JP4566484B2 - Dryer felt for paper machine - Google Patents

Description

【００４５】
一方、基布の経糸に断面円形モノフィラメントを用いた場合（試料Ｂ）は、緯糸と交錯する箇所での接触面積が少なく、交錯する緯糸との拘束が少ないため幅方向の剛性および耐ズレ性の強化に対する寄与が少ない。また、断面四角形モノフィラメント（試料Ｃ）では、高い経糸充填率にする際には、隣り合った断面四角形糸の側面同士が互いに干渉し合って、ある程度まで充填率を高めて行くと、断面四角形モノフィラメントの平坦な表面と基布幅方向の並行性が維持できなくなり｛図２（Ａ）参照｝、基布表面の一部では経糸の断面四角形の隅部が基布表面１１０’に表出して薄い不織布層を介してドライヤーフェルトの表面性に影響する。また基布の製織時に経糸捌きに影響して、製織効率等の低下をきたす。
【００４６】
しかし、本発明は基布の経糸に「厚さ方向に直線部のない断面形状」モノフィラメントを用いるので、断面形状は扁平であり、交錯する緯糸とは長径側の広い面積で接触し、交錯する緯糸と強く拘束し、緯糸方向の剛性および耐ズレ性の強化に大きく寄与する。また、経糸充填率を高めても断面の側面の滑らかな曲面形状により、基布表面１０’に平滑な表面性が維持され｛図２（Ｂ）参照｝、経糸同士の捌きが良く製織性を損なうこともない。
【００４７】
表２の試料Ｄ、試料Ｅ、試料Ｆ、試料Ｇは、経糸にそれぞれ「厚さ方向に直線部のない断面形状」（ＡＴＮ形）、断面円形、断面四角形のモノフィラメントを用いて同じ織組織（表２／２破れ斜文緯２重織）で織成した基布表面の経糸方向、緯糸方向の摩擦係数を測定したデータである。経糸方向の摩擦係数は、試料Ｄは０．１７６、試料Ｅは０．１９５、試料Ｆは０．２０３、試料Ｇは０．２０１であり、試料Ｆ＞試料Ｇ＞試料Ｅ＞試料Ｄの順で小さくなる。また緯糸方向の摩擦係数も、試料Ｄは０．１７９、試料Ｅは０．１８９、試料Ｆは０．２１４、試料Ｇは０．２０７であり、試料Ｆ＞試料Ｇ＞試料Ｅ＞試料Ｄの順で摩擦係数が小さくなる。このように、断面ＡＴＮ形の試料Ｄが最も摩擦係数が小さくなる。断面四角形の試料Ｇの摩擦係数は、大きい方に属す。上記測定した基布の摩擦係数がニードリングフェルトの表面性を直接代表する数値ではないが、例えば同じ材質、繊度、積層量のウェブを同条件で積層した場合には、特にウェブ厚さが薄くなる程ニードルフェルトの表面性との相関が高くなることは言うまでもない。つまり「厚さ方向に直線部のない断面形状」（ＡＴＮ形）品の方が、断面四角形品よりもニードリングフェルトの表面性を改善することが可能であると言える。
【００４８】
【表２】

【００４９】
本発明の実施に当たっては、経糸に用いる「厚さ方向に直線部のない断面形状」モノフィラメントは、厚さ方向寸法が０．２５ｍｍ〜０．３５ｍｍ、幅方向寸法との比が１：１．３〜１：２．０の範囲内の四角形に内接する断面形状である。０．３５ｍｍを幅方向寸法の上限とするのは経糸方向の柔軟性を良好に保持するためで、これを超えて大きくすると好ましい柔軟性の発現が困難となる。また、０．２５ｍｍ未満になると、経糸の剛直性が充分に確保できなく、緯糸の交錯点で深く交錯することが出来ず、充填率を高めても形態保持性、走行安定性の改善が期待できない。
【００５０】
一方、経糸に使用する「厚さ方向に直線部のない断面形状」モノフィラメントの有するドライヤーフェルトの平滑性を有効に発揮させるため、厚さ方向寸法と幅方向寸法との比は、１：１．３を下限とする。なお、厚さ方向寸法と幅方向寸法との比の上限を１：２．０とするのは、側面の曲面形状を実質確保して、経糸の高い充填率とニードルパンチングの損傷回避効果を発現し、基布の耐久性を確保するためである。
【００５１】
経糸の充填率を高くするには、製織時の経糸密度の設定による他、ヒートセット加工時の緯糸方向の収縮量が多くなるような加工条件ならびに乾熱収縮率の高い緯糸を選定して用いる。乾熱収縮率の高い緯糸を用いる場合には、緯糸の少なくとも一層に用いる。全ての緯糸層に用いる方が経糸の充填率を高くすることができる。乾熱収縮率の高い緯糸を用いる場合は、経糸の充填率１３０％〜１７５％の範囲が実現可能になる。
【００５２】
本発明の実施に当たり、緯糸に用いる乾熱高収縮率の高いモノフィラメントとは、１６０℃において１２％〜２６％、１８０℃において１４％〜３０％の範囲、より好適には１６０℃において１２％〜２１．４％、１８０℃において１４％〜２４％の範囲の乾熱収縮率を有するものを言い、ドライヤーカンバス用に一般に入手可能なものである。例えば、ポリエステルモノフィラメントでは、Ｓｈａｋｅｓｐｅａｒｅ社製のＰＸ−４０５が市販され入手可能である。
【００５３】
