CN110709547A

CN110709547A - Stack warp dry fabric with long floating warps and high stability

Info

Publication number: CN110709547A
Application number: CN201880035806.0A
Authority: CN
Inventors: 马克·P·蒂斯保特
Original assignee: AstenJohnson Inc
Current assignee: AstenJohnson Inc
Priority date: 2017-05-30
Filing date: 2018-05-11
Publication date: 2020-01-17
Also published as: US20180347114A1; EP3631064A4; WO2018222370A3; EP3631064A2; EP3631064B1; WO2018222370A2

Abstract

An industrial textile, preferably suitable for use as a dryer fabric in a papermaking machine, is provided. The industrial textile has a first surface and a second surface and is defined by a first warp system and a second warp system interwoven with a weft system in a repeating pattern. In the repeat pattern, each warp yarn of the plurality of warp yarns in the first warp yarn system is interwoven with the weft yarn system over at least 5 weft yarns of the plurality of weft yarns, under 1 weft yarn of the plurality of weft yarns, over 1 weft yarn of the plurality of weft yarns, and under 1 weft yarn of the plurality of weft yarns on the first surface with an embossment. Further, each warp yarn of the plurality of warp yarns in the second warp yarn system is interwoven with the weft yarn system over the second surface in a repeating pattern below at least 5 weft yarns of the plurality of weft yarns, above 1 weft yarn of the plurality of weft yarns, below 1 weft yarn of the plurality of weft yarns, and above 1 weft yarn of the plurality of weft yarns to have an embossment. Each warp yarn of the plurality of warp yarns in the first warp yarn system is stacked on a corresponding warp yarn of the plurality of warp yarns in the second warp yarn system to form a stacked pair of the plurality of warp yarns.

Description

Stack warp dry fabric with long floating warps and high stability

Is incorporated by reference

The following documents are incorporated by reference as if fully set forth:

us provisional patent application No. 62/512,327 filed on 30/5/2017.

Background

The present invention relates to industrial textiles, and more particularly to papermaking fabrics.

A number of weaves are known in the art that are used to achieve different results for different applications.

WO 2011/022831, assigned to the assignee of the present invention, discloses a dryer fabric for a paper machine having stacked warp yarns with a warp fill of about 193%, woven with filling weft yarns (filler yarns) and critical weft yarns (critical pick).

US 9,365,958 relates to a stretchable fabric for clothing which is a single layer woven with long floats and is independent of the paper making or industrial conveying fabric used in the paper making or filtering operation. Accordingly, there is no need or need to be concerned with increasing the life of industrial and especially papermaking fabrics by providing a machine side surface dominated by long Machine Direction (MD) floats to increase wear resistance.

Disclosure of Invention

The present invention relates to an industrial textile, preferably suitable for use as a dryer fabric in a paper machine. The industrial textile has a first surface and a second surface and is defined by a first warp system and a second warp system interwoven with a weft system in a repeating pattern. In the repeat pattern, each warp yarn of the plurality of warp yarns in the first warp yarn system interweaves with the weft yarn system on the first surface over at least 5 weft yarns of the plurality of weft yarns, under 1 weft yarn of the plurality of weft yarns, over 1 weft yarn of the plurality of weft yarns, and under 1 weft yarn of the plurality of weft yarns to form embossments on the first surface over the at least 5 weft yarns of the plurality of weft yarns. Further, each warp yarn of the plurality of warp yarns in the second warp yarn system interweaves with the weft yarn system over the second surface in a repeating pattern under at least 5 of the plurality of weft yarns, over 1 of the plurality of weft yarns, under 1 of the plurality of weft yarns, and over 1 of the plurality of weft yarns to form embossments over the second surface under the at least 5 of the plurality of weft yarns. Each warp yarn of the plurality of warp yarns in the first warp yarn system is stacked on a corresponding warp yarn of the plurality of warp yarns in the second warp yarn system to form a stacked pair of the plurality of warp yarns.

In one embodiment, the embossments on the first surface are above 7 weft yarns and the embossments on the second surface are below 7 weft yarns.

Preferably, the weft yarn system comprises alternating larger diameter stuffer wefts and smaller diameter critical wefts.

In one preferred arrangement, the warp yarns of the first warp system weave only under the critical weft yarns and the warp yarns of the second warp system weave only over the critical weft yarns.

