foundation fabrics are advanced, and needle punching the combined layers of said fabrics and said batts so that the component fibers are caused to be entangled with each other.
Referring to Figure 3 illustrating a needle punched papermaking felt of the present invention, an outside found-ation fabric 7 and an inside foundation fabric 8 each woven in endless forms are laid one over the other batts 2 consisting of synthetic fibers and/or natural fibers are laid over one or both sides of the foundation fabrics. The component fibers of the warps and wefts consisting the foundation fabric and ~1~89~3 the component fibers of the batts are firmly entangled with each other to form a felt construction. This felt construc-tion is subjected to finishing processes such as a chemical treatment or singeing when necessary. In the foundation fabric as shown in Figure 3, all of the foundation fabric are of the single layer fabrics in many cases, however, some of them may be of multiple layer fabrics which can relatively easily be woven and the rest of them may be of single layer fabrics, for example, the foundation fabric may be woven with one fabric of a single layer fabric and one fabric of a double layer fabric instead of a fabric of a triple layer fabric which is used in the conventional practice. The res-pective weave constructions, component yarns, yarn densities, length ratio and width ratio of the component fabrics are selectively determined so that the properties and performance of the foundation fabric can meet the requirements of the papermaking conditions to which the foundation fabric is sub-jected, namely, the dewatering ability, pickup performance, dimensional stability, marking preventing capability, resis-tance to tension and wear resistance, and also so that thesuperposed foundation fabrics are heaped up perfectly to each other without stretching and slackening even if the contraction or elongation of the foundation fabrics are caused by the needle punching process. Generally, it is preferable to form the outside foundation fabric 7 with yarns of superior elasticity in a dense construction to provide a surface capable of preventing the marking, whereas it is preferable to form the inside foundation fabric 8 with non-compressible yarns in a relatively coarse construction to provide the inside found-ation fabric 8 with a capability of maintaining space underhigh compressive force and good dewatering ability. Synthetic 1 ~8~3 spun yarns, synthetic-natural fiber blended spun yarns, synthetic multifilament yarns or synthetic monofilament yarns are used as to component yarns of the fabrics. Single synthetic monofilament yarns or twisted synthetic monofilament yarns are preferable particularly for the needle punched felts used under high speed and high nipping pressure. These yarns are used individually or in combination of different types~
Synthetic fibers of the polyamide system, polyester system, polyacrylonitrile system, polyolefin system and polypropylene system are used. Wool is used in most cases as the material for the natural fiber, however, cotton and flax may be used.
Epoxy resin, phenol resin, melamine resin, formaldehyde resin, polyamide resin, polyvinyl resin and polyurethane resin are used for the resin treatment of the felts. Batts are formed in one bo ten layers and are needled with foundation fabrics while the layer of batts are being laid over the surface of the foundation fabric, or further are needled several re-quired times after the laying of batts has been completed to cause the component fibers to be firmly entangled with each other. A thin layer of the batt can be interposed between the adjacent component fabrics. Such provision of a thin layer of the batt contributes to enhancing the binding between the component foundation fabrics as well as increasing the elastic-ity of the felt. Synthetic fibers and natural fibers used for forming the batts are staple fibers of the same kind of the above mentioned yarns.
Needle punched papermaking felts according to the present invention are manufactured by using a needle punching machine as illustrated in Figure 4~ A plurality of foundation fabrics woven by taking into consideration the weave con-struction, component yarns, yarn density, length ratio and width ratio as described hereinbefore, are laid one over the ~ 158903 other and extended over the rollers of the needle punching machine. The layers of the foundation fabrics are tightened with a stretching roller 9 so that the outside foundation fabric 7 and the inside foundation fabric 8 are tightened and made to adhere to each other, and then turned slowly by a driving roller 3 and a driven roller 4 along the guide rollers 10. A batt of fibers is supplied continuously over the surface of the foundation fabric 7 from a feed lattice in required number of layers while the foundation fabrics 7 and 8 and the layers of the batt are subjected to needling operation of a needle board 6. After a required number of layers of the batt has been form~d over the surface of the foundation fabric 7, the batt supply is interrupted. The foundation fabrics and the layers of the batt are subjected to further needling when required. Thus the component fibers are caused to be entangled firmly with each other. When the - -felt is required to be provided with a batt on the opposite side of the foundation fabric, it is only necessary to turn inside out and to repeat the same batt supplying and needling procedure. When the felt is required to be provided with thin layers of batts between the adjacen~ foundation fabrics, the following process is put into the above mentioned process that is first a single foundation fabric is subjected to the batt supplying and needling process, then the batt supply is interrupted after a thin layer of batt has been supplied over the surface of the foundation fabric, then the first hybrid layer of said first foundation fabric and said first thin layer of batts is loosened and a second foundation fabric îs laid over the first thin layer of batt formed over the sur-face of the fir~t foundation fabric, then the foundationfabrics are tightened, and then the second thin layer of batt and needling procedure is repeated. After the needling ~ 7 -~ 15~a03 process, the felt is subjected to the conventional finishing processes, such as chemical treatment and singeing, according to the purpose.
