EP3631064B1 - High stability stacked warp yarn dryer fabric with long warp floats - Google Patents
High stability stacked warp yarn dryer fabric with long warp floats Download PDFInfo
- Publication number
- EP3631064B1 EP3631064B1 EP18810133.1A EP18810133A EP3631064B1 EP 3631064 B1 EP3631064 B1 EP 3631064B1 EP 18810133 A EP18810133 A EP 18810133A EP 3631064 B1 EP3631064 B1 EP 3631064B1
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- European Patent Office
- Prior art keywords
- yarns
- warp
- warp yarns
- weft
- over
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- 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
- D21F7/12—Drying
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F1/00—Wet end of machines for making continuous webs of paper
- D21F1/0027—Screen-cloths
- D21F1/0036—Multi-layer screen-cloths
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D1/00—Woven fabrics designed to make specified articles
- D03D1/0094—Belts
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
- D03D13/004—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft with weave pattern being non-standard or providing special effects
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D3/00—Woven fabrics characterised by their shape
- D03D3/04—Endless fabrics
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D9/00—Open-work fabrics
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F1/00—Wet end of machines for making continuous webs of paper
- D21F1/0027—Screen-cloths
- D21F1/0036—Multi-layer screen-cloths
- D21F1/0045—Triple layer fabrics
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- 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
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
- D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
- D10B2331/30—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polycondensation products not covered by indexing codes D10B2331/02 - D10B2331/14
- D10B2331/301—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polycondensation products not covered by indexing codes D10B2331/02 - D10B2331/14 polyarylene sulfides, e.g. polyphenylenesulfide
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2505/00—Industrial
Definitions
- the invention relates to industrial textiles, and more particularly to papermaking fabrics.
- WO 2011/022831 which is assigned to the assignee of the present invention, discloses a dryer fabric for a papermaking machine having stacked warp yarns with about 193% warp fill woven with filler wefts and critical picks.
- Applicant's prior International Application Publication WO 93/01350 discloses an industrial textile including first and second systems of warp yarns interwoven with a system of weft yarns, with the first surface being formed by the warp yarns in the first system of warp yarns being interwoven with the system of weft yarns to form floats on the first surface, and the second surface being formed by the warp yarns in the second system of warp yarns being interwoven with the system of weft yarns to form floats on the second surface.
- the warp yarns of the first and second systems of warp yarns are arranged to form stacked pairs.
- U.S. Patent 5,465,764 also discloses a textile including first and second systems of warp yarns interwoven with a system of weft yarns, with the first system of warp yarns being interwoven with the system of weft yearns with adjacent pairs of the first system warp yarns being provided that form floats on the first surface, and the second system of warp yarns being woven with the system of weft yarns and forming floats on the second surface.
- US 9,365,958 is directed to a stretchable fabric for clothing that is a single layer woven with long floats and is unrelated to papermaking fabrics or industrial conveying fabrics used in papermaking or filtration operations. There is therefore no need or concern with increasing the life of an industrial fabric, and in particular, a papermaking fabric by providing a machine side surface dominated by long machine direction (MD) floats for increased wear resistance.
- MD machine direction
- the invention concerns an industrial textile, preferably suitable for use as a dryer fabric in a papermaking machine.
- the industrial textile has first and second surfaces and is defined by first and second systems of warp yarns interwoven with a system of weft yarns in a repeating pattern.
- each of the warp yarns in the first system of warp yarns is interwoven with the system of weft yarns on the first surface over at least 5 of the weft yarns, under 1 of the weft yarns, over 1 of the weft yarns, and under 1 of the weft yarns forming a float on the first surface over the at least 5 of the weft yarns.
- each of the warp yarns in the second system of warp yarns is interwoven with the system of weft yarns on the second surface under at least 5 of the weft yarns, over 1 of the weft yarns, under 1 of the weft yarns, and over 1 of the weft yarns in the repeating pattern forming a float on the second surface under the at least 5 of the weft yarns.
- Each of the warp yarns of the first system of warp yarns is stacked over a corresponding one of the warp yarns of the second system of warp yarns to form stacked pairs of the warp yarns.
- the float on the first surface is over 7 weft yarns, and the float on the second surface is under 7 weft yarns.
- the system of weft yarns includes alternating larger diameter filler wefts and smaller diameter critical picks.
- the warp yarns of the first system of warp yarns only weave under the critical picks, and the warp yarns of the second system of warp yarns only weave over the critical picks.
- the repeating pattern of the warp yarns of the first system of warp yarns of under 1 of the weft yarns, over 1 of the weft yarns and under 1 of the weft yarns forms a locking weave for maintianing a position of the warp yarns of the first system of warp yarns
- the repeating pattern of the warp yarns of the second system of warp yarns of over 1 of the weft yarns, under 1 of the weft yarns, and over 1 of the weft yarns forms a locking weave for maintianing a position of the warp warns of the second system of warp yarns.
- this allows the stacked pairs of the warp yarns to be spaced apart to form an open mesh pattern while still maintaining a high stability for the industrial textile.
- the stacked pairs of the warp yarns are spaced apart by at least 40% of a cross-direction dimension of one of the warp yarns.
- the floats on the first surface are arranged with a diagonal twill.
- the first system of warp yarns is made from a different material than the second system of warp yarns.
- the warp yarns of the first and second systems of warp yarns have a rectangular cross-section.
- the cross-section of the warp yarns of the first and second systems of warp yarns are the same.
- the weft yarns have a circular cross-section. However, this can be varied.
- the warp and/or weft yarns may be grooved and/or profiled in the manner described by US 6,773,786 to assist in rendering the fabric contamination resistant.
- the first system of warp yarns and second system of warp yarns each have at least about 96% warp fill. This is particulary useful for dryer fabrics for papermaking machines.
- the industrial textile is woven with an 8 shed, 10 step pattern.
- the number of steps needed to weave the industrial textile may need to be increased.
- the present industrial textile has preferred applications as a papermaking fabric.
- the industrial textile is preferably flat woven, and the ends are seamed to form an endless belt that can then be used in papermaking applications on a papermaking machine.
- One preferred application is a dryer fabric for a papermaking fabric.
- the resulting constructions are a rugged and wear resistant industrial textile that resists warp nesting and canting and is highly stable (meaning it is resistive to out of plane distortion due in part to its diagonal stability).
- the fabric is adaptable to a wide range of applications by appropriate selection of warp and weft yarn types, sizes and shapes. For example, air permeability of the fabric is easily adjusted according to need; the fabric can be rendered temperature or contamination resistant by appropriate selection of the warp yarn materials and sizes.
- the fabric provides for high seam strength due to the stacked warp construction which preferably utilizes approximately 100% of the warp yarns to form the seam, and which also provides the fabric with approximately 200% warp fill.
- warp fill refers to the amount of warp yarns in a given space relative to total space considered.
- Warp fill can be over 100% when there are more warp strands jammed into the available space than the space can dimensionally accommodate in a single plane.
- a fabric with approximately 200% warp fill or more may have two layers of warp yarns each woven at at least approximately 100% warp fill. In this context, those skilled in the art would understand that 190% to 210% would be considered approximately 200% warp fill.
- the fabric can be highly stable, and resists creasing and distortion when the warp yarns in each layer are woven at 100% warp fill, or more, and are thus immediately adjacent to and braced against one another. This in combination with the locking weave of the warp yarns provides enhanced stability in combination with increased longevity due to the long warp floats.
- the weave pattern of the novel fabrics provide long floats of the warp yarns on both exterior surfaces that enhance the ability of these fabrics to resist abrasive wear.
- the fabric design can be adapted for many different applications by proper warp and weft selection which will allow the fabric to obtain a wide range of air permeabilities.