Preferably, the repeating pattern of warp yarns of the first warp system below one of the plurality of weft yarns, above one of the plurality of weft yarns and below one of the plurality of weft yarns forms a lock weave for maintaining the position of the warp yarns of the first warp system, and the repeating pattern of warp yarns of the second warp system above one of the plurality of weft yarns, below one of the plurality of weft yarns and above one of the plurality of weft yarns forms a lock weave for maintaining the position of the warp yarns of the second warp system. In certain preferred arrangements of the packing fabric, this allows for the spacing of stacked pairs of a plurality of warp yarns to form an open mesh pattern, while still maintaining high stability for the industrial textile. In a preferred arrangement, the stacked pair of plurality of warp yarns is separated by at least 40% of the transverse dimension of one of the plurality of warp yarns.

In one preferred arrangement, the embossments on the first surface are arranged with diagonal twill.

In one embodiment, the first warp system is made of a different material than the second warp system.

In several preferred arrangements, the warp yarns of the first warp system and the second warp system have a rectangular cross-section. Preferably, the cross-sections of the warp yarns of the first warp system and the second warp system are the same. Preferably, the weft yarns have a circular cross-section. However, this may vary. The warp and/or weft yarns may be grooved (grooved) and/or profiled (profiled) in the manner described in US 6,773,786 to help impart stain resistance to the fabric.

For preferred applications, the first warp system and the second warp system each have at least about 96% warp fill. This is particularly useful for paper machine dryer fabrics.

In one arrangement where the floats in the first and second warp systems are above 5 of the plurality of weft yarns on the top surface and below 5 of the plurality of weft yarns on the bottom surface, the industrial textile is woven in an 8-shed, 10-fly (step) mode. Depending on the length of the warp floats, it may be desirable to increase the number of flights required to weave industrial textiles.

As noted above, the industrial textiles of the present invention have preferred applications, such as papermaking fabrics. The industrial textile is preferably flat woven and the ends are joined to form an endless belt, which can then be used in papermaking applications on a papermaking machine. One preferred application is dryer fabrics for papermaking fabrics.

The resulting construction is a strong, durable, and abrasion resistant industrial textile that resists warp bunching and tipping, and is highly stable (meaning that it resists out-of-plane deformation, in part, due to its diagonal stability). By appropriate selection of the warp and weft yarn types, sizes and shapes, the fabric can be adapted for a wide range of applications. For example, the air permeability of the fabric can be easily adjusted as desired; by proper selection of the warp yarn materials and dimensions, the fabric can be made to resist high temperature or contamination. In addition, the fabric provides high seam strength due to the stacked warp yarn configuration, which preferably utilizes about 100% warp yarns to form the seam and also provides about 200% warp fill to the fabric. The term "warp fill" refers to: the number of warp yarns in a given space relative to the total space considered. When there are more warp yarn bundles stuck in the available space, the warp filling may exceed 100% of the space that can be accommodated in a single plane in size. A fabric having a warp fill of about 200% or more may have two layers of warp yarns, each layer woven with at least about 100% warp fill. In this case, those skilled in the art will appreciate that 190% to 210% is considered to be about 200% warp fill. The fabric may be highly stable and wrinkle and deformation resistant when the warp yarns in each layer are woven with 100% or more warp fill and thus are in close proximity to each other and support each other. This in combination with the lock-weaving of the warp yarns provides higher stability and increased life span due to the long warp floats. The weave pattern of the novel fabric provides long floats of warp yarns on both outer surfaces, enhancing the ability of these fabrics to resist abrasion.

By proper warp and weft yarn selection, which will allow the fabric to achieve a wide range of air permeability, the fabric design can be tailored for a variety of different applications. Although the fabric caliper (thickness) can be reduced to allow use in high speed applications, the stability of the textile can be maintained as the weft yarns are provided with warp yarn support and lock-weaving. The two separate warp systems provide the additional benefit that the materials used in each warp system can be optimized to resist the environmental effects to which each fabric surface is exposed. For example, the monofilament warp yarns used to form the first fabric surface may be composed of PPS (polyphenylene sulfide) or PCTA (polycyclohexanedimethanol terephthalate) polymers, which are more resistant to heat and hydrolytic degradation (and more expensive) than PET (polyethylene terephthalate) yarns. Warp yarns formed from PET polymers can be used on the paper side of textiles (in papermaking applications), where heat resistance as well as hydrolysis resistance are less critical properties.

Fabrics according to the present invention, such as those shown in the figures, are woven using polymeric monofilament warp yarns of rectangular cross-section having dimensions of 0.25x1.05mm or 0.36x 1.07mm to achieve an aspect ratio of between 4:1 and 3:1, but other cross-sectional shapes and ratios may be used. The weft yarns used in these fabrics have a generally circular cross-sectional shape and range in size from about 0.50mm to 1.0 mm; although other dimensions may be used depending on the particular application.