It is obvious from what has been described herein-before that, since the foundation fabric of the needle punched papermaking felt of the present invention is formed by laying a plurality of relatively easily woven foundation fabrics one over the other, various foundation fabrics of different weave constructions, component yarns and yarn densities can be selectively combined to provide the foundation fabric with papermaking properties according to the purpose. Accordingly, the papermaking properties, such as dewatering ability, dimen-sional stability, marking preventing property and wear resis-tance, are the same with or superior to those of the convent-ional papermaking felts. Furthermore, according to the present invention, the cost of equipment is remarkably reduced, only a reduced floor space for installing the machines is necessary, and the training time is saved as the operators of ordinary skill can meet the operating requirements, since the founda-tion fabrics of the present invention can be woven with anordinary loom for weaving them without using special heavy loom which is necessary for the conventional methods and only the provision of a stretching roller for the needle punching machine is necessary. When some special heavy loom have already been installed, the weaving efficiency will be improved when those special heavy loom are used for weaving relatively easily woven foundation fabrics. Still further, even if increased installation of loom is necessary for the purpose of increasing the production, it is only necessary to install ordinary loom for papermaking felt. Thus the present invention is capable of remarkably reducing the manufacturing cost.
~ ~8903 Embodiment 1:
An outside foundation fabric was woven in an end-less form with an ordinary loom by using polyamide staple fiber/wool blended spun yarns of 5's in a construction of a warp density: 60 ends/5 cm, weft density: 54 picks/5 cm, length ratio: 103% and weave construction: 1/3 broken twill.
An inside foundation fabric was woven also in an endless form with an ordinary loom ~y using polyamide monofilament yarns of 1800 denier in a construction of a warp density: 50 ends/
5 cm, weft density: 42 picks/5 cm length ratio: 100% and plain weave construction. I`he outside foundation fabric and the inside foundation fabric were laid one over the other and extended tightly on a needle punching machine as shown in Figure 4. The foundation fabric and the layers of batts of polyamide staple fiber/wool blended fibers were subjected to needling while the batt was supplied over the surface of the foundation fabric in five layers to form a felt. The felt was subjected to five cycles of needling after the supply of the batt had been interrupted, and then the felt was sub-jected to the conventional drying process and singeing process.Thus a needle punched papermaking felt was obtained. The respective water contents of wet papers after squeezing with the needle punched felt of this embodiment and the conventional needle punched felt comprising a single sheet of double layer fabric of 1/3 broken twill weave outside and plain weave inside were 56% and 5~O~ which verified the superiority of the felt of the present invention to the conventional felt in the dewatering ability. No mark was observed over the surface of the s~ueezed paper. Furthermore the cost of equip-ment was reduced remarkably, since the installation of anyspecial heavy loom was unnecessary.
Embodiment 2:
An outside foundation fabric was woven in an end---less form with an ordinary loom by using polyamide staple fiber spun yarns of 6's in a construction of a warp density:
56 ends f 5 cm, weft density: 50 picks / 5 cm, length ratio:
101% and plain weave construction. An inside foundation fabric was woven in an endless form also with an ordinary loom by using the twisted yarns consisting of two 840 denier polyester monofilament yarns in a construction of a warp density: 48 ends/ 5 cm, weft density: 40 picks/ 5 cm, length ratio: 100% and plain weave construction. The outside found-ation fabric and the inside foundation fabric were laid one over the other and extended tightly on a needle punching machine in the manner the same with that of Embodiment 1.
The foundation fabric and the layers of batt of polyamide staple fibers were subjected to needling while the b~tt was supplied over the surface of the foundation fabric in four layers to form a felt. The felt was subjected to five cycles of needling after the supply of the batt had been interrupted.
Thus a needle punched felt was obtainedO The dimensional stability of this felt was extremely excellent, while the dewatering ability was superior. The use of an ordinary loom provided the same advantageous effect with that of Embodiment 1.