- fabric caliper thickness
- the two independent warp systems provide a further benefit in that the materials used in each can be optimized to resist the environmental effects to which each fabric surface is exposed.
- the monofilament warp yarns used to form a first fabric surface can be comprised of PPS (polyphenylene sulfide) or PCTA (polycylcohexane dimethanol terephthalic acid) polymers which are more resistant to thermal and hydrolytic degradation than PET (polyethylene terephthalate) yarns (and more expensive).
- PPS polyphenylene sulfide
- PCTA polycylcohexane dimethanol terephthalic acid
- PET polyethylene terephthalate yarns (and more expensive).
- Warp yarns formed from PET polymer could be utilized on the paper side of the textile (in papermaking applications) where heat and hydrolysis resistance are less critical properties.
- Fabrics according to the invention such as are shown in the Figures were woven using rectangular cross-section polymeric monofilament warp yarns whose dimensions are 0.25 x 1.05mm or 0.36 x 1.07mm to obtain a width to height ratio of between 4:1 and 3:1, but other cross-sectional shapes and ratios may be employed.
- the weft yarns used in these fabrics have a generally circular cross-sectional shape and range in size from about 0.50mm to 1.0mm; although other sizes may be employed depending upon the specific application.
- the fabric according to the invention is an industrial textile, which can have many industrial applications, such as conveyor belts, filtration fabrics, specialty fabrics for non-woven applications, etc.
- the words "paper side” (PS) and “machine side” (MS) designate surfaces of the fabric with reference to their use in one preferred application in a papermaking machine; however, these terms merely represent first and second or upper and lower surfaces of the planar fabric. "Yarn” is used to generically identify a monofilament or multifilament fiber.
- Warp and “weft” are used to designate yarns or monofilaments based on their position in the loom that extend in perpendicular directions in the fabric and either could be a machine direction (MD) or cross-machine direction (CMD) yarn in the fabric once it is installed on a papermaking machine, depending on whether the fabric is flat woven or continuously woven.
- the fabric is flat woven and seamed at the warp ends in order to form a continuous belt, so that the warp yarns are MD yarns and the weft yarns are CMD yarns.
- One preferred application of the fabrics according to the invention is on a papermaking machine, and the fabric could have application as a base for a press fabric, or a dryer fabric for use in the corresponding press and dryer sections of a papermaking machine. These are generally all referred to as a "papermaking fabric” regardless of the position of use in a papermaking machine.
- Other applications include filtration fabrics, as well as other non-woven applications.
- an industrial textile 20 in accordance with a first preferred embodiment of the present construction is illustrated using a weave diagram ( Fig. 1 ) and a cross-section taken along the MD.
- the industrial textile 20 includes a first surface 24 and a second surface 26.
- the first surface 24 corresponds to the PS and the second surface 26 corresponds to the MS.
- the industrial textile 20 is woven with first and second systems of warp yarns 21, 22, which are interwoven with a system of weft yarns 30 in a repeating pattern.
- the warp yarns are identified as warp yarns 1-16, with the first group of warp yarns including the even numbered warp yarns, i.e., 2, 4, 6, 8, 10, 12, 14, 16, and the second system of warp yarns including the odd numbered warp yarns, i.e. 1, 3, 5, 7, 9, 11, 13, 15.
- the weft yarns 31-40 are interwoven with the warp yarns 1-16, of which preferably there are alternating larger diameter filler wefts 31, 33, 35, 37, 39, and a smaller diameter critical picks 32, 34, 36, 38, 40.
- Each of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in the first system of warp yarns 21 is interwoven with the system of weft yarns 30 with a float on the first surface 24 over at least five of the weft yarns 31 - 40.
- the floats of each of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in the first system of warp yarns 21 are over 7 of the weft yarns 31-40. This is shown in connection with the warp yarn 2 in Figure 2 and would be true for each of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in the first system of warp yarns 21.
- each of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first system of warp yarns 21 then extends 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 in the repeating pattern.
- the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first system of warp yarns 21 only weave under the critical picks 32, 34, 36, 38, 40.
- the first and second systems of warp yarns 21, 22 are woven with 8 sheds in 10 steps.
- Each of the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 in the second system of warp yarns 22 is interwoven with the system of weft yarns 30 with a float on the second surface 26 under at least five of the weft yarns 31-40.
- the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 in the second system of warp yarns 22 are interwoven with the system of weft yarns 30 with a float on the second surface under 7 of the weft yarns 31-40.
- the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 in the second system of warp yarns 22 then weave over one of the weft yarns 32, 34, 36, 38, 40 under one of the weft yarns 31, 33, 35, 37, 39, and over one of the weft yarns, 32, 34, 36, 38, 40 in the repeating pattern.
- each of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first system of warp yarns 21 is stacked over a corresponding one of the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 of the second system of warp yarns 22 to form stacked pairs of warp yarns.
- warp yarn 2 is stacked over warp yarn 1.
- the even numbered warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in the first system of warp yarns 21 are stacked over the corresponding ones of the odd numbered warp yarns 1, 3, 5, 7, 9, 11, 13, 15 in the second system of warp yarns 22.
- the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 of the second system of warp yarns 22 only weave under the critical picks 32, 34, 36, 38, 40 which have the smaller diameter D2 than the filler wefts 31, 33, 35, 37 which have a larger diameter D1.
- the repeating pattern of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first system of warp yarns 21 of under one of the weft yarns, over one of the weft yarns and under one of the weft yarns forms a locking weave for maintaining a position of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first system of warp yarns 21 in position within the industrial textile.
- the repeating pattern of the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 of the second system of warp yarns 22 of over one of the weft yarns, under one of the weft yarns, and over one of the weft yarns, also forms a locking weave for maintaining a position of the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 of the second system of warp yarns 22 in position.
- 100% warp fill is provided for each of the first and second systems of warp yarns 21, 22, which, in combination with the locking weaves, provide an extremely stable fabric 20.
- the warp yarns 1-16 preferably have a rectangular cross-sectional shape which contributes to the stability of the fabric 20 and its smoothness.
- the warp yarns 1-16 are preferably monofilaments formed of a polymeric material.
- the dimensions are 0.25 x 1.05 mm or 0.36 x 1.07 mm to obtain a width to height ratio of between 4:1 and 3:1.
- cross-sectional shapes and ratios may also be used, such as oval or flattened 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 that in some preferred arrangements may range in size from 0.6 mm, 0.7 mm, 0.8 mm, or 0.9 mm. Other sizes may also be used depending on the intended application for the fabric.
- the fabric 20 is woven at 22 picks per inch (weft yarns per inch) (8.7 yarns/cm).
- first and second systems of warp yarns, 21, 22 also allow different materials to be used for the first and second system of warp yarns 21, 22 in order to provide optimal materials on the first and second surfaces 24, 26, of the industrial textile 20 for the preferred application.
- the monofilament warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first system of warp yarns 21 used to form the first surface 24 can be comprised of PPS (polyphenylene sulfide) or PCTA (polycylcohexane dimethanol terephthalic acid) polymers which are more resistant to thermal and hydrolytic degradation than PET (polyethylene terephthalate) yarns (and more expensive).
- the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 of the second system of warp yarns can be formed from PET polymer since the PS of the textile (at least in papermaking applications) is where heat and hydrolysis resistance are less critical yarn properties.
- these materials are merely exemplary, and that other materials could be used depending on the particular application.
- These warp yarns 1- 16 may be grooved, profiled, coated, or otherwise treated for contamination resistance.
- the long warp floats due to the long warp floats, a higher contact area can be achieved that reduces fabric wear rates in comparison to similar fabrics having more defined knuckles due to the weave.
- the long warp floats also provide for benefits in contamination resistance in comparison to similar weft proud fabrics.