Brief description of the drawings

The foregoing summary, as well as the following detailed description of preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings, which illustrate preferred embodiments of the invention. In the drawings:

fig. 1 is a weave diagram showing a first embodiment of an industrial textile having the present configuration.

FIG. 2 is a cross-sectional view illustrating a weave pattern of two of the stacked warp yarns in the fabric construction shown in FIG. 1.

Fig. 3 is a top view of a second embodiment of an industrial textile constructed in accordance with the present invention.

Figure 4 is a cross-sectional view showing the weave path of the two pairs of stacked warp yarns shown in figure 3.

Fig. 5 is a top plan view of a third embodiment of an industrial textile constructed in accordance with the invention.

Figure 6 is a cross-sectional view showing the weave path of two pairs of the stacked warp yarns shown in figure 5.

Fig. 7 is a weave diagram illustrating a fourth embodiment of an industrial textile having a construction of the present invention.

FIG. 8 is a cross-sectional view illustrating a weave pattern of two of the stacked warp yarns in the fabric construction shown in FIG. 7.

Fig. 9 is a weave diagram of a fifth embodiment of an industrial textile having a high stability construction.

Detailed Description

Certain terminology is used in the following description for convenience only and is not limiting. The fabric according to the invention is an industrial textile which may have many industrial applications, such as conveyor belts, filter fabrics, specialty fabrics for non-woven applications, and the like. The terms "paper side" (PS) and "machine side" (MS) refer to the surface of the fabric in relation to its use in one preferred application on a papermaking machine; however, these terms only refer to a first surface and a second surface or an upper surface and a lower surface of a flat textile. "yarn" is commonly used to identify monofilament or multifilament fibers. Depending on whether the fabric is flat woven or continuous woven, the "warp" and "weft" yarns are used to designate the yarns or monofilaments in the loom based on the position of the yarns or monofilaments in the fabric that extend in the vertical direction, and which may be Machine Direction (MD) or cross-machine direction (CMD), in the fabric, once installed on the paper machine. In a preferred arrangement, the fabric is warp flat-woven and joined at the ends of the warp yarns to form a continuous belt, such that the warp yarns are MD yarns and the weft yarns are CMD yarns.

One preferred application of the fabric according to the invention is on a paper machine, and the fabric may be applied as a base for a press fabric or dryer fabric used in the respective press and dryer sections of a paper machine. Regardless of the location of use in a papermaking machine, these are commonly referred to as "papermaking fabrics". Other applications include filter fabrics and other non-woven applications.

Referring to fig. 1 and 2, a first preferred embodiment industrial textile 20 constructed in accordance with the present invention is shown using a weave pattern (fig. 1) and cross-sections taken in the MD. Industrial textile 20 includes a first surface 24 and a second surface 26. In one preferred construction as a papermaker's fabric, the first surface 24 corresponds to the PS and the second surface 26 corresponds to the MS.

Industrial textile 20 is woven with a first warp system 21 and a second warp system 22 that are interwoven with weft system 30 in a repeating pattern. The warp yarns are identified as warp yarns 1-16, the first set of warp yarns comprises even numbered warp yarns, i.e. 2, 4, 6, 8, 10, 12, 14, 16, and the second set of warp yarns comprises odd numbered warp yarns, i.e. 1, 3, 5, 7, 9, 11, 13, 15. Weft yarns 31-40 are interwoven with warp yarns 1-16, wherein there are preferably alternating larger diameter

stuffer weft yarns

31, 33, 35, 37, 39 and smaller diameter

critical weft yarns

32, 34, 36, 38, 40. Each of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in the first warp system 21 is interwoven with the weft system 30 with an embossment over at least 5 of the weft yarns 31-40 on the first surface 24. In the first embodiment of industrial textile 20, the float of each of warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in first warp system 21 is over 7 of weft yarns 31-40. This is illustrated in connection with warp yarn 2 in figure 2 and is true for each of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in the first warp system 21. To form a lock weave, each of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first warp system 21 then extends in a repeating pattern under one of the

weft yarns

32, 34, 36, 38, 40, over one of the

weft yarns

31, 33, 35, 37, 39, and under another one of the

weft yarns

32, 34, 36, 38, 40. Preferably, the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first warp system 21 only weave under the

critical weft yarns

32, 34, 36, 38, 40. Preferably, first warp system 21 and second warp system 22 are woven in 8-shed in 10-fly.