本発明に適用するモノフィラメント糸としては、ＰＥＴやＰＢＴなどのポリエステル繊維、ナイロン６、ナイロン４６、ナイロン６６などのポリアミド繊維、ポリプロピレン繊維などのポリオレフィン繊維をはじめ、耐熱性に優れたＰＰＳやＰＥＥＫ等を主体として成るモノフィラメント糸を経糸および／または緯糸に、単独あるいはそれらを組み合わせて用いる。寸法安定性および耐摩耗性、耐屈曲疲労性等の点からはＰＥＴやＰＢＴなどのポリエステル繊維、耐熱性等の点からはＰＰＳやＰＥＥＫ糸が好適である。
【００５４】
基布の織組織としては、経糸方向の柔軟性を確保した上で、特に緯糸方向の剛性を必要とするために、緯２重織あるいは緯３重織が用いられる。特に緯糸方向の剛性に重きを置く場合は、表１／３破れ斜文裏３／１破れ斜文緯２重織｛図４（Ａ）｝を基本として、その中層に緯糸を一本置きに織成する緯２．５重織｛図４（Ｂ）｝、中層に各々一本ずつ緯糸を織成する３重織｛図４（Ｃ）｝が用いられる。勿論、表１／３正則斜文裏３／１正則斜文緯２重織も用いることが出来る。また、表面の平坦度を向上させるものとして経糸が長浮きする緯２重織で図４（Ｄ）（Ｅ）に示すような表２／２正則斜文や表２／２破れ斜文緯２重織｛図４（Ｄ）｝、表３／３正則斜文や表３／３破れ斜文緯２重織｛図４（Ｅ）｝等の織組織を用いることが出来る。
【００５５】
より高い緯糸方向の剛性を特に必要とする場合、例えばフェルト幅が５ｍ以上の広幅の場合には、表層および裏層の両層の緯糸には直径寸法が０．３ｍｍ〜０．７ｍｍの範囲の断面円形モノフィラメントを用いる。経糸に「厚さ方向に直線部のない断面形状」モノフィラメントを用い、経糸充填率を１００％〜１７５％、好適には経糸充填率を１２５％〜１７５％の範囲にすることにより、隣接する経糸同士の拘束が強まり、また、緯糸との交錯はより深く強固なものになり、緯糸方向の剛性がより補強されるとともに耐ズレ性が改善され、形態保存性、走行安定性に優れたドライヤーフェルトとなる。また中層の緯糸にはウェブ繊維との交絡接着性、通気度の調整のためにマルチ糸、スパン糸等を適宜用いることができる。さらに中間層の緯糸には、緯糸方向のさらなる剛性強化目的で、断面円形モノフィラメントを用いることが望ましい。その場合の緯糸の直径寸法は、０．３ｍｍ〜０．７ｍｍの範囲が好ましい。
【００５６】
基布に積層するウェブの積層量は、湿紙への密着性、クッション性により、必要な積層量が設定される。ウェブと基布との交絡接着性を充分に確保するためや、低い通気度を得るために表層と裏層の緯糸の一方だけに断面円形モノフィラメントを織成し、他の緯糸にマルチフィラメントやスパン糸を用いることが出来る。緯糸の片層にモノフィラメント以外の剛直性の劣る糸を用いた場合は、当然、緯糸方向の剛性が低下するが、経糸充填率を、好適には１３０％〜１７０％に高めて、耐ズレ性の改善を図り、形態保存性、走行安定性の改善を図ると共に、片層緯糸の直径寸法が０．３ｍｍ〜０．７ｍｍの範囲の剛直な断面円形モノフィラメントにより緯糸方向の剛性を補強する。これらによりフェルト幅が５ｍ以上の用途にも適用可能な緯糸方向の剛性が得られる。
【００５７】
なお、緯糸の材質、直径寸法の他に、緯糸の面では、好ましい緯糸方向の剛性、耐ズレ性、通気度を得るために、また、ワープループ継手の生産効率も考慮して、緯糸の密度は緯糸２重織では１２本×２／２．５４ｃｍ〜２０本×２／２．５４ｃｍ、緯糸３重織りでは１２本×３／２．５４ｃｍ〜２０本×３／２．５４ｃｍの範囲で適宜選択できる。
【００５８】
所謂シングルラン形式に使用されるパートにおいては、前述のようにドライヤーフェルトの厚さの薄いことが不可欠とされているので、ウェブ繊維の積層量も限定して使用される。ウェブ繊維の積層量が少ないと基布との交絡接着性が低下しやすくなるので、また、シングルラン形式の乾燥部で広幅、高抄速の用途の場合、さらに一層の緯糸方向の剛性と耐ズレ性が必要となるので、表層および裏層に剛直性の優れた断面円形モノフィラメントを織成し、中層にスパン糸等のウェブ繊維との交絡性によい糸を用いる、緯２．５重織若しくは緯３重織りが好適である。
【００５９】
また、シングルラン形式の乾燥部で、特に表面性を重視する場合には、ウェブ繊維は積層量を限定して使用されることによって、不織布層は薄くなり基布の表面性が薄いウェブ層を介して湿紙に影響しやすくなるので、表面平滑性に優れる接紙面側表面の経糸が長浮きする緯２重の斜文織の織組織が好適である。経糸に使用する「厚さ方向に直線部のない断面形状」モノフィラメントの平坦性もあって基布としての表面平滑性が得られる。
【００６０】
ウェブに使用する繊維の太さは、フェルトのクッション性、高い通気度を重きに置く場合は１１dtex以上、２２dtex程度まで、薄い厚さ、低い通気度を求める場合には１１dtex以下、２dtexまでを適宜単独あるいは複数の種類の繊度の繊維を混綿して適宜選択される。ウェブの積層量は、通常３００ｇ／ｍ²前後程度が用いられるが、厚さを薄くするためには１００ｇ／ｍ²程度以下も選択される。また、ウェブの材質は、ポリエステル繊維、ポリアミド繊維、アクリル繊維、芳香族ポリアミド繊維、その他の繊維を使用することができる。