- industrial textile 20 is formed into a continuous loop for use as a papermaking fabric, and more particularly as a papermaking dryer fabric, for use on a papermaking machine.
- a seam is created at the ends of the warp yarns 1-16.
- the seam uses 100% of the warp yarns to form the seam.
- Seams can be formed in a known manner by unweaving and back-weaving warp yarns from the first system of warp yarns 21 back into the fabric along the paths of the corresponding stacked ones of the warp yarns from the second system of warp yarns 22 that have been cut back from the end of the fabric to form seam loops at each end of the planar fabric, with the seam loops then being interdigitated and joined by a pintle to form an endless fabric loop.
- Other types of seaming such as QuickLink seam, which was developed by AstenJohnson, the assignee of the present invention, can also be utilized.
- the warp fill is preferably about 200% warp fill, with each layer having warp yarns woven at about 100% warp fill.
- the industrial textile 120 is similar to the industrial textile 20 and includes first and second systems of warp yarns 121, 122 that are interwoven with a system of weft yarns 130.
- the arrangement is similar to the industrial textile 20 with the exception that the floats in the first warp system 121 are over five of the weft yarns 131-138 and the floats in the second system of warp yarns 122 are under 5 of the weft yarns 131-138.
- the warp yarns 102, 104 of the first system of warp yarns 121 are woven in stacked pairs over the warp yarns 101, 103 of the second system of warp yarns 122 as shown.
- the warp yarn 102 weaves over weft yarns 131-135, under weft yarn 136 over weft yarn 137 and under weft 138.
- the weft yarns 132, 134, 136, 138 are critical pics having a smaller diameter than the filler wefts 131, 133, 135, 137.
- the warp yarn 101 of the second system of warp yarns 122 which is stacked under the warp yarn 102, weaves under weft yarn 131, over weft yarn 132, under weft yarn 133, over weft yarn 134, and then under weft yarns 135-138.
- the next stacked pair of warp yarns 104, 103 are woven with the 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.
- the warp yarn 103 which is stacked under the warp yarn 104 weaves under weft yarns 131-135 over weft yarn 136, under weft yarn 137, and over weft yarn 138.
- This stacked arrangement of warp yarns 101-104 extends across the fabric width in an alternating arrangement as shown in Figure 3 .
- the warp yarns 102, 104 of the first system of warp yarns 121 only weave under the critical pics 132, 134, 136, 138 and the warp yarns 101, 103 of the second system of warp yarns 122 only weave over the critical pics 132, 134, 136, 138.
- each of the warp yarns 102, 104 in the first system of warp yarns 121 forms a locking weave after each float by weaving under one of the weft yarns 132, 134, 136, 138 over one of the weft yarns 131, 133, 135, 137 and under one of the weft yarns 132, 134, 136, 138.
- the warp yarns 101, 103 of the second system of warp yarns 122 form a locking weave after each of the floats by weaving over one of the weft yarns 132, 134, 136, 138, under one of the weft yarns 131, 133, 135, 137, and over one of the weft yarns 132, 134, 136, 138.
- This provides enhanced stability for the fabric 120 which is also preferably woven with 100% warp fill in each of the first system of warp yarns 121 and the second system of warp yarns 122.
- the warp yarns 101-104 and the weft yarns 131-138 are similar to the warp yarns 1-16 and weft yarns 31-40 as described above in connection with the first embodiment of the industrial textile 20. As shown in Figure 3 , this arrangement provides a diagonal twill on the first surface 124 of the industrial textile 120. A diagonal twill would also be provided on the second surface 126.
- a third embodiment of the industrial textile 120' is shown.
- the third embodiment of the industrial textile 120' is woven with the same repeating weave pattern as the second embodiment of the industrial textile 120 and similar elements have been marked with the same reference numbers as in the second embodiment with a prime.
- the warp yarns 101' - 104' correspond to the warp yarns 101-104 in the second embodiment 120
- the weft yarns 131' - 138' correspond with the weft yarns 131-138 of the second embodiment 120.
- the warp yarns 101'-104' in each of the layers are woven with less than 80% warp fill in order to provide an open mesh.
- the first system of warp yarns 121' is woven with approximately 50% warp fill and the second system of warp yarns 122' is also woven with approximately 50% warp fill so that an open mesh dryer fabric as shown in Figure 5 can be produced.
- the stacked pairs of warp yarns 102', 101', and 104', 103', are maintained in position by their locking weave as discussed above in connection with the industrial textile 120. This allows for further applications of the industrial textiles according to the invention.
- the industrial textiles 120, 120' are formed into endless belts by seaming at the warp ends as discussed above in connection with the first embodimemt of the industrial textile 20.
- a preferred application for the industrial textile 120 is as a papermaking fabric, and in particular, a dryer fabric for a papermaking machine.
- a preferred application for the industrial textile 120' is for use as a dryer fabric. However, those skilled in the art will recognize that there are other applications.
- the industrial textile 220 is similar to the industrial textile 20 and includes first and second systems of warp yarns 221, 222 that are interwoven with a system of weft yarns 230.
- the arrangement is similar to the industrial textile 20 with the exception that the floats in the first warp system 221 are over seven of the weft yarns 231-242 and the floats in the second system of warp yarns 222 are under 7 of the weft yarns 231-242.
- the warp yarns 202, 204, 206, 208, 210, 212, 214, 216 of the first system of warp yarns 221 are woven in stacked pairs over the warp yarns 201, 203, 205, 207, 209, 211, 213, 215 of the second system of warp yarns 222 as shown.
- the warp yarn 202 weaves over weft yarns 231-237, under weft yarn 238 over weft yarn 239 and under weft 240.
- the weft yarns 232, 234, 236, 238, 240, 242 are critical pics having a smaller diameter than the filler wefts 231, 233, 235, 237, 239. 241.
- the warp yarn 201 of the second system of warp yarns 222 which is stacked under the warp yarn 202, weaves under weft yarn 231, over weft yarn 232, under weft yarn 233, over weft yarn 234, and then under weft yarns 235-242.
- the next stacked pair of warp yarns 204, 203 are woven with the 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.
- the warp yarn 203 which is stacked under the warp yarn 204 weaves under weft yarns 231-237 over weft yarn 238, under weft yarn 239, and over weft yarn 240, under weft yarn 241, and over weft yarn 242.
- the weave diagram in Fig. 7 shows the paths of the remaining stacked pairs of warp yarns in a clearly defined manner, and in this embodiment, the warp pattern repeats with warp yarns 205-208 having the same weave pattern as warp yarns 201-204.
- the stacked arrangement of warp yarns 201-216 extends across the fabric width.
- the warp yarns 202, 204, 206, 208, 210, 214, 216 of the first system of warp yarns 221 only weave under the critical pics 232, 234, 236, 238, 240, 242 and the warp yarns 201, 203, 205, 207, 209, 211, 213, 215 of the second system of warp yarns 222 only weave over the critical pics 232, 234, 236, 238, 240, 242.
- each of the warp yarns 202, 204, 206, 208, 210, 212, 214, 216 in the first system of warp yarns 221 forms a locking 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.
- the warp yarns 201, 203, 205, 207, 209, 211, 213, 215 of the second system of warp yarns 222 form a locking weave after each of the floats 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 enhanced stability for the fabric 220 which is also preferably woven with 100% warp fill in each of the first system of warp yarns 221 and the second system of warp yarns 222.
- the warp yarns 201-216 and the weft yarns 231-242 are similar to and can have the same constructions as the warp yarns 1-16 and weft yarns 31-40 as described above in connection with the first embodiment of the industrial textile 20. As shown in Figure 7 , this arrangement provides a diagonal twill on the first surface 224 of the industrial textile 220. A diagonal twill would also be provided on the second surface 226.