Each of the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 in the second warp system 22 is interwoven with the weft system 30 with an embossment on the second surface 26 under at least five of the weft yarns 31-40. In the first embodiment 20, the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 in the second warp system 22 are preferably interwoven with the weft system 30 with embossments on the second surface under at least 7 of the weft yarns 31-40. To form a lock weave, warp yarns 1, 3, 5, 7, 9, 11, 13, 15 of the second warp system 22 are then woven in a repeating pattern over one of

weft yarns

32, 34, 36, 38, 40, under one of

weft yarns

31, 33, 35, 37, 39, and over one of

weft yarns

32, 34, 36, 38, 40. As shown, each of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in the first warp system 21 is stacked on a corresponding warp yarn of warp yarns 1, 3, 5, 7, 9, 11, 13, 15 in the second warp system 22 to form stacked pairs of warp yarns. As shown in fig. 2, warp yarn 2 is stacked over warp yarn 1. With regard to the weaving pattern shown in fig. 1, the even-numbered warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in the first warp system 21 are stacked over corresponding ones of the odd-numbered warp yarns 1, 3, 5, 7, 9, 11, 13, 15 in the second warp system 22. The warp yarns 1, 3, 5, 7, 9, 11, 13, 15 of the second warp system 22 only weave under a

critical weft yarn

32, 34, 36, 38, 40 having a smaller diameter D2 than a

stuffer weft yarn

31, 33, 35, 37 having a larger diameter D1. The repeating pattern of warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first warp system 21, i.e. below one of the weft yarns, above one of the weft yarns and below one of the weft yarns, forms a lock weave to maintain the position of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first warp system 21 in place within the industrial textile. The repeating pattern of warp yarns 1, 3, 5, 7, 9, 11, 13, 15 of the second warp system 22, i.e. above one of the weft yarns, below one of the weft yarns and above one of the weft yarns, also forms a lock weave to keep the position of warp yarns 1, 3, 5, 7, 9, 11, 13, 15 of the second warp system 22 in place.

In a preferred arrangement of industrial textile 20, each of first warp system 21 and second warp system 22 is provided with a 100% warp fill, which together with the lock weave provides an extremely stable fabric 20.

In a preferred arrangement, warp yarns 1-16 preferably have a rectangular cross-sectional shape, which contributes to the stability of fabric 20 and its smoothness. Warp yarns 1-16 are preferably monofilaments formed of a polymeric material. In one embodiment, the dimensions are 0.25 × 1.05mm or 0.36 × 1.07mm to obtain an aspect ratio between 4:1 and 3: 1. One skilled in the art will recognize that other cross-sectional shapes and ratios may also be used, such as elliptical or flat shapes with rounded sides, and aspect ratios of 2:1 to 6: 1. The weft yarns 31-40 preferably have a circular cross-sectional shape, which in some preferred arrangements may range in size from 0.6mm, 0.7mm, 0.8mm or 0.9 mm. Other dimensions may also be used depending on the intended application of the fabric. In one preferred arrangement, the fabric 20 is woven with 22 picks per inch (picks per inch) (8.7 yarns/cm).

The use of first warp system 21 and second warp system 22 also allows different materials to be used for first warp system 21 and second warp system 22 in order to provide the best materials on first surface 24 and second surface 26 of industrial textile 20 for a preferred application.

For example, the monofilament warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first warp yarn system 21 used to form the first surface 24 may be constructed of PPS (polyphenylene sulfide) or PCTA (polycyclohexanedimethanol terephthalate) polymers that are more resistant to thermal and hydrolytic degradation (and more expensive) than PET (polyethylene terephthalate) yarns. Since (at least in papermaking applications) the PS of the textile is a yarn property where heat resistance and hydrolysis resistance are less critical, the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 of the second warp system may be formed of a PET polymer. Those skilled in the art will appreciate from this disclosure that these materials are merely exemplary, and that other materials may be used depending on the particular application. These warp yarns 1-16 may be grooved, profiled, coated or otherwise treated to resist contamination.

Furthermore, due to the long warp floats, a higher contact area can be achieved that reduces the wear rate of the fabric compared to a similar fabric with more defined weave points (knuckle) due to weaving. Long warp floats also provide an anti-contamination benefit compared to similar weft-blown fabrics (wet spun fabrics).

Preferably, industrial textile 20 is formed into continuous loops (continuous loops) for use as a papermaker's fabric, and more particularly, as a papermaker's dryer fabric for use in a paper machine. To form the loops, a seam is formed at the ends of the warp yarns 1-16. Preferably, the seam uses 100% of the warp yarns to form the seam. The seam may be formed in a known manner by back weaving (unweaving) and back weaving (back-weaving) the plurality of warp yarns from the first warp system 21 back into the fabric along the path of respective stacked warp yarns of the plurality of warp yarns from the second warp system 22, which has been cut from the ends of the fabric to form seaming loops at each end of the flat fabric, and then interdigitated and joined by a pintle (pintle) to form the endless fabric loop. Other types of joints may also be utilized, such as the QuickLink seam developed by AstenJohnson, the assignee of the present invention. In a preferred arrangement for papermaking, the warp fill is preferably about 200% warp fill, with each layer having warp yarns woven at about 100% warp fill. This contributes to the stability of industrial textile 20 and to resistance to wrinkling and deformation due to the fact that warp yarns 1-16 in each layer are woven with approximately 100% warp fill and are therefore in close proximity and support to each other. This combined lock-weaving provides industrial textile 20 with enhanced fabric stability.