【００６１】
本発明では「厚さ方向に直線部のない断面形状」モノフィラメントを経糸に用い、経糸充填率を高めに設定して幅方向に隣り合った経糸が充分密着するように構成するものであるから、幅方向の撓みに対する自由度を減少させる作用を生じ、緯糸に用いる前記直径寸法範囲の断面円形モノフィラメントの剛性と相俟って、断面円形や断面四角形モノフィラメントを用いた場合に比べ、その幅方向の剛性と共に耐ズレ性を向上させることが可能になる。
【００６２】
本発明では基布の経糸に「厚さ方向に直線部のない断面形状」モノフィラメントを用い、高い経糸充填率を実現できるので、表層および裏層に断面円形モノフィラメントを用いた緯２重織、緯２．５重織もしくは緯３重織の表１／３破れ斜文裏３／１破れ斜文の織組織において、広幅、高抄速の用途に充分な緯糸方向の剛性および耐ズレ性を備え、問題のない表面平滑性で基布の厚さが１．３ｍｍ〜１．８ｍｍ、フェルトとしてはシングルラン形式の用途に適した１．７ｍｍ〜２．２ｍｍの範囲内の厚さを有するドライヤーフェルトが実現できる。
【００６３】
また、表層または裏層に断面円形モノフィラメントを用い、残りの１層にマルチフィラメント糸、スパン糸等のウェブとの交絡性の優れる糸条を用いた経糸長浮き緯２重織組織においても、充分に緯糸方向の剛性を補強し、少ないウェブ積層量であっても基布の平滑な表面性により表面平滑性に優れた表面性で、基布の厚さが１．３ｍｍ〜１．８ｍｍ、好適には１．３ｍｍ〜１．６ｍｍの範囲、フェルトとしてはシングルラン形式の用途に適した１．７ｍｍ〜２．２ｍｍの範囲内の厚さを有するドライヤーフェルトが実現できる。
【００６４】
また、本発明では基布の経糸に「厚さ方向に直線部のない断面形状」モノフィラメントを用い、高い経糸充填率を実現できるので、また緯糸の一層にウェブとの交絡性に優れるマルチフィラメント糸、スパン糸等を用いることが出来るので、少ないウェブ積層量であっても表面平滑性に優れたドライヤーフェルトをシングルラン形態の用途に適した１，０００〜６，０００ｃｍ³/ｃｍ²・分、好適には１，０００〜４，５００ｃｍ³/ｃｍ²・分の範囲内の通気度を有するドライヤーフェルトが実現できる。
【００６５】
なお、本発明の実施に関わる各試験の方法については、以下による。
▲１▼乾熱収縮率
原糸を３００ｍｍの長さにカットした５本の試料を熱風乾燥機中で２０分間処理する。取り出した試料を標準状態（温度２０℃、相対湿度６５％）の室内中に約３０分以上放置してからその長さを測定して、次式で求めた５本の試料の平均値で表す。

【００６６】
▲２▼通気度
ＪＩＳ Ｌ−１０９６：１９９９ フラジール形法に準拠した測定装置を用いて測定する。
【００６７】
▲３▼３点曲げ剛性
図５の試験機２０により、幅３ｃｍ（図５の紙面表裏方向の寸法）の試料Ｓの両端上面を、１００ｍｍ
だけ離間させて固定配置した直径２０ｍｍの丸棒２１に係止し、試料Ｓの中央部を直径１０ｍｍローラー２２と荷重計（図示せず）を介して上方に引っ張る。ローラー２２の引上げ量と共に表示値は増大していくが、ある程度引上げると荷重計の表示値は増大しなくなる。この時の最大表示値を剛性値と称し、単位ｃＮ／３ｃｍで表す。
【００６８】
経糸方向の３点曲げ剛性を試験する場合は、試料Ｓの長手方向（幅３ｃｍと直角方向）を経糸方向にし
、緯糸方向の剛性を測定する場合は、試料Ｓの長手方向を緯糸方向とする。
【００６９】
▲４▼ズレ角度
図６（Ａ）（Ｂ）はズレ角度測定装置３０を示し、固定柱３１の上端部と基端部に横アーム３２，３３の一端が、それぞれ枢支ピン３４，３５にて上下揺動可能に取り付けられ、横アーム３２，３３の他端は連結アーム３６でリンク状に連結され、常時は上側の横アーム３２が固定水平アーム３７にピン３８にて固定されている。また、上端側の横アーム３２の基部には、その傾斜角度を指示する指針３９が取り付けてある。
【００７０】
横アーム３２および固定水平アーム３７で、所定長、所定幅の試料Ｓの上端を固定し、下端に試料Ｓの幅１ｃｍあたり１ｋｇの荷重を懸垂する。この状態で下側の横アーム３３に試料Ｓの下端を固定し、その後、荷重を取り去る。このようにして、図６（Ａ）のごとく試料Ｓを固定し、ピン３８を引き抜き、図６（Ｂ）のごとく下向きのモーメントをかける。この状態で一定時間放置後、図６（Ｃ）のズレ寸法ｘ１（加熱前）を指針３９により測定し、その状態のまま温度１３０℃で一定時間処理を行う。その後、再度、ズレの寸法ｘ２（加熱後）を指針３９により測定する。
ズレ角度θ１（加熱前）、θ２（加熱後）の計算は、図６（Ｃ）のごとくズレの寸法ｘ（ｍｍ）、枢枝ピン３４の中心点から指針３９の先端までの長さＬ（＝１２０ｍｍ）より、次式で計算される。