- Fig. 9 shows a further alternative embodiment of a high stability industrial textile 320 is shown.
- the industrial textile 320 includes first and second systems of warp yarns 321, 322 that are interwoven with a system of weft yarns 330.
- the floats in the first warp system 321 are over at least 5, and preferably over seven of the weft yarns 331-338 and the floats in the second system of warp yarns 322 are under at least 5 and preferably under 7 of the weft yarns 331-338.
- the warp yarns 301-316 are woven in adjacent pairs that are stacked.
- Adjacent warp yarns 303, 304 are arranged on the first surface 324 and are woven along the same path over at least 5 of the weft yarns 331-338, and are stacked over adjacent warp yarns 301, 302 which are arranged on the second surface 326 and are woven along the same path under at least 5 of the weft yarns 331-338.
- Adjacent first surface warp yarns 307, 308 are also woven along the same path and are stacked over adjacent second surface warp yarns 305, 306 which are woven along the same path.
- adjacent first surface warp yarns 311, 312 are also woven along the same path over at least 5 of the weft yarns 331-338 and are stacked over adjacent second surface warp yarns 309, 310 that are woven along the same path under at least 5 of the weft yarns
- adjacent first surface warp yarns 315, 316 are also woven along the same path over at least 5 of the weft yarns 331-338 and are stacked over adjacent second surface warp yarns 313, 314 that are woven along the same path under at least 5 of the weft yarns.
- the weave diagram in Fig. 9 shows the repeat, and in this example, the warp yarn floats are over/under 7 of the weft yarns 331-338.
- a distinct double float arrangement is provided with a distinct diagonal twill.
- the warp yarns 303, 304 of the first system of warp yarns 321 weave over weft yarns 331-337, and under weft yarn 338.
- next adjacent pair of warp yarns 307, 308 are woven as an adjacent pair over weft yarns 231-233, under weft yarn 234, and over weft yarns 235-238.
- the adjacent warp yarns 205, 206 which are stacked under the warp yarns 207, 208 weave under weft yarns 231-237, and over weft yarn 238.
- the arrangement of adjacent warp yarns 311, 312 of the first system of warp yarns 321 over adjacent warp yarns 309, 310 of the second system of warp yarns 322, as well as the arrangement of adjacent warp yarns 315, 316 of the first system of warp yarns 321 over adjacent warp yarns 313, 314 of the second system of warp yarns 322 are similar.
- the interweaving of the warp yarns of the first and second systems of warp yarns 321, 322 is only with critical pics 332,334, 336, 338, and not with the filler wefts 331, 333, 335, 337.
- 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 helps to resist creasing and distortion due to the fact that the warp yarns 301-316 in each layer are woven at about 100% warp fill, and thus are immediately adjacent to and braced against one another.
- the filler 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 the smaller critical pics 32, 34, 36, 38, 40; 132, 134, 136, 138; 132', 134', 136', 138'; 232, 234, 236, 238, 240, 242; 332, 334, 446, 338 have 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
- (D1 - D2)/2 ⁇ 2t This provides for generally smooth first and second surfaces in the industrial textiles 20, 120, 120', 220, 320.
- D1 0.90mm
- D2 0.60mm
- t 1.55mm.
Description
- The invention relates to industrial textiles, and more particularly to papermaking fabrics.
- Numerous weaves are known in the art which are employed to achieve different results for different applications.
-
WO 2011/022831 , which is assigned to the assignee of the present invention, discloses a dryer fabric for a papermaking machine having stacked warp yarns with about 193% warp fill woven with filler wefts and critical picks. - Applicant's prior International Application Publication
WO 93/01350 -
U.S. Patent 5,465,764 also discloses a textile including first and second systems of warp yarns interwoven with a system of weft yarns, with the first system of warp yarns being interwoven with the system of weft yearns with adjacent pairs of the first system warp yarns being provided that form floats on the first surface, and the second system of warp yarns being woven with the system of weft yarns and forming floats on the second surface. -
US 9,365,958 - The invention concerns an industrial textile, preferably suitable for use as a dryer fabric in a papermaking machine. The industrial textile has first and second surfaces and is defined by first and second systems of warp yarns interwoven with a system of weft yarns in a repeating pattern. In the repeating pattern, each of the warp yarns in the first system of warp yarns is interwoven with the system of weft yarns on the first surface over at least 5 of the weft yarns, under 1 of the weft yarns, over 1 of the weft yarns, and under 1 of the weft yarns forming a float on the first surface over the at least 5 of the weft yarns. Additionally, each of the warp yarns in the second system of warp yarns is interwoven with the system of weft yarns on the second surface under at least 5 of the weft yarns, over 1 of the weft yarns, under 1 of the weft yarns, and over 1 of the weft yarns in the repeating pattern forming a float on the second surface under the at least 5 of the weft yarns. Each of the warp yarns of the first system of warp yarns is stacked over a corresponding one of the warp yarns of the second system of warp yarns to form stacked pairs of the warp yarns.
- In one embodiment, the float on the first surface is over 7 weft yarns, and the float on the second surface is under 7 weft yarns.
- Preferably, the system of weft yarns includes alternating larger diameter filler wefts and smaller diameter critical picks.
- In one preferred arrangement, the warp yarns of the first system of warp yarns only weave under the critical picks, and the warp yarns of the second system of warp yarns only weave over the critical picks.
- Preferably, the repeating pattern of the warp yarns of the first system of warp yarns of under 1 of the weft yarns, over 1 of the weft yarns and under 1 of the weft yarns forms a locking weave for maintianing a position of the warp yarns of the first system of warp yarns, and the repeating pattern of the warp yarns of the second system of warp yarns of over 1 of the weft yarns, under 1 of the weft yarns, and over 1 of the weft yarns forms a locking weave for maintianing a position of the warp warns of the second system of warp yarns. In prefered arrangements for certain filter fabrics, this allows the stacked pairs of the warp yarns to be spaced apart to form an open mesh pattern while still maintaining a high stability for the industrial textile. On one preferred arrangement, the stacked pairs of the warp yarns are spaced apart by at least 40% of a cross-direction dimension of one of the warp yarns.
- In one preferred arrangement, the floats on the first surface are arranged with a diagonal twill.
- In one embodiment, the first system of warp yarns is made from a different material than the second system of warp yarns.
- In several of the preferred arrangements, the warp yarns of the first and second systems of warp yarns have a rectangular cross-section. Preferably, the cross-section of the warp yarns of the first and second systems of warp yarns are the same. Preferably, the weft yarns have a circular cross-section. However, this can be varied. The warp and/or weft yarns may be grooved and/or profiled in the manner described by
US 6,773,786 to assist in rendering the fabric contamination resistant. - For a preferred application, the first system of warp yarns and second system of warp yarns each have at least about 96% warp fill. This is particulary useful for dryer fabrics for papermaking machines.
- In one arrangement where the floats in the first and second systems of warp yarns are over 5 of the weft yarns on a top surface and under 5 weft yarns on a bottom surface, the industrial textile is woven with an 8 shed, 10 step pattern. Depending on the length of the warp floats, the number of steps needed to weave the industrial textile may need to be increased.
- As noted above, the present industrial textile has preferred applications as a papermaking fabric. The industrial textile is preferably flat woven, and the ends are seamed to form an endless belt that can then be used in papermaking applications on a papermaking machine. One preferred application is a dryer fabric for a papermaking fabric.