Referring to fig. 3 and 4, a second embodiment of an industrial textile 120 is shown. Industrial textile 120 is similar to industrial textile 20 and includes a first warp system 121 and a second warp system 122 interwoven with a weft system 130. The arrangement is similar to the industrial textile 20 except that the floats in the first warp system 121 are above five of the weft yarns 131-138 and the floats in the second warp system 122 are below five of the weft yarns 131-138. As shown,

warp yarns

102, 104 of first warp system 121 are woven in stacked pairs over

warp yarns

101, 103 of second warp system 122. Warp yarn 102 weaves over weft yarns 131-135, under weft yarn 136, over weft yarn 137, and under weft yarn 138. As in the first embodiment,

weft yarns

132, 134, 136, 138 are critical weft yarns having a smaller diameter than

stuffer weft yarns

131, 133, 135, 137. Warp yarn 101 of second warp yarn system 122, which is stacked below warp yarn 102, weaves under shute yarn 131, over shute yarn 132, under shute yarn 133, over shute yarn 134, and then under shute yarns 135-138. The next stacked pair of

warp yarns

104, 103 is woven with warp yarn 104 extending over weft yarn 131, under weft yarn 132, over weft yarn 133, under weft yarn 134, and over weft yarns 135-138. Warp yarn 103, which is stacked below warp yarn 104, weaves under shute yarns 131-135, over shute yarn 136, under shute yarn 137, and over shute yarn 138. As shown in FIG. 3, this stacked arrangement of warp yarns 101-104 extends across the width of the fabric in an alternating arrangement. As in industrial textile 20,

warp yarns

102, 104 of first warp system 121 weave only under

critical weft yarns

132, 134, 136, 138, and

warp yarns

101, 103 of second warp system 122 weave only over

critical weft yarns

132, 134, 136, 138. As in the first embodiment of industrial textile 20, each of

warp yarns

102, 104 in first warp system 121 forms a lock weave after each embossment by weaving under one of

weft yarns

132, 134, 136, 138, over one of

weft yarns

131, 133, 135, 137, and under one of

weft yarns

132, 134, 136, 138. Similarly,

warp yarns

101, 103 of second warp system 122 form a lock weave after each float by weaving over one of

weft yarns

132, 134, 136, 138, under one of

weft yarns

131, 133, 135, 137, and over one of

weft yarns

132, 134, 136, 138. This provides increased stability to the fabric 120, which is also preferably woven with 100% warp fill in each of the first warp system 121 and the second warp system 122. Warp yarns 101-104 and weft yarns 131-138 are similar to warp yarns 1-16 and weft yarns 31-40 described above in connection with the first embodiment of the industrial textile 20. As shown in fig. 3, this arrangement provides a diagonal twill on the first surface 124 of the industrial textile 120. Diagonal may also be provided on the second surface 126.

Referring now to fig. 5, as well as fig. 6, a third embodiment of an industrial textile 120' is shown. The third embodiment of the industrial textile 120' is woven in the same repeating weave pattern as the second embodiment of the industrial textile 120, and similar components have been identified with the same reference numerals as the second embodiment with a prime. For example, warp yarns 101 '-104' correspond to warp yarns 101-104 of the second embodiment 120, and weft yarns 131 '-138' correspond to weft yarns 131-138 of the second embodiment 120. The main difference is that the warp yarns 101 '-104' in each layer are woven with less than 80% warp fill to provide an open mesh, based on the lock weave provided for the warp yarns 101 '-104'. In a preferred embodiment, the first warp system 121 'is woven with about 50% warp fill and the second warp system 122' is also woven with about 50% warp fill, thereby creating an open mesh dryer fabric as shown in FIG. 5. As discussed above in connection with industrial textile 120, stacked warp yarn pairs 102 ', 101' and 104 ', 103' are held in place by their lock-stitches. This allows for further applications of the industrial textile according to the invention.

Preferably, the industrial textile 120, 120' is formed into an endless belt by joining at the warp ends, as discussed above in connection with the first embodiment of the industrial textile 20. A preferred application of industrial textile 120 is as a papermaker's fabric, and in particular a dryer fabric for a paper machine.