ｔａｎθ＝ｘ／１２０、 θ＝ｔａｎ^-1（ｘ／１２０）
上記より求めたズレ角度θから、ドライヤーフェルトの走行時における織組織のズレを推定し、ドライヤーフェルトの走行安定性の評価に用いる。
【００７１】
▲５▼摩擦係数
摩擦係数の測定には図７に示す装置４０を用いる。この装置４０は、固定した接触部材４１上で試料Ｓの上に重錘４２を載置して垂直方向に荷重Ｗを加えた状態で、重錘４２に結んだ引き紐４３を、滑車４４を介して矢印方向に引張って走行させた時（速度５０ｍｍ／分）、動き始めた時の摩擦力Ｆを測定（例；引き紐４３の途中にバネ秤を設置して、その値を見る）し、摩擦力Ｆと荷重（Ｗ＝５ｋｇ）とに基
づいて、摩擦係数（μ）＝摩擦力（Ｆ）／荷重（Ｗ）の関係式から摩擦係数を算出した。試料Ｓとしては、幅１０ｃｍ、長さ１５ｃｍのものを用い、経糸方向の摩擦係数を求める場合は試料Ｓの長さ方向を経糸方向とし、緯糸方向の摩擦係数を求める場合は試料Ｓの長さ方向を緯糸方向とする。
【００７２】
▲６▼厚さ
ＪＩＳ Ｌ−１０９６：１９９９ 厚さ測定法に準拠して厚さ測定機により測定する。但し、測定圧は１４．７ｋＰａで測定した。
【００７３】
（基布における流れ方向（経糸方向）および幅方向（緯糸方向）の剛性確認）
基布にウェブを積層、ニードリングし絡合一体化するドライヤーフェルトは、使用時の湿紙への密着性、クッション性、吸湿性、また通気度等の機能により、ウェブの材質等の仕様、積層量、ニードルパンチングの条件、ニードリング後の樹脂加工やヒートセット加工条件を適宜選択するものであり、これらの仕様条件は本発明の主要な改良目的である経糸方向の柔軟性、緯糸方向の剛性、耐ズレ性にも少なからず影響するものである。
【００７４】
本発明の請求項と効果を対照して説明するために、先ず、本発明の主要素である基布の試作１、２、３およびこれに対する比較例としての試作４〜７について、表３〜表５に基づいて説明する。基布の構成およびその構成からの特性によって、基布にウェブを積層し、絡合一体化されたドライヤーフェルトの作用効果を明確に確認出来る。
【００７５】
【表３】

【００７６】
【表４】

【００７７】
【表５】

【００７８】
試作１〜３（表３）は、いずれもウェブを積層する前の状態での本発明のドライヤーフェルトに用いられる基布についての試作である。また、試作４〜７（表４および表５）もウェブを積層する前の基布の試作であって、試作１〜３の比較例として試作したものである。
【００７９】
各表において、ＴＭはポリエステルモノフィラメント、ＡＣはアクリル繊維のスパン糸を表す。高収縮糸は乾熱収縮率の高いモノフィラメントを表す。
【００８０】
（試作１）
試作１の基布を表３に示す仕様と図４（Ａ）に示す織組織に基づいて織成し、ヒートセット加工を施して作成した。
すなわち、経糸に寸法が厚さ０．３０ｍｍ×幅０．４６ｍｍの「厚さ方向に直線部の無い断面形状」（ＡＴＮ形）ポリエステルモノフィラメント｛図１（Ｂ）の断面形状｝、表層および裏層の緯糸に寸法が直径０．５０ｍｍの高収縮糸の断面円形ポリエステルモノフィラメントを用い、表１／３破れ斜文裏３／１破れ斜文緯２重織組織で、経糸充填率１４５．１％、緯糸密度１６．６本×２／２．５４ｃｍで作成した。作成した基布は厚さ１．８０ｍｍであった。
【００８１】
（試作２）
試作２の基布を表３に示す仕様と図４（Ａ）に示す織組織に基づいて織成し、ヒートセット加工を施して作成した。
すなわち、経糸に寸法が厚さ０．３０ｍｍ×幅０．４６ｍｍの「厚さ方向に直線部の無い断面形状」（ＡＴＮ形）ポリエステルモノフィラメント｛図２（Ｂ）の断面形状｝、表層および裏層の緯糸に寸法が直径０．５０ｍｍの断面円形ポリエステルモノフィラメントを用い、表１／３破れ斜文裏３／１破れ斜文緯２重織組織で、経糸充填率１３４．１％、緯糸密度１６．２本×２／２．５４ｃｍで作成した。作成した基布は厚さ１．８４ｍｍであった。
【００８２】
（試作３）
試作３の基布を表３に示す仕様と図４（Ｄ）に示す織組織に基づいて織成し、ヒートセット加工を施して作成した。
すなわち、経糸に寸法が厚さ０．３０ｍｍ×幅０．４６ｍｍの「厚さ方向に直線部の無い断面形状」（ＡＴＮ形）ポリエステルモノフィラメント｛図２（Ｂ）の断面形状｝、表層の緯糸に寸法が直径０．４０ｍｍの断面円形ポリエステルモノフィラメントを、裏層の緯糸に綿番手６^Sのアクリルスパン糸５本の撚糸を用い、表２／２破れ斜文裏３／１破れ斜文緯２重織組織で、経糸充填率１３３．３％、緯糸密度１５．１本×２／２．５４ｃｍで作成した。作成した基布は厚さ１．６８ｍｍであった。
【００８３】
（試作４）
試作４の基布を表４に示す仕様と図４（Ａ）に示す織組織に基づいて織成し、ヒートセット加工を施して作成した。