- The resulting constructions are a rugged and wear resistant industrial textile that resists warp nesting and canting and is highly stable (meaning it is resistive to out of plane distortion due in part to its diagonal stability). The fabric is adaptable to a wide range of applications by appropriate selection of warp and weft yarn types, sizes and shapes. For example, air permeability of the fabric is easily adjusted according to need; the fabric can be rendered temperature or contamination resistant by appropriate selection of the warp yarn materials and sizes. In addition the fabric provides for high seam strength due to the stacked warp construction which preferably utilizes approximately 100% of the warp yarns to form the seam, and which also provides the fabric with approximately 200% warp fill. The term "warp fill" refers to the amount of warp yarns in a given space relative to total space considered. Warp fill can be over 100% when there are more warp strands jammed into the available space than the space can dimensionally accommodate in a single plane. A fabric with approximately 200% warp fill or more may have two layers of warp yarns each woven at at least approximately 100% warp fill. In this context, those skilled in the art would understand that 190% to 210% would be considered approximately 200% warp fill. The fabric can be highly stable, and resists creasing and distortion when the warp yarns in each layer are woven at 100% warp fill, or more, and are thus immediately adjacent to and braced against one another. This in combination with the locking weave of the warp yarns provides enhanced stability in combination with increased longevity due to the long warp floats. The weave pattern of the novel fabrics provide long floats of the warp yarns on both exterior surfaces that enhance the ability of these fabrics to resist abrasive wear.
- The fabric design can be adapted for many different applications by proper warp and weft selection which will allow the fabric to obtain a wide range of air permeabilities. Although fabric caliper (thickness) can be made low to allow for use in high speed applications, the stability of the textile is maintained due to the warp yarn bracing and locking weave provided with the weft yarns. The two independent warp systems provide a further benefit in that the materials used in each can be optimized to resist the environmental effects to which each fabric surface is exposed. For example, the monofilament warp yarns used to form a first fabric surface can be comprised of PPS (polyphenylene sulfide) or PCTA (polycylcohexane dimethanol terephthalic acid) polymers which are more resistant to thermal and hydrolytic degradation than PET (polyethylene terephthalate) yarns (and more expensive). Warp yarns formed from PET polymer could be utilized on the paper side of the textile (in papermaking applications) where heat and hydrolysis resistance are less critical properties.
- Fabrics according to the invention such as are shown in the Figures were woven using rectangular cross-section polymeric monofilament warp yarns whose dimensions are 0.25 x 1.05mm or 0.36 x 1.07mm to obtain a width to height ratio of between 4:1 and 3:1, but other cross-sectional shapes and ratios may be employed. The weft yarns used in these fabrics have a generally circular cross-sectional shape and range in size from about 0.50mm to 1.0mm; although other sizes may be employed depending upon the specific application.
- The foregoing Summary and the following detailed description will be better understood when read in conjunction with the appended drawings, which illustrate a preferred embodiment of the invention. In the drawings:
-
Figure 1 is a weave diagram showing a first embodiment of an industrial textile having the present construction. -
Figure 2 is a cross-sectional view showing the weave pattern of two of the stacked warp yarns in the fabric construction shown inFigure 1 . -
Figure 3 is a top view of a second embodiment of an industrial textile of the present construction. -
Figure 4 is a cross-sectional view showing the weave paths of two pairs of stacked warp yarns shown inFigure 3 . -
Figure 5 is a top view of an industrial textile according to a third embodiment of the present construction. -
Figure 6 is a cross-sectional view showing the weave path of two pairs of the stacked warp yarns shown inFigure 5 . -
Figure 7 is a weave diagram showing a fourth embodiment of an industrial textile having the present construction. -
Figure 8 is a cross-sectional view showing the weave pattern of two of the stacked warp yarns in the fabric construction shown inFigure 7 . -
Figure 9 is a weave diagram of a fifth embodiment of an industrial textile having a high stability construction. - 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 can have many industrial applications, such as conveyor belts, filtration fabrics, specialty fabrics for non-woven applications, etc. The words "paper side" (PS) and "machine side" (MS) designate surfaces of the fabric with reference to their use in one preferred application in a papermaking machine; however, these terms merely represent first and second or upper and lower surfaces of the planar fabric. "Yarn" is used to generically identify a monofilament or multifilament fiber. "Warp" and "weft" are used to designate yarns or monofilaments based on their position in the loom that extend in perpendicular directions in the fabric and either could be a machine direction (MD) or cross-machine direction (CMD) yarn in the fabric once it is installed on a papermaking machine, depending on whether the fabric is flat woven or continuously woven. In the preferred arrangement, the fabric is flat woven and seamed at the warp ends in order to form a continuous belt, so that the warp yarns are MD yarns and the weft yarns are CMD yarns.
- One preferred application of the fabrics according to the invention is on a papermaking machine, and the fabric could have application as a base for a press fabric, or a dryer fabric for use in the corresponding press and dryer sections of a papermaking machine. These are generally all referred to as a "papermaking fabric" regardless of the position of use in a papermaking machine. Other applications include filtration fabrics, as well as other non-woven applications.
- Referring to
Figures 1 and 2 , anindustrial textile 20 in accordance with a first preferred embodiment of the present construction is illustrated using a weave diagram (Fig. 1 ) and a cross-section taken along the MD. Theindustrial textile 20 includes afirst surface 24 and asecond surface 26. In one preferred construction as a papermaking fabric, thefirst surface 24 corresponds to the PS and thesecond surface 26 corresponds to the MS. - The
industrial textile 20 is woven with first and second systems ofwarp yarns weft yarns 30 in a repeating pattern. The warp yarns are identified as warp yarns 1-16, with the first group of warp yarns including the even numbered warp yarns, i.e., 2, 4, 6, 8, 10, 12, 14, 16, and the second system of warp yarns including the odd numbered warp yarns, i.e. 1, 3, 5, 7, 9, 11, 13, 15. The weft yarns 31-40 are interwoven with the warp yarns 1-16, of which preferably there are alternating largerdiameter filler wefts critical picks warp yarns warp yarns 21 is interwoven with the system ofweft yarns 30 with a float on thefirst surface 24 over at least five of the weft yarns 31 - 40. In the first embodiment of theindustrial textile 20, the floats of each of thewarp yarns warp yarns 21 are over 7 of the weft yarns 31-40. This is shown in connection with the warp yarn 2 inFigure 2 and would be true for each of thewarp yarns warp yarns 21. In order to form a locking weave each of thewarp yarns warp yarns 21 then extends under one of theweft yarns weft yarns weft yarns warp yarns warp yarns 21 only weave under thecritical picks warp yarns - Each of the
warp yarns warp yarns 22 is interwoven with the system ofweft yarns 30 with a float on thesecond surface 26 under at least five of the weft yarns 31-40. In thefirst embodiment 20, preferably thewarp yarns warp yarns 22 are interwoven with the system ofweft yarns 30 with a float on the second surface under 7 of the weft yarns 31-40. In order to form the locking weave, thewarp yarns warp yarns 22 then weave over one of theweft yarns weft yarns warp yarns warp yarns 21 is stacked over a corresponding one of thewarp yarns warp yarns 22 to form stacked pairs of warp yarns. As illustrated inFigure 2 , warp yarn 2 is stacked over warp yarn 1. With respect to the weave diagram shown inFigure 1 , the even numberedwarp yarns warp yarns 21 are stacked over the corresponding ones of the odd numberedwarp yarns warp yarns 22. Thewarp yarns warp yarns 22 only weave under thecritical picks filler wefts warp yarns warp yarns 21 of under one of the weft yarns, over one of the weft yarns and under one of the weft yarns forms a locking weave for maintaining a position of thewarp yarns warp yarns 21 in position within the industrial textile. The repeating pattern of thewarp yarns warp yarns 22 of over one of the weft yarns, under one of the weft yarns, and over one of the weft yarns, also forms a locking weave for maintaining a position of thewarp yarns warp yarns 22 in position. - In a preferred arrangement of the
industrial textile 20, 100% warp fill is provided for each of the first and second systems ofwarp yarns stable fabric 20. - In a preferred arrangement, the warp yarns 1-16 preferably have a rectangular cross-sectional shape which contributes to the stability of the
fabric 20 and its smoothness. The warp yarns 1-16 are preferably monofilaments formed of a polymeric material. In one embodiment, the dimensions are 0.25 x 1.05 mm or 0.36 x 1.07 mm to obtain a width to height ratio of between 4:1 and 3:1. Those skilled in the art will recognize that other cross-sectional shapes and ratios may also be used, such as oval or flattened 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 that in some preferred arrangements may range in size from 0.6 mm, 0.7 mm, 0.8 mm, or 0.9 mm. Other sizes may also be used depending on the intended application for the fabric. In one preferred arrangement, thefabric 20 is woven at 22 picks per inch (weft yarns per inch) (8.7 yarns/cm). - The use of first and second systems of warp yarns, 21, 22 also allow different materials to be used for the first and second system of
warp yarns second surfaces industrial textile 20 for the preferred application. - For example, the
monofilament warp yarns warp yarns 21 used to form thefirst surface 24 can be comprised of PPS (polyphenylene sulfide) or PCTA (polycylcohexane dimethanol terephthalic acid) polymers which are more resistant to thermal and hydrolytic degradation than PET (polyethylene terephthalate) yarns (and more expensive). Thewarp yarns - Additionally, due to the long warp floats, a higher contact area can be achieved that reduces fabric wear rates in comparison to similar fabrics having more defined knuckles due to the weave. The long warp floats also provide for benefits in contamination resistance in comparison to similar weft proud fabrics.