A preferred application of the industrial textile 120' is as a dryer fabric. However, those skilled in the art will recognize other applications.

Referring to fig. 7 and 8, a fourth embodiment of an industrial textile 220 is shown. Industrial textile 220 is similar to industrial textile 20 and includes a first warp system 221 and a second warp system 222 interwoven with a weft system 230. The arrangement is similar to the industrial textile 20 except that the floats in the first warp system 221 are above the seven weft yarns in weft yarns 231-242 and the floats in the second warp system 222 are below the seven weft yarns in weft yarns 231-242. As shown, the warp yarns 202, 204, 206, 208, 210, 212, 214, 216 of the first warp system 221 are woven in stacked pairs above the warp yarns 201, 203, 205, 207, 209, 211, 213, 215 of the second warp system 222. Warp yarn 202 weaves over shute yarns 231-237, under shute yarn 238, over shute yarn 239, and under shute yarn 240. In a similar manner to the first embodiment, the

weft yarns

232, 234, 236, 238, 240, 242 are critical weft yarns having a smaller diameter than the

weft yarns

231, 233, 235, 237, 239, 241. Warp yarn 201 of second warp yarn system 222, which is stacked below warp yarn 202, weaves below weft yarn 231, above weft yarn 232, below weft yarn 233, above weft yarn 234, and then below weft yarns 235-242. The next stacked pair of warp yarns 204, 203 is woven with warp yarn 204 extending over weft yarn 231, under weft yarn 232, over weft yarn 233, under weft yarn 234, and over weft yarns 235-242. Warp yarn 203, which is stacked below warp yarn 204, weaves below shute yarns 231-237, above shute yarn 238, below shute yarn 239, above shute yarn 240, below shute yarn 241, and above shute yarn 242. The weave diagram in figure 7 shows the paths of the remaining pairs of stacked warp yarns in a clearly defined manner and in this embodiment the warp pattern repeats with warp yarns 205 and 208 having the same weave pattern as warp yarns 201 and 204. The stacked arrangement of warp yarns 201-216 extends across the width of the fabric. As in industrial textile 20, warp yarns 202, 204, 206, 208, 210, 214, 216 of first warp system 221 weave only under

critical weft yarns

232, 234, 236, 238, 240, 242, and warp yarns 201, 203, 205, 207, 209, 211, 213, 215 of second warp system 222 weave only over

critical weft yarns

232, 234, 236, 238, 240, 242. As in the first embodiment of the industrial textile 220, each of the warp yarns 202, 204, 206, 208, 210, 212, 214, 216 in the first warp system 221 forms a lock weave after each float by weaving under one of the

weft yarns

232, 234, 236, 238, 240, 242, over one of the

weft yarns

231, 233, 235, 237, 239, 241, and under one of the

weft yarns

232, 234, 236, 238, 240, 242. Similarly, the warp yarns 201, 203, 205, 207, 209, 211, 213, 215 of the second warp yarn system 222 form a latch weave after each float by weaving over one of the

weft yarns

232, 234, 236, 238, 240, 242, under one of the

weft yarns

231, 233, 235, 237, 239, 241, and over one of the

weft yarns

232, 234, 236, 238, 240, 242. This provides increased stability to the fabric 220, which is also preferably woven with 100% warp fill in each of the first 221 and second 222 warp systems. Warp yarns 201-216 and weft yarns 231-242 are similar to and may have the same construction as warp yarns 1-16 and weft yarns 31-40 described above in connection with the first embodiment of the industrial textile 20. As shown in fig. 7, this arrangement provides a diagonal twill on the first surface 224 of the industrial textile 220. Diagonal may also be provided on the second surface 226.

Fig. 9 shows another alternative embodiment of a high stability industrial textile 320. Industrial textile 320 includes a first warp system 321 and a second warp system 322 interwoven with a weft system 330. Here, the floats in the first warp system 321 are over at least 5, preferably over 7, of the weft yarns 331-338, and the floats in the second warp system 322 are under at least 5, preferably under 7, of the weft yarns 331-338. Warp yarns 301-316 are woven into adjacent pairs of the stack.