すなわち、経糸に直径寸法が０．４０ｍｍの断面円形ポリエステルモノフィラメント、表層および裏層の緯糸に直径寸法が０．４０ｍｍの断面円形ポリエステルモノフィラメントを用い、表１／３破れ斜文裏３／１破れ斜文緯２重織組織で、経糸充填率１３２．６％、緯糸密度１５．５本×２／２．５４ｃｍで作成した。作成した基布は厚さ１．８６ｍｍであった。
【００８４】
（試作５）
試作５の基布を表４に示す仕様と図４（Ａ）に示す織組織に基づいて織成し、ヒートセット加工を施して作成した。
すなわち、経糸に寸法が直径０．３０ｍｍの断面円形ポリエステルモノフィラメント、表層および裏層の緯糸に直径寸法が０．５０ｍｍの断面円形ポリエステルモノフィラメントを用い、表１／３破れ斜文裏３／１破れ斜文緯２重織組織で、経糸充填率１４８．９％、緯糸密度１４．３本×２／２．５４ｃｍで作成した。作成した基布は厚さ１．８３ｍｍであった。
【００８５】
（試作６）
試作６の基布を表５に示す仕様と図４（Ｄ）に示す織組織に基づいて織成し、ヒートセット加工を施して作成した。
すなわち、経糸に直径寸法が０．４０ｍｍの断面円形ポリエステルモノフィラメント、表層の緯糸に直径寸法が０．４０ｍｍの断面円形ポリエステルモノフィラメントを、裏層の緯糸に綿番手６^Sのアクリルスパン糸５本の撚糸を用い、表２／２破れ斜文裏３／１破れ斜文緯２重織組織で、経糸充填率１３３．５％、緯糸密度１３．９本×２／２．５４ｃｍで作成した。作成した基布は厚さ１．６６ｍｍであった。
【００８６】
（試作７）
試作７の基布を表５に示す仕様と図４（Ｄ）に示す織組織に基づいて織成し、ヒートセット加工を施して作成した。
すなわち、経糸に寸法が厚さ寸法０．２８ｍｍ×幅寸法０．５６ｍｍの断面四角形ポリエステルモノフィラメント、表層の緯糸に直径寸法が０．４０ｍｍの断面円形ポリエステルモノフィラメントを、裏層の緯糸に綿番手２０^Sのアクリルスパン糸１２本の撚糸を用い、表２／２破れ斜文裏３／１破れ斜文緯２重織組織で、経糸充填率１２１．３％、緯糸密度１５．０本×２／２．５４ｃｍで作成した。作成した基布は厚さ１．６０ｍｍであった。
【００８７】
上記の本発明の試作１〜３および比較例とした試作４〜７のドライヤーフェルト用基布の流れ方向（経糸方向）および幅方向（緯糸方向）の剛性を、前記の図５に示す３点曲げ剛性の試験機２０により確認した。荷重は接紙面側（図５の図示下側）から掛けている。これはドライヤーフェルト使用時にシリンダー上で湿紙に押圧している状態に相当する。測定は各基布についてサンプル３点にて行い、測定結果の平均値を図４（Ａ）の織組織の基布については、表６の試作１、２、４、５に、図４（Ｄ）の織組織の基布については、表６の試作３、６、７にそれぞれ示した。
【００８８】
【表６】

【００８９】
なお、図４（Ａ）の表１／３破れ斜文裏３／１破れ斜文緯２重織りの織組織は、緯糸方向の剛性、耐ズレ性を高めに得やすく、柔軟性が得にくい織組織である。図４（Ｄ）の表２／２破れ斜文裏１／３破れ斜文緯２重織りの織組織は、経糸方向の柔軟性は得やすいが、耐ズレ性が得にくい織組織である。
【００９０】
（径糸方向の３点曲げ剛性）
経糸方向の３点曲げ剛性の結果は、試作１で６０ｃＮ／３ｃｍ、試作２で６５ｃＮ／３ｃｍ、試作３で３５ｃＮ／３ｃｍ、試作４で１２０ｃＮ／３ｃｍ、試作５で７０ｃＮ／３ｃｍ、試作６で１０５ｃ
Ｎ／３ｃｍ、試作７で４５ｃＮ／３ｃｍであった。
【００９１】
したがって、経糸方向の３点曲げ剛性は、図４（Ａ）の織組織の場合、試作１は６０ｃＮ／３ｃｍであり、試作２は６５ｃＮ／３ｃｍであり、経糸に直径０．４０ｍｍの断面円形モノフィラメントを用いた従来のドライヤーフェルトの基布（試作４で１２０ｃＮ／３ｃｍ）と比較して、柔軟性が極めて良好であることが判った。また、経糸に繊度が小さい直径０．３０ｍｍ断面円形モノフィラメントを用いた従来のドライヤーフェルトの基布（試作５で７０ｃＮ／３ｃｍ）と比較しても、同等またはそれより柔軟であることが判った。
【００９２】
図４（Ｄ）の織組織の場合、試作３は３５ｃＮ／３ｃｍであり、試作１および試作２に比べてさらに柔軟である。また、経糸に直径０．４０ｍｍの断面円形モノフィラメントを用いた従来のドライヤーフェルトの基布（試作６で１０５ｃＮ／３ｃｍ）と比較して、格段に柔軟である。経糸に寸法が厚さ０．２８ｍｍ×幅０．５６ｍｍの断面四角形モノフィラメントを用いた従来のドライヤーフェルトの基布（試作７で４５ｃＮ／３ｃｍ）に対しては、基布の厚さが１．６８ｍｍと試作７の１．６０ｍｍよりも若干厚いにも関わらず、経糸方向の柔軟性は同等以上であることが判った。
【００９３】
（緯糸方向の３点曲げ剛性）
緯糸方向の３点曲げ剛性の結果は、試作１で８１５ｃＮ／３ｃｍ、試作２で７７５ｃＮ／３ｃｍ、試作３で４０５ｃＮ／３ｃｍ、試作４で４４５ｃＮ／３ｃｍ、試作５で７４５ｃＮ／３ｃｍ、試作６で３５５ｃＮ／３ｃｍ、試作７で２９５ｃＮ／３ｃｍであった。
【００９４】