- Preferably,
industrial textile 20 is formed into a continuous loop for use as a papermaking fabric, and more particularly as a papermaking dryer fabric, for use on a papermaking machine. In order to form the loop, a seam is created at the ends of the warp yarns 1-16. Preferably, the seam uses 100% of the warp yarns to form the seam. Seams can be formed in a known manner by unweaving and back-weaving warp yarns from the first system ofwarp yarns 21 back into the fabric along the paths of the corresponding stacked ones of the warp yarns from the second system ofwarp yarns 22 that have been cut back from the end of the fabric to form seam loops at each end of the planar fabric, with the seam loops then being interdigitated and joined by a pintle to form an endless fabric loop. Other types of seaming, such as QuickLink seam, which was developed by AstenJohnson, the assignee of the present invention, can also be utilized. 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 theindustrial textile 20 and helps to resist creasing and distortion due to the fact that the warp yarns 1-16 in each layer are woven at about 100% warp fill, and thus are immediately adjacent to and braced against one another. This in connection with the locking weave provides enhanced fabric stability for theindustrial textile 20. - Referring to
Figures 3 and 4 , a second embodiment of anindustrial textile 120 is shown. Theindustrial textile 120 is similar to theindustrial textile 20 and includes first and second systems ofwarp yarns weft yarns 130. The arrangement is similar to theindustrial textile 20 with the exception that the floats in thefirst warp system 121 are over five of the weft yarns 131-138 and the floats in the second system ofwarp yarns 122 are under 5 of the weft yarns 131-138. Thewarp yarns warp yarns 121 are woven in stacked pairs over thewarp yarns warp yarns 122 as shown. Thewarp yarn 102 weaves over weft yarns 131-135, underweft yarn 136 overweft yarn 137 and underweft 138. As in the first embodiment, theweft yarns filler wefts warp yarn 101 of the second system ofwarp yarns 122, which is stacked under thewarp yarn 102, weaves underweft yarn 131, overweft yarn 132, underweft yarn 133, overweft yarn 134, and then under weft yarns 135-138. The next stacked pair ofwarp yarns warp yarn 104 extending overweft yarn 131, underweft yarn 132, overweft yarn 133, underweft yarn 134, and over weft yarns 135-138. Thewarp yarn 103 which is stacked under thewarp yarn 104 weaves under weft yarns 131-135 overweft yarn 136, underweft yarn 137, and overweft yarn 138. This stacked arrangement of warp yarns 101-104 extends across the fabric width in an alternating arrangement as shown inFigure 3 . As in theindustrial textile 20, thewarp yarns warp yarns 121 only weave under thecritical pics warp yarns warp yarns 122 only weave over thecritical pics industrial textile 20, each of thewarp yarns warp yarns 121 forms a locking weave after each float by weaving under one of theweft yarns weft yarns weft yarns warp yarns warp yarns 122 form a locking weave after each of the floats by weaving over one of theweft yarns weft yarns weft yarns fabric 120 which is also preferably woven with 100% warp fill in each of the first system ofwarp yarns 121 and the second system ofwarp yarns 122. The warp yarns 101-104 and the weft yarns 131-138 are similar to the warp yarns 1-16 and weft yarns 31-40 as described above in connection with the first embodiment of theindustrial textile 20. As shown inFigure 3 , this arrangement provides a diagonal twill on thefirst surface 124 of theindustrial textile 120. A diagonal twill would also be provided on thesecond surface 126. - Referring now to
Figures 5 and 6 , a third embodiment of the industrial textile 120' is shown. The third embodiment of the industrial textile 120' is woven with the same repeating weave pattern as the second embodiment of theindustrial textile 120 and similar elements have been marked with the same reference numbers as in the second embodiment with a prime. For example, the warp yarns 101' - 104' correspond to the warp yarns 101-104 in thesecond embodiment 120, and the weft yarns 131' - 138' correspond with the weft yarns 131-138 of thesecond embodiment 120. The primary difference is that based on the locking weave provided for the warp yarns 101'-104', the warp yarns 101'-104' in each of the layers are woven with less than 80% warp fill in order to provide an open mesh. In a preferred embodiment, the first system of warp yarns 121' is woven with approximately 50% warp fill and the second system of warp yarns 122' is also woven with approximately 50% warp fill so that an open mesh dryer fabric as shown inFigure 5 can be produced. The stacked pairs of warp yarns 102', 101', and 104', 103', are maintained in position by their locking weave as discussed above in connection with theindustrial textile 120. This allows for further applications of the industrial textiles according to the invention. - Preferably the
industrial textiles 120, 120' are formed into endless belts by seaming at the warp ends as discussed above in connection with the first embodimemt of theindustrial textile 20. A preferred application for theindustrial textile 120 is as a papermaking fabric, and in particular, a dryer fabric for a papermaking machine. - A preferred application for the industrial textile 120' is for use as a dryer fabric. However, those skilled in the art will recognize that there are other applications.