Adjacent warp yarns

303, 304 are disposed on the first surface 324 and woven over at least 5 of the weft yarns 331-338 along the same path and stacked over

adjacent warp yarns

301, 302, the

adjacent warp yarns

301, 302 being disposed on the second surface 326 and woven under at least 5 of the weft yarns 331-338 along the same path. Adjacent first

surface warp yarns

307, 308 are also woven along the same path and are stacked above adjacent second

surface warp yarns

305, 306 woven along the same path. Similarly, adjacent first

surface warp yarns

311, 312 are also woven in the same path over at least 5 of the weft yarns 331-338 and stacked over adjacent second

surface warp yarns

309, 310, the adjacent second

surface warp yarns

309, 310 are woven in the same path under at least 5 of the weft yarns, and adjacent first

surface warp yarns

315, 316 are also woven in the same path over at least 5 of the weft yarns 331-338 and stacked over adjacent second

surface warp yarns

313, 314, the second

surface warp yarns

313, 314 are woven in the same path under at least 5 of the weft yarns. The weave pattern in FIG. 9 shows the repeat, and in this example the warp floats over/under 7 of the weft yarns 331-338. Different double float arrangements are provided with different diagonal twills based on the paired arrangement of the warp yarns 301-316 in the first surface 324 and the second surface 326. As shown,

warp yarns

303, 304 of first warp system 321 weave over weft yarns 331-337 and under weft yarn 338.

Warp yarns

301, 302 of the second system warp yarn 322 are stacked below

warp yarns

303, 304 and weave under shute yarns 331-333, over shute yarn 334 and under shute yarns 335-338. The next adjacent pair of

warp yarns

307, 308 is woven as an adjacent pair over shutes 231 & 233, under shute 234 and over shute 235 & 238. Adjacent warp yarns 205, 206, which are stacked below warp yarns 207, 208, weave below weft yarns 231-237 and above weft yarn 238. The arrangement of

adjacent warp yarns

311, 312 of the first warp system 321 over

adjacent warp yarns

309, 310 of the second warp system 322 and the arrangement of

adjacent warp yarns

315, 316 of the first warp system 321 over

adjacent warp yarns

313, 314 of the second warp system 322 are similar. The interweaving of the warp yarns of the first warp system 321 and the second warp system 322 utilizes only the

critical weft yarns

332, 334, 336, 338 and does not utilize the

stuffer weft yarns

331, 333, 335, 337. Preferably, the warp fill is about 200% warp fill, with each layer having warp yarns woven at about 100% warp fill. This contributes to the stability of the industrial textile 320 and to the resistance to wrinkling and deformation due to the fact that the warp yarns 301-316 in each layer are woven with approximately 100% warp fill and are therefore immediately adjacent to and supporting each other.

Preferably, in order to provide smooth first and

second surfaces

24, 26 of the fabric 20, and first and

second surfaces

124, 126 of the

industrial textiles

120, 120', 220, 320; 124 ', 126'; 224. 226; 324. 326, the

stuffer wefts

31, 33, 35, 37, 39; 131. 133, 135, 137; 131 ', 133', 135 ', 137'; 231. 233, 235, 237, 239, 241; 331. 333, 335, 337 have a diameter D1, and smaller

critical weft yarns

32, 34, 36, 38, 40; 132. 134, 136, 138; 132 ', 134', 136 ', 138'; 232. 234, 236, 238, 240, 242; 332. 334, 446, 338 has a diameter D2 which is smaller than D1 and the warp yarns 1-16, 101-104, 101 '-104', 210-216, 301-316 have a rectangular cross-section with a thickness t. Preferably, (D1-D2)/2 ≈ 2 t. This provides generally smooth first and second surfaces in

industrial textile

20, 120', 220, 320. In an exemplary embodiment, D1-0.90 mm, D2-0.60 mm, and t-1.55 mm. Those skilled in the art will recognize that other dimensions may be used depending on the particular application.

Having thus described the invention in detail, it will be apparent and will be apparent to those skilled in the art that many more physical modifications are possible (only some of which are illustrated in the detailed description of the invention) without departing from the inventive concepts and principles embodied in the detailed description of the invention. It should also be appreciated that many embodiments are possible which incorporate only a portion of the preferred embodiments and that such embodiments do not alter the inventive concepts and principles embodied therein with respect to those portions. The present embodiments and alternative configurations are therefore to be considered in all respects as illustrative and/or illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all alternative embodiments and variations of embodiments that fall within the meaning and range of equivalency of the claims are intended to be embraced therein.