したがって緯糸方向の３点曲げ剛性は、図４（Ａ）の織組織の場合、試作１は８１５ｃＮ／３ｃｍであり、試作２は７７５ｃＮ／３ｃｍであり、緯糸に直径寸法が０．５０ｍｍの断面円形モノフィラメントを用いたこともあり、緯糸に直径０．４０ｍｍの断面円形モノフィラメントを用いた従来のドライヤーフェルトの基布（試作４で４４５ｃＮ／３ｃｍ）と比較して、ほぼ同じ厚さであるにも関わらず緯糸方向の剛性が高く、経糸に直径寸法が０．３０ｍｍの断面円形モノフィラメント、緯糸に直径寸法が同じ０．５０ｍｍの断面円形モノフィラメントを用いた従来のドライヤーフェルトの基布（試作５で７４５ｃＮ／３ｃｍ）と同等またはそれ以上であることが判った。また、試作１は緯糸に高収縮のモノフィラメントを使用しているので、経糸充填率を１４５．１％と高く出来たことにより、緯糸方向の３点曲げ剛性（８１５ｃＮ／３ｃｍ）は、断面円形モノフィラメントを用いた経糸充填率１３４．１％の試作２における緯糸方向の３点曲げ剛性（７７５ｃＮ／３ｃｍ）よりもさらに高い。
【００９５】
図４（Ｄ）の織組織の場合、試作３の緯糸方向の３点曲げ剛性は４０５ｃＮ／３ｃｍであり、試作１や試作２に比べて剛性が低い。表層の緯糸に直径寸法が０．４０ｍｍの断面円形モノフィラメント、裏層の緯糸にスパン糸の撚り糸を用いた構成は、試作３、試作６、７ともほぼ同じであり、経糸に寸法が厚さ０．３０ｍｍ×幅０．４６ｍｍの「厚さ方向に直線部の無い断面形状」（ＡＴＮ形）モノフィラメントを用いたドライヤーフェルトの基布（試作３）は、経糸に直径０．４０ｍｍの断面円形モノフィラメントを用いたドライヤーフェルトの基布（試作６で３５５ｃＮ／３ｃｍ）および経糸に厚さ方向の寸法が０．２８ｍｍ、幅方向の寸法が０．５６ｍｍの断面四角形モノフィラメントを用いたドライヤーフェルトの基布（試作７で２９５ｃＮ／３ｃｍ）に比べ、緯糸方向の３点曲げ剛性はほぼ同じか若干高いことが判った。
【００９６】
（基布での走行安定性の評価）
上記本発明の試作１〜３および比較例とした試作４〜７のドライヤーフェルト用基布における加熱前（装着２分後）および加熱後（処理３分後）のズレ角度を、前記の図６に示す測定装置３０により測定して、ドライヤーフェルト走行時の織組織のズレを推定し、走行安定性を評価した。測定は、各基布についてサンプル数３について行い、測定結果の平均値を表７に示した。
【００９７】
【表７】

【００９８】
加熱前（装着２分後）のズレ角度θ１は、試作１で２．５８°、試作２で３．４２°、試作３で４．０８°、試作４で５．２５°、試作５で９．０８°、試作６で１１．９２°、試作７で５．９２°、であった。
【００９９】
加熱後（処理３分後）のズレ角度θ２は、試作１で６．６７°、試作２で７．７５°、試作３で８．２５°、試作４で１０．８３°、試作５で１４．３３°、試作６で１６．０８°、試作７で１１．１７°であった。
【０１００】
したがって、ズレ角度θは、図４（Ａ）の織組織の場合、試作１では加熱前２．５８°および加熱後６．６７°で、試作２では加熱前３．４２°および加熱後７．７５°であり、それぞれで、経糸繊度が大きい直径が０．４０ｍｍの断面円形モノフィラメントを用いたドライヤーフェルト基布（試作４で加熱前５．２５°、加熱後１０．８３°）よりもズレ角度θが小さい。また、経糸繊度が小さい直径が０．３０ｍｍの断面円形モノフィラメントを用いたドライヤーフェルト基布（試作５で加熱前９．０８°、加熱後１４．３３°）よりもそれぞれズレ角度θがかなり小さく、走行安定性が改善されることが判った。また、試作１と試作２では経糸充填率が高い試作１の方が加熱前および加熱後のそれぞれでズレ角度θが小さく、より走行安定性が優れていることが判った。
【０１０１】
図４（Ｄ）の織組織の場合、試作３で加熱前４．０８°および加熱後８．２５°であり、それぞれで、経糸繊度が大きい直径寸法が０．４０ｍｍの断面円形モノフィラメントを用いたドライヤーフェルト基布（試作６で加熱前１１．９２°および加熱後１６．０８°）よりもズレ角度θが小さく、また、寸法が厚さ０．２８ｍｍ×幅０．５６ｍｍの断面四角形モノフィラメントを用いた従来のドライヤーフェルト基布（試作７で加熱前５．９２°および加熱後１１．１７°）よりもズレ角度θが小さく、走行安定性、形態保持性に優れていることが判った。
【０１０２】
以上のように、図４（Ａ）表１／３破れ斜文裏３／１破れ斜文緯２重織の織組織の場合も、図４（Ｄ）表２／２破れ斜文裏３／１破れ斜文緯２重織りの織組織の場合も、本発明の試作１〜３のドライヤーフェルト用基布は、比較例としての試作４〜７のドライヤーフェルト用基布に比べ、経糸方向の柔軟性に優れており、緯糸方向の剛性も同じ緯糸構成について見れば比較例の試作ドライヤーフェルト用基布よりも優れることが判った。走行安定性、形態保持性の評価となる耐ズレ性も、本発明の試作１〜３が試作４〜７に比べ改善されることが判った。