- Referring to
Figures 7 and 8 , a fourth embodiment of anindustrial textile 220 is shown. Theindustrial textile 220 is similar to theindustrial textile 20 and includes first and second systems ofwarp yarns weft yarns 230. The arrangement is similar to theindustrial textile 20 with the exception that the floats in thefirst warp system 221 are over seven of the weft yarns 231-242 and the floats in the second system ofwarp yarns 222 are under 7 of the weft yarns 231-242. Thewarp yarns warp yarns 221 are woven in stacked pairs over thewarp yarns warp yarns 222 as shown. Thewarp yarn 202 weaves over weft yarns 231-237, underweft yarn 238 overweft yarn 239 and underweft 240. In a similar manner to the first embodiment, theweft yarns filler wefts warp yarn 201 of the second system ofwarp yarns 222, which is stacked under thewarp yarn 202, weaves underweft yarn 231, overweft yarn 232, underweft yarn 233, overweft yarn 234, and then under weft yarns 235-242. The next stacked pair ofwarp yarns warp yarn 204 extending overweft yarn 231, underweft yarn 232, overweft yarn 233, underweft yarn 234, and over weft yarns 235-242. Thewarp yarn 203 which is stacked under thewarp yarn 204 weaves under weft yarns 231-237 overweft yarn 238, underweft yarn 239, and overweft yarn 240, underweft yarn 241, and overweft yarn 242. The weave diagram inFig. 7 shows the paths of the remaining stacked pairs of warp yarns in a clearly defined manner, and in this embodiment, the warp pattern repeats with warp yarns 205-208 having the same weave pattern as warp yarns 201-204. The stacked arrangement of warp yarns 201-216 extends across the fabric width. As in theindustrial textile 20, thewarp yarns warp yarns 221 only weave under thecritical pics warp yarns warp yarns 222 only weave over thecritical pics industrial textile 220, each of thewarp yarns warp yarns 221 forms a locking weave after each float by weaving under one of theweft yarns weft yarns weft yarns warp yarns warp yarns 222 form a locking weave after each of the floats by weaving over one of theweft yarns weft yarns weft yarns fabric 220 which is also preferably woven with 100% warp fill in each of the first system ofwarp yarns 221 and the second system ofwarp yarns 222. The warp yarns 201-216 and the weft yarns 231-242 are similar to and can have the same constructions as the warp yarns 1-16 and weft yarns 31-40 as described above in connection with the first embodiment of theindustrial textile 20. As shown inFigure 7 , this arrangement provides a diagonal twill on thefirst surface 224 of theindustrial textile 220. A diagonal twill would also be provided on thesecond surface 226. -
Fig. 9 shows a further alternative embodiment of a high stabilityindustrial textile 320 is shown. Theindustrial textile 320 includes first and second systems ofwarp yarns weft yarns 330. Here, the floats in thefirst warp system 321 are over at least 5, and preferably over seven of the weft yarns 331-338 and the floats in the second system ofwarp yarns 322 are under at least 5 and preferably under 7 of the weft yarns 331-338. The warp yarns 301-316 are woven in adjacent pairs that are stacked.Adjacent warp yarns adjacent warp yarns surface warp yarns surface warp yarns surface warp yarns surface warp yarns surface warp yarns surface warp yarns Fig. 9 shows the repeat, and in this example, the warp yarn floats are over/under 7 of the weft yarns 331-338. Based on the paired arrangement of the warp yarns 301-316 in the first surface 324 and the second surface 326, a distinct double float arrangement is provided with a distinct diagonal twill. As shown, thewarp yarns warp yarns 321 weave over weft yarns 331-337, and underweft yarn 338. Thewarp yarns warp yarns 322, which are stacked under thewarp yarns weft yarn 334, and under weft yarns 335-338. The next adjacent pair ofwarp yarns weft yarn 234, and over weft yarns 235-238. Theadjacent warp yarns warp yarns weft yarn 238. The arrangement ofadjacent warp yarns warp yarns 321 overadjacent warp yarns warp yarns 322, as well as the arrangement ofadjacent warp yarns warp yarns 321 overadjacent warp yarns warp yarns 322 are similar. The interweaving of the warp yarns of the first and second systems ofwarp yarns filler wefts industrial textile 320 and helps to resist creasing and distortion due to the fact that the warp yarns 301-316 in each layer are woven at about 100% warp fill, and thus are immediately adjacent to and braced against one another. - In order to provide for smooth first and
second surfaces fabric 20, as well as the first andsecond surfaces industrial textiles filler wefts critical pics industrial textiles - Having thus described the present invention in detail, it is to be appreciated and will be apparent to those skilled in the art that many physical changes, only a few of which are exemplified in the detailed description of the invention, could be made without altering the inventive concepts and principles embodied therein. It is also to be appreciated that numerous embodiments incorporating only part of the preferred embodiment are possible which do not alter, with respect to those parts, the inventive concepts and principles embodied therein. The present embodiment and optional configurations are therefore to be considered in all respects as exemplary 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 alternate embodiments and changes to this embodiment which come within the meaning and range of equivalency of said claims are therefore to be embraced therein.
Claims (12)
- An industrial textile (20, 120, 120', 220, 320) having first and second surfaces (24, 26; 124, 126; 124', 126'; 224, 226; 324, 326), the textile comprising:
first and second systems of warp yarns (21, 22; 121, 122; 121', 122'; 221, 222; 321, 322) interwoven with a system of weft yarns (30, 130, 130', 230, 330) in a repeating pattern in which:each of the warp yarns (2, 4, 6, 8, 10, 12, 14, 16; 102, 104; 102', 104'; 202, 204, 206, 208, 210, 212, 214, 216; 303, 304, 307, 308, 311, 312, 315, 316) in the first system of warp yarns (21, 121, 121', 221, 321) is interwoven with the system of weft yarns (30, 130, 130', 230, 330) on the first surface (24, 124, 124', 224, 324) over at least 5 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338), under 1 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338), over 1 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338), and under 1 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338) in the repeating pattern forming a float on the first surface (24, 124, 124', 224, 324) over the at least 5 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338),and each of the warp yarns (1, 3, 5, 7, 9, 11, 13, 15; 101, 103; 101', 103'; 201, 203, 205, 207, 209, 211, 213, 215; 301, 302, 305, 306, 309, 310, 313, 314) in the second system of warp yarns (22, 122, 122', 222, 322) is interwoven with the system of weft yarns (30, 130, 130', 230. 330) on the second surface (26, 126, 126', 226, 326), and each of the warp yarns (1, 3, 5, 7, 9, 11, 13, 15; 101, 103; 101', 103'; 201, 203, 205, 207, 209, 211, 213, 215; 303, 304, 307, 308, 311, 312, 315, 316) of the first system of warp yarns (21, 121, 121', 221, 321) is stacked over a corresponding one of the warp yarns (1, 3, 5, 7, 9, 11, 13, 15; 101, 103; 101', 103'; 201, 203, 205, 207, 209, 211, 213, 215; 301, 302, 305, 306, 309, 310, 313, 314) of the second system of warp yarns (22, 122, 122', 222, 322) to form stacked pairs of the warp yarns.characterized in thateach of the warp yarns (1, 3, 5, 7, 9, 11, 13, 15; 101, 103; 101', 103'; 201, 203, 205, 207, 209, 211, 213, 215; 301, 302, 305, 306, 309, 310, 313, 314) in the second system of warp yarns (22, 122, 122', 222, 322) is interwoven with the system of weft yarns (30, 130, 130', 230. 330) on the second surface (26, 126, 126', 226, 326) under at least 5 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338), over 1 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338), under 1 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338) and over 1 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338) in the repeating pattern forming a float on the second surface (26, 126, 126', 226, 326) under the at least 5 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338). - The industrial textile (20) of claim 1, wherein the float on the first surface (24) is over 7 weft yarns (31-40), and the float on the second surface (26) is under 7 weft yarns (31-40).
- The industrial textile (20, 120, 120', 220, 320) of claim 1, wherein the system of weft yarns (30, 130, 130', 230, 330) includes alternating larger diameter filler wefts (31, 33, 35, 37; 131, 133, 135, 137; 131', 133', 135', 137'; 231, 233, 235, 237, 239, 241; 331, 333, 335, 337) and smaller diameter critical picks (32, 34, 36, 38; 132, 134, 136, 138; 132', 134', 136', 138'; 232, 234, 236, 238, 240, 242; 332, 334, 336, 338).
- The industrial textile (20, 120, 120', 220, 320) of claim 3, wherein the warp yarns of the first system of warp yarns (21, 121, 121', 221, 321) only weave under the critical picks (32, 34, 36, 38; 132, 134, 136, 138; 132', 134', 136', 138'; 232, 234, 236, 238, 240, 242; 332, 334, 336, 338), and the warp yarns of the second system of warp yarns (22, 122, 122', 222, 322) only weave over the critical picks (32, 34, 36, 38; 132, 134, 136, 138; 132', 134', 136', 138'; 232, 234, 236, 238, 240, 242; 332, 334, 336, 338).