Embodiment 3:
An outside foundation fabric was woven in an end-less form with an ordinary loom by using the twisted yarns consisting of two 420 denier polyacrylonitrile multifilament yarns as warps and polyester staple fibers/wool blended spun yarns of 5's as wefts in a construction of warp density:
62 ends/5 cm, weft density: 56 picks/S cm, length ratio:
1 15~03 102% and weft backed weave construction which is a weave construction that can ~e relatively easily formed as for multiple layer fabric. An inside foundation fabric was woven by using 1800 denier polyester monofilament yarns in a con-struction of warp density: 48 ends/ 5 cm, weft density: 40 picks/5cm, length ratio: 101% and plain weave construction in ; an endless form. The outside foundation fabric and the inside foundation fabric were extended tightly on a needle punching machine in the same manner a~ described hereinbefore. The foundation fabric and the layers of batts of polyester staple fibers/wool blended fibers were subjected to needling while the batt was supplied over the surface of the foundation fabric in four layers, and then the foundation fabric was turned inside out, then subjected to needling while a layer of the batt was supplied over the inside surface of the oun-dation fabric. The outside surface and the inside surface of felt were subjected to additional two cycles of needling respectively after the supply of the batt had been interr-upted to cause the component fibers to be entangled firmly with each other. The needle punched papermaking felt was finished by melamine resin treatment. The water content of a wet paper squeezed by this felt was 55%, which was smaller by 2% as compared with that of a paper squeezed by a conven-tional papermaking felt of the same specification except that the foundation fabric of the felt was of a triple layer fabric woven with a special heavy loom. The felt of this embodiment was superior in the dewatering ability, excellent in the dimensional stability and marking preventing property. This embodiment also reduced the cost of equipment remarkably, 30 since the foundation fabric could be woven with an ordinary loom.
~ 1589~3 Embodiment 4:
An outside foundation fabric was woven in an end-less form with an existing special heavy loom by using epoxy resin treated polyamide staple fiber/polyester staple fiber blended spun yarns of 6's in a construction of warp density:
58 ends/5 cm, weft density: 54 picks/5cm, length ratio: 102%
and weft backed weave construction. An inside foundation fabric was woven in an endless form with an ordinary loom by using epoxy resin treated 1800 denier single twisted poly-amide multifilament yarns in a construction of warp density:48 ends/5 cm, weft density: 40 picks/5 cm, length ratio:
100% and plain weave construction. First the inside found-ation fabric was extended tightly on a nee~le punching machine and subjected to needling while a thin layer of a batt of polyester staple fiber/wool fibers was supplied, then loosened and the outside foundation fabric was laid over the inside foundation fabric carrying a thin layer of needle punched batt, and then the foundation fabrics were retightened.
The fabrics thus combined were subjected to needling while
2~ ~our layers of the batts were being formed over the surface of the outside foundation fabric~ The combined fabrics were subjected to three cycles of needling after the supply of the batt had been interrupted to finish the papermaking felt.
The component fabrics of the felt were made to adhere firmly to each other. The felt of this embodiment had an elasticity greater ~han that of the conventional felts, good dimensional stability, whereas the dewatering ability of this felt was approximately the same degree with that of the conventional felts.
The component fabrics of the felt were made to adhere firmly to each other. The felt of this embodiment had an elasticity greater ~han that of the conventional felts, good dimensional stability, whereas the dewatering ability of this felt was approximately the same degree with that of the conventional felts.
Claims (6)
1. A needle punched papermaking felt, comprising a plurality of layers of relatively easily woven endless foundation fabrics, including at least an inside foundation fabric and an outside foundation fabric, said fabrics con-sisting of synthetic filament yarns, synthetic fiber spun yarns, synthetic-natural fiber blended spun yarns or two or more kinds of those yarns, said yarns forming warps and wefts, the wefts being as thick or thicker than said warps, and batts consisting of synthetic fibers and/or natural fibers and being laid over one or both sides of said founda-tion fabric, wherein the component fibers are caused to be entangled with each other by needle punching.
2. A needle punched papermaking felt as set forth in claim 1, wherein all of said foundation fabrics are single layer fabrics.
3. A needle punched papermaking felt as set forth in claim 1, wherein some of said foundation fabrics are relative-ly easily woven multiple layer fabrics and the rest of them are single layer fabrics.
4. A needle punched papermaking felt as set forth in any one of claims l to 3, wherein thin layers of batts con-sisting of synthetic fibers and/or natural fibers are inter-posed between said layers of said relatively easily woven foundation fabrics.
5. Method of manufacturing a needle punched paper-making felt, comprising weaving a plurality of relatively easily woven endless foundation fabrics, setting up said foundation fabrics to a needle punching machine under tension, supplying and laying batts consisting of synthetic fibers and/or natural fibers over said layers of foundation fabrics while said layers of foundation fabrics are advanced, and needle punching the combined layers of said foundation fabrics and said batts so that the component fibers are caused to be entangled with each other.