【０１０３】
次に、基布にウェブを積層し、ニードルパンチングしたドライヤーフェルトの状態での本発明の実施例について、表８〜表９に基づいて説明する。各表でのウェブ仕様欄における記号Ｎはナイロン６６、ＡＣはアクリルと、それぞれウェブの材質を表し、その後の数字はウェブの繊度（単位はdtex、表中では繊度の数字に続けて上付きの「Ｔ」と表記する）を示す。
【０１０４】
（実施例）
実施例１〜２は、基布の表裏両面にウェブを積層形成したドライヤーフェルトについての実施例で、実施例３〜６は、基布の片面（表面）にウェブを積層形成したドライヤーフェルトについての実施例である。以下、表８〜表９に基づいて、各実施例について説明する。
【０１０５】
【表８】

【０１０６】
【表９】

【０１０７】
（実施例１）
実施例１のドライヤーフェルトを表８に示す仕様と図４（Ａ）に示す基布の織組織に基づいて織成、ヒートセット加工を施し、表８に示す仕様のウェブを積層ニードリングして基布と絡合一体化した後、ヒートセット加工を施して作成した。
【０１０８】
すなわち、経糸１１に寸法が厚さ０．３０ｍｍ×幅０．４６ｍｍの「厚さ方向に直線部の無い断面形状」（ＡＴＮ形）ポリエステルモノフィラメント｛図１（Ｂ）の断面形状｝、表層および裏層の緯糸１２，１３に直径寸法が０．５０ｍｍの断面円形ポリエステルモノフィラメントを用い、表１／３破れ斜文裏３／１破れ斜文緯２重織組織で基布１０ａを織成し、ヒートセット加工を施した上、基布１０ａの表層に、表８の仕様に示す繊度６．６dtexのナイロン６６繊維ステープルと繊度１１dtexのアクリル繊維ステープルとを重量比６０％：４０％で混合したウェブ１５を３２０ｇ／ｍ²、裏層に表層と同様の配合のウェブ１６を１００ｇ／ｍ²の積層量で積層し、ニードリングにて絡合一体化して表層，裏層にそれぞれ不織布層１５，１６を形成した後、ヒートセット加工を施して、経糸密度が７３．６本／２．５４ｃｍ、緯糸密度が１７．２×２本／２．５４ｃｍのドライヤーフェルト１００Ａを作成した。構成の概念を図８（Ａ）に示す。この時の経糸充填率は１３３．３％であり、基布１０ａの厚さは１．７７ｍｍとなった。ドライヤーフェルト１００Ａの厚さは４．４２ｍｍ、通気度は５，７２０ｃｍ³/ｃｍ²・分であった。また、ニードリング前の基布１０ａの経糸強度に対するニードリングの傷付きでの強度保持率は、従来の断面円形モノフィラメントを経糸とした基布のドライヤーフェルトに比べ差がなかった。
【０１０９】
（実施例２）
実施例２のドライヤーフェルトを表８に示す仕様と図４（Ａ）に示す基布の織組織に基づいて織成、ヒートセット加工を施し、表８に示す仕様のウェブを積層ニードリングして基布と絡合一体化した後、ヒートセット加工を施して作成した。
【０１１０】
すなわち、経糸１１に寸法が厚さ０．３０ｍｍ×幅０．４６ｍｍの「厚さ方向に直線部の無い断面形状」（ＡＴＮ形）ポリエステルモノフィラメント｛図１（Ｂ）の断面形状｝、表層および裏層の緯糸１２，１３に直径寸法が０．５０ｍｍの断面円形高収縮ポリエステルモノフィラメントを用い、表１／３破れ斜文裏３／１破れ斜文緯２重織組織で基布１０ａを織成し、ヒートセット加工を施した上、基布１０ａの表層に表８の仕様に示す繊度６．６dtexのナイロン６６繊維ステープルと繊度１１dtexのアクリル繊維ステープルを重量比６０％：４０％で混合したウェブ１５を３２０ｇ／ｍ²、裏層に表層と同様の配合のウェブ１６を１００ｇ／ｍ²の積層量で積層し、ニードリングにて絡合一体化して表層，裏層にそれぞれ不織布層１５，１６を形成した後、ヒートセット加工を施して、経糸密度が８０．４本／２．５４ｃｍ、緯糸密度が１６．８×２本／２．５４ｃｍのドライヤーフェルト１００Ａを作成した。構成の概念を図８（Ａ）に示す。この時の経糸充填率は１４５．６％であり、基布１０ａの厚さは１．８０ｍｍとなった。
ドライヤーフェルト１００Ａの厚さは４．２５ｍｍ、通気度は４，８９０ｃｍ³/ｃｍ²・分であった。また、ニードリング前の基布の経糸強度に対するニードリングの傷付きでの強度保持率は、従来の断面円形モノフィラメントを経糸とした基布のドライヤーフェルトに比べ差がなかった。
【０１１１】
（実施例３）
実施例３のドライヤーフェルトを表８に示す仕様と図４（Ａ）に示す基布の織組織に基づいて織成、ヒートセット加工を施し、表８に示す仕様のウェブを積層ニードリングして基布と絡合一体化した後、ヒートセット加工を施して作成した。
【０１１２】