Claims

1. An industrial textile having a first surface and a second surface, the textile comprising:

a first warp system and a second warp system interwoven with the weft system in a repeating pattern, wherein:

each warp yarn of the plurality of warp yarns in the first warp yarn system is interwoven with the weft yarn system over at least 5 weft yarns of the plurality of weft yarns, under 1 weft yarn of the plurality of weft yarns, over 1 weft yarn of the plurality of weft yarns, and under 1 weft yarn of the plurality of weft yarns in the repeating pattern over the first surface to form an embossment over the at least 5 weft yarns of the plurality of weft yarns on the first surface,

each warp yarn of a plurality of warp yarns in the second warp yarn system is interwoven with the weft yarn system over the second surface under at least 5 weft yarns of the plurality of weft yarns, over 1 weft yarn of the plurality of weft yarns, under 1 weft yarn of the plurality of weft yarns, and over 1 weft yarn of the plurality of weft yarns in the repeating pattern to form embossments over the second surface under the at least 5 weft yarns of the plurality of weft yarns, and

each warp yarn of the plurality of warp yarns in the first warp yarn system is stacked on a respective warp yarn of the plurality of warp yarns in the second warp yarn system to form a stacked pair of the plurality of warp yarns.

2. The industrial textile of claim 1, wherein the embossments on the first surface are above 7 weft yarns and the embossments on the second surface are below 7 weft yarns.

3. The industrial textile of claim 1, wherein the weft yarn system comprises alternating larger diameter stuffer weft yarns and smaller diameter critical weft yarns.

4. The industrial textile of claim 3, wherein the plurality of warp yarns of the first warp system weave only under the critical weft yarns and the plurality of warp yarns of the second warp system weave only over the critical weft yarns.

5. The industrial textile of claim 1, wherein the repeating pattern of the plurality of warp yarns of the first warp yarn system below 1 of the plurality of weft yarns, above 1 of the plurality of weft yarns, and below 1 of the plurality of weft yarns forms a lock weave for maintaining the position of the plurality of warp yarns of the first warp yarn system, and the repeating pattern of the plurality of warp yarns of the second warp yarn system above 1 of the plurality of weft yarns, below 1 of the plurality of weft yarns, and above 1 of the plurality of weft yarns forms a lock weave for maintaining the position of the plurality of warp yarns of the second warp yarn system.

6. The industrial textile of claim 1, wherein the stacked pairs of the plurality of warp yarns are spaced to form an open mesh pattern.

7. The industrial textile of claim 6, wherein the stacked pair of the plurality of warp yarns are separated by at least 40% of a transverse dimension of one of the plurality of warp yarns.

8. The industrial textile of claim 1, wherein the embossments on the first surface are arranged with diagonal twill.

9. The industrial textile of claim 1, wherein the first warp system is made of a different material than the second warp system.

10. The industrial textile of claim 1, wherein the plurality of warp yarns of the first warp system and the second warp system have a rectangular cross-section.

11. The industrial textile of claim 10, wherein the cross-sections of the plurality of warp yarns of the first warp yarn system and the second warp yarn system are the same.

12. The industrial textile of claim 10, wherein the plurality of weft yarns have a circular cross-section.

13. The industrial textile according to claim 12, wherein the weft yarn system comprises alternating larger stuffer weft yarns having a diameter D1 and smaller critical weft yarns having a diameter D2, the plurality of warp yarns of the first and second warp yarn systems having the rectangular cross-section having a thickness t, wherein D1> D2 and (D1-D2)/2 ≈ t.

14. The industrial textile of claim 1, wherein each of the first warp system and the second warp system has at least 100% warp fill.

15. The industrial textile of claim 1, wherein the first warp system and the second warp system are woven in 8-shed in 10-fly.

16. The industrial textile of claim 1, wherein the industrial textile is a papermaking fabric.

17. The industrial textile of claim 1, wherein the industrial textile is a dryer fabric for a papermaking fabric.

18. An industrial textile having a first surface and a second surface, the textile comprising:

adjacent pairs of a plurality of warp yarns in the first warp yarn system are interwoven with the weft yarn system along the same path over at least 5 weft yarns of the plurality of weft yarns and under 1 weft yarn of the plurality of weft yarns in the repeating pattern on the first surface to form adjacent embossed pairs over the at least 5 weft yarns of the plurality of weft yarns on the first surface,

adjacent pairs of the plurality of warp yarns in the second warp yarn system are interwoven with the weft yarn system along the same path over the second surface under at least 5 of the plurality of weft yarns and over 1 of the plurality of weft yarns in the repeating pattern to form adjacent embossed pairs under the at least 5 of the plurality of weft yarns on the second surface, and

the adjacent pairs of the plurality of warp yarns in the first warp system are stacked on corresponding adjacent pairs of the plurality of warp yarns in the second warp system to form stacked adjacent pairs of the plurality of warp yarns.

19. The industrial textile of claim 18, wherein the weft yarn system comprises alternating larger diameter stuffer weft yarns and smaller diameter critical weft yarns.

20. The industrial textile of claim 19, wherein the plurality of warp yarns of the first warp system weave only under the critical weft yarns and the plurality of warp yarns of the second warp system weave only over the critical weft yarns.