6. Method of manufacturing a needle punched paper-making felt as set forth in claim 5, wherein said method is adapted to interpose thin layers of batts consisting of synthetic fibers and/or natural fibers between the adjacent relatively easily woven endless foundation fabrics, and comprises needle punching a first hybrid layer of the first one of said foundation fabric and a first thin layer of said batts while said batts are delivered over the surface of said first foundation fabric, interrupting the delivery of said batts, laying the second one of said foundation fabric over said first hybrid layer of said first foundation fabric and said first thin layer of batts, needle punching the second hybrid of said first hybrid layer, said second foundation fabric and a second thin layer of said batts while said second layer of batts is delivered over the surface of said second foundation fabric, and repeating said procedure.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP56010864A JPS57128290A (en) | 1981-01-29 | 1981-01-29 | Needle felt for papermaking and method |
| JP10864/1981 | 1981-01-29 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1158903A true CA1158903A (en) | 1983-12-20 |
Family
ID=11762213
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000393805A Expired CA1158903A (en) | 1981-01-29 | 1982-01-08 | Needle punched papermaking felt and method of manufacturing the same |
Country Status (8)
| Country | Link |
|---|---|
| JP (1) | JPS57128290A (en) |
| KR (1) | KR850001411B1 (en) |
| AU (1) | AU551082B2 (en) |
| CA (1) | CA1158903A (en) |
| DE (1) | DE3200030A1 (en) |
| FI (1) | FI820193L (en) |
| FR (1) | FR2498652B1 (en) |
| SE (1) | SE448244B (en) |
Families Citing this family (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DD230570A3 (en) * | 1982-09-24 | 1985-12-04 | Forster Tuchfabriken Veb | TEXTILE FLAKE WITH SPECIFIC SURFACE EFFECTS |
| DD225600A3 (en) * | 1982-09-24 | 1985-07-31 | Forster Tuchfabriken Veb | METHOD FOR REMOVING VISIBLE ERRORS IN TEXTILE FLUID SURFACES |
| DD230573A3 (en) * | 1982-09-24 | 1985-12-04 | Forster Tuchfabriken Veb | METHOD FOR CONVERTING TEXTILE FLUID IMAGES |
| US5005610A (en) * | 1989-01-03 | 1991-04-09 | Albany International Corporation | Papermaking fabric pin seam with braided yarns in joining loops |
| US5204150A (en) * | 1989-08-17 | 1993-04-20 | Albany International Corp. | Loop formation in on-machine-seamed press fabrics using yarns comprising mxd6 polyamide resin material |
| JP4355524B2 (en) | 2003-06-30 | 2009-11-04 | イチカワ株式会社 | Felt for papermaking |
| DE102011009227A1 (en) * | 2011-01-22 | 2012-07-26 | Trützschler Nonwovens Gmbh | Apparatus for producing a nonwoven fabric composite |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| USRE21890E (en) * | 1941-08-26 | Industrial and papermakers felts | ||
| GB902503A (en) * | 1960-04-01 | 1962-08-01 | Thomas Hardman & Sons Ltd | Improvements in the manufacture of felts for use in the manufacture of paper and other products |
| GB1236780A (en) * | 1967-11-06 | 1971-06-23 | Huyck Corp | Improvements in papermaking apparatus |
| DD96997A1 (en) * | 1971-11-16 | 1973-04-12 | ||
| DE2437303A1 (en) * | 1974-08-02 | 1976-02-12 | Marx Gmbh J J | Paper making wet felt - made of several superposed woven mesh fabrics coated with matted fibre layers |
| US4283454A (en) * | 1980-02-08 | 1981-08-11 | Porritts & Spencer Inc. | Papermakers wet felt with ribbed and smooth surface textures |
-
1981
- 1981-01-29 JP JP56010864A patent/JPS57128290A/en active Pending
- 1981-12-22 SE SE8107729A patent/SE448244B/en unknown
-
1982
- 1982-01-04 DE DE19823200030 patent/DE3200030A1/en not_active Ceased
- 1982-01-06 AU AU79234/82A patent/AU551082B2/en not_active Expired
- 1982-01-08 CA CA000393805A patent/CA1158903A/en not_active Expired
- 1982-01-19 KR KR8200197A patent/KR850001411B1/en active
- 1982-01-19 FR FR8200733A patent/FR2498652B1/en not_active Expired
- 1982-01-22 FI FI820193A patent/FI820193L/en not_active Application Discontinuation
Also Published As
| Publication number | Publication date |
|---|---|
| SE8107729L (en) | 1982-07-30 |
| KR850001411B1 (en) | 1985-09-30 |
| AU551082B2 (en) | 1986-04-17 |
| KR830009314A (en) | 1983-12-19 |
| FR2498652B1 (en) | 1986-10-10 |
| AU7923482A (en) | 1982-08-05 |
| JPS57128290A (en) | 1982-08-09 |
| DE3200030A1 (en) | 1982-08-26 |
| FI820193L (en) | 1982-07-30 |
| FR2498652A1 (en) | 1982-07-30 |
| SE448244B (en) | 1987-02-02 |
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| Date | Code | Title | Description |
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| MKEX | Expiry |