- The industrial textile (20, 120, 120', 220, 320) of claim 1, wherein the repeating pattern of the warp yarns of the first system of warp yarns (21, 121, 121', 221, 321) of under 1 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338), over 1 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338), and under 1 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338) forms a locking weave for maintianing a position of the warp warns of the first system of warp yarns (21, 121, 121', 221, 321), and the repeating pattern of the warp yarns of the second system of warp yarns (22, 122, 122', 222, 322) of over 1 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338), under 1 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338), and over 1 of the weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338) forms a locking weave for maintaining a position of the warp warns of the second system of warp yarns (22, 122, 122', 222, 322).
- The industrial textile (120') of claim 1, wherein the stacked pairs of the warp yarns (101' - 104') are spaced apart to form an open mesh pattern.
- The industrial textile (120') of claim 6, wherein the stacked pairs of the warp yarns (101' - 104') are spaced apart by at least 40% of a cross-direction dimension of one of the warp yarns (101' - 104').
- The industrial textile (20, 120, 120', 220, 320) of claim 1, wherein the floats on the first surface (24, 124, 124', 224, 324) are arranged with a diagonal twill.
- The industrial textile (20, 120, 120', 220, 320) of claim 1, wherein the system of weft yarns (31-40; 131-138; 131'-138'; 231-242; 331-338) includes alternating larger filler wefts (31, 33, 35, 37; 131, 133, 135, 137; 131', 133', 135', 137'; 231, 233, 235, 237, 239, 241; 331, 333, 335, 337) having a diameter D1 and smaller critical picks (32, 34, 36, 38; 132, 134, 136, 138; 132', 134', 136', 138'; 232, 234, 236, 238, 240, 242; 332, 334, 336, 338) having a diameter D2, the warp yarns of the first and second systems of warp yarns (21, 22; 121, 122; 121', 122'; 221, 222; 321, 322) have a rectangular cross-section have a thickness t, wherein D1 > D2, and (D1 - D2)/2 ≈ t.
- The industrial textile (20, 120, 220, 320) of claim 1, wherein the first system of warp yarns and second systems of warp yarns (21, 22; 121, 122; 121', 122'; 221, 222; 321, 322) each have at least 100% warp fill.
- The industrial textile (20) of claim 1, wherein the first and second systems of warp yarns (21, 22) are woven with 8 sheds in 10 steps.
- The industrial textile (20, 120, 220, 320) of claim 1, wherein the industrial textile is a papermaking fabric.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201762512327P | 2017-05-30 | 2017-05-30 | |
PCT/US2018/032241 WO2018222370A2 (en) | 2017-05-30 | 2018-05-11 | High stability stacked warp yarn dryer fabric with long warp floats |
Publications (3)
Publication Number | Publication Date |
---|---|
EP3631064A2 EP3631064A2 (en) | 2020-04-08 |
EP3631064A4 EP3631064A4 (en) | 2021-01-20 |
EP3631064B1 true EP3631064B1 (en) | 2022-03-30 |
Family
ID=64454932
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP18810133.1A Active EP3631064B1 (en) | 2017-05-30 | 2018-05-11 | High stability stacked warp yarn dryer fabric with long warp floats |
Country Status (4)
Country | Link |
---|---|
US (1) | US20180347114A1 (en) |
EP (1) | EP3631064B1 (en) |
CN (1) | CN110709547A (en) |
WO (1) | WO2018222370A2 (en) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10328850B2 (en) * | 2017-05-26 | 2019-06-25 | Toyota Boshoku Kabushiki Kaisha | Skin material for vehicle interior |
US11525196B2 (en) * | 2021-02-10 | 2022-12-13 | Voith Patent Gmbh | Woven structured fabric with crossing twill lines |
Family Cites Families (17)
Publication number | Priority date | Publication date | Assignee | Title |
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US4231401A (en) * | 1978-06-16 | 1980-11-04 | Unaform, Inc. | Fabric for papermaking machines |
US4467839A (en) * | 1981-04-28 | 1984-08-28 | Scapa Inc. | Papermakers fabric using differential melt yarns |
DE3635000A1 (en) * | 1986-10-14 | 1988-04-21 | Oberdorfer Fa F | DOUBLE-LAYER PAPER MACHINE SCREEN WITH COARSE-TEXTURED RUNNING SIDE AND FINE-STRUCTURED PAPER SIDE |
US5343896A (en) * | 1990-06-06 | 1994-09-06 | Asten Group, Inc. | Papermakers fabric having stacked machine direction yarns |
US5188884A (en) * | 1991-07-08 | 1993-02-23 | Wangner Systems Corporation | Woven papermaking fabric having low profile seam |
EP0594617A1 (en) * | 1991-07-12 | 1994-05-04 | Jwi Limited | Multi-plane dewatering fabric |
DE4302031C1 (en) * | 1993-01-26 | 1993-12-16 | Heimbach Gmbh Thomas Josef | Fourdrinier for paper mfg. machine for large contact surface area - comprises oven plastics filaments with gp. in sub-gps. shrunk for longitudinal filaments side by side, for flexibility |
US5709250A (en) * | 1994-09-16 | 1998-01-20 | Weavexx Corporation | Papermakers' forming fabric having additional fiber support yarns |
US5544678A (en) * | 1995-04-14 | 1996-08-13 | Jwi Ltd. | Composite forming fabric woven with an Nx2N machine side layer |
US5988229A (en) * | 1998-08-20 | 1999-11-23 | Wangner Systems Corporation | Papermakers forming fabric with weft dominated paper support surface |
US7360560B2 (en) * | 2006-01-31 | 2008-04-22 | Astenjohnson, Inc. | Single layer papermakers fabric |
GB2473039A (en) | 2009-08-28 | 2011-03-02 | Ian Gerald Lang | Seam for a woven industrial fabric |
CA2680924A1 (en) * | 2009-09-29 | 2011-03-29 | Richard Stone | Papermakers' forming fabric including pairs of machine side complementary yarns |
EP2761069B1 (en) * | 2011-09-27 | 2016-07-20 | AstenJohnson, Inc. | Ten-shed semi-duplex through-air dryer fabric |
CA2773501A1 (en) * | 2012-04-02 | 2013-10-02 | Derek Chaplin | Single layer through-air dryer fabrics |
JP6636689B2 (en) | 2013-07-31 | 2020-01-29 | サンコ テキスタイル イスレットメレリ サン ベ ティク エーエスSanko Tekstil Isletmeleri San. Ve Tic. A.S. | Stretchable woven fabric and manufacturing method thereof |
FI20155205A (en) * | 2015-03-24 | 2016-09-25 | Valmet Technologies Oy | The drying wire |
-
2018
- 2018-05-11 WO PCT/US2018/032241 patent/WO2018222370A2/en active Application Filing
- 2018-05-11 CN CN201880035806.0A patent/CN110709547A/en active Pending
- 2018-05-11 US US15/977,239 patent/US20180347114A1/en not_active Abandoned
- 2018-05-11 EP EP18810133.1A patent/EP3631064B1/en active Active
Also Published As
Publication number | Publication date |
---|---|
WO2018222370A3 (en) | 2019-01-10 |
US20180347114A1 (en) | 2018-12-06 |
EP3631064A4 (en) | 2021-01-20 |
EP3631064A2 (en) | 2020-04-08 |
CN110709547A (en) | 2020-01-17 |
WO2018222370A2 (en) | 2018-12-06 |
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