すなわち、経糸１１に寸法が厚さ０．３０ｍｍ×幅０．４６ｍｍの「厚さ方向に直線部の無い断面形状」（ＡＴＮ形）ポリエステルモノフィラメント｛図１（Ｂ）の断面形状｝、表層および裏層の緯糸１２，１３に直径寸法が０．５０ｍｍの断面円形高収縮ポリエステルモノフィラメントを用い、表１／３破れ斜文裏３／１破れ斜文緯２重織組織で基布１０ａを織成し、ヒートセット加工を施した上、基布１０ａの表層に表８の仕様に示す繊度６．６dtexのナイロン６６繊維ステープルのウェブ１５を２６０ｇ／ｍ²の積層量で積層し、ニードリングにて絡合一体化して表層に不織布層１５を形成した後、ヒートセット加工を施して、経糸密度が８０．５本／２．５４ｃｍ、緯糸密度が１７．５×２本／２．５４ｃｍのドライヤーフェルト１００Ｂを作成した。構成の概念を図８（Ｂ）に示す。この時の経糸充填率は１４５．８％であり、基布１０ａの厚さは１．８２ｍｍとなった。ドライヤーフェルト１００Ｂの厚さは２．６６ｍｍ、通気度は３，２４０ｃｍ³/ｃｍ²・分であった。また、ニードリング前の基布の経糸強度に対するニードリングの傷付きでの強度保持率は、従来の断面円形モノフィラメントを経糸とした基布のドライヤーフェルトに比べ差がなかった。
【０１１３】
（実施例４）
実施例４のドライヤーフェルトを表９に示す仕様と図４（Ｃ）に示す基布の織組織に基づいて織成、ヒートセット加工を施し、表９に示す仕様のウェブを積層ニードリングして基布と絡合一体化した後、ヒートセット加工を施して作成した。
【０１１４】
すなわち、経糸１１に寸法が厚さ０．３０ｍｍ×幅０．４６ｍｍの「厚さ方向に直線部の無い断面形状」（ＡＴＮ形）ポリエステルモノフィラメント｛図１（Ｂ）の断面形状｝、表層および裏層の緯糸１２，１３に直径寸法が０．４０ｍｍの断面円形高収縮ポリエステルモノフィラメント、中層の緯糸１４にアクリルスパンの綿番手６^Sの４本撚りの糸を用い、表１／３破れ斜文裏３／１破れ斜文緯３重織組織で基布１０ｃを織成し、ヒートセット加工を施した上、基布１０ｃの表層に表８の仕様に示す繊度６．６dtexのナイロン６６繊維ステープルと繊度１１dtexのアクリル繊維ステープルを重量比６０％：４０％で混合したウェブ１５を１００ｇ／ｍ²の積層量で積層し、ニードリングにて絡合一体化して表層に不織布層１５を形成した後、ヒートセット加工を施して、経糸密度が８０．６本／２．５４ｃｍ、緯糸密度が１６．５×２本／２．５４ｃｍのドライヤーフェルト１００Ｃを作成した。構成の概念を図８（Ｃ）に示す。この時の経糸充填率は１４６．０％であり、基布１０ｃの厚さは１．７２ｍｍとなった。ドライヤーフェルト１００Ｃの厚さは１．９２ｍｍ、通気度は１，８２０ｃｍ³/ｃｍ²・分であった。また、接紙面側の不織布層１５の表面の平滑性は非常に良好であった。ニードリング前の基布の経糸強度に対するニードリングの傷付きでの強度保持率は、従来の断面円形モノフィラメントを経糸とした基布のドライヤーフェルトに比べ差がなかった。
【０１１５】
実施例１〜２は、共に経糸１１に寸法が厚さ０．３０ｍｍ×幅０．４６ｍｍの「厚さ方向に直線部の無い断面形状」（ＡＴＮ形）ポリエステルモノフィラメント、表層および裏層の緯糸１２，１３に直径寸法が０．５０ｍｍの断面円形ポリエステルモノフィラメントを用い、また織組織も経糸と緯糸の交錯が強固で耐ズレ性の良好な図４（Ａ）の表１／３破れ斜文裏３／１破れ斜文緯２重織組織で基布１０ａを織成した。ヒートセット加工を施したその基布１０ａの表面および裏面にクッション性、耐久性に実績のある繊維ウェブ１５，１６を積層し、ニードルパンチングで交絡接合している。特に、実施例２は緯糸１２，１３に乾熱収縮率の高いポリエステルモノフィラメントを使用したので、織成後のヒートセット加工で経糸充填率を実施例１の１３３．３％に対し、実施例２では１４５．６％と高く出来、また耐ズレ性（加熱後のズレ角度θ２）は、実施例１では６．５０°であるのに対し実施例２では５．２５°と一層向上することが出来た。またいずれも経糸充填率を１３０％〜１７５％の範囲内とすることが出来た。
【０１１６】
また、同じ織組織、ウェブ仕様である、後述の比較例１、２と比べると、経糸に直径寸法が０．４０ｍｍの断面円形ポリエステルモノフィラメントを使用した比較例１に対しては、経糸方向の柔軟性（経糸方向の３点曲げ剛性の結果は実施例１では３４０ｃＮ／３ｃｍ、実施例２では３１０ｃＮ／３ｃｍに対し、比較例１では５６０ｃＮ／３ｃｍ）、緯糸方向の剛性（緯糸方向の３点曲げ剛性の結果は実施例１では１，２３０ｃＮ／３ｃｍ、実施例２では１，１６０ｃＮ／３ｃｍに対し比較例１では８１０ｃＮ／３ｃｍ）共に優れており、耐ズレ性（加熱後のズレ角度θ２は比較例１では８．９５°）は大いに良好であった。ニードルパンチングでの損傷についてはパンチング前後における基布の経糸方向の強力が同程度の保持率であった。
【０１１７】
経糸に寸法が直径０．３０ｍｍの断面円形ポリエステルモノフィラメントを使用した比較例２に対しては、経糸方向の柔軟性（経糸方向の３点曲げ剛性の結果は、比較例２では４４０ｃＮ／３ｃｍ）も良好であり、緯糸方向の剛性（緯糸方向の３点曲げ剛性は、比較例２では９３０ｃＮ／３ｃｍ）および耐ズレ性（加熱後のズレ角度θ２は、比較例２では９．５１°）共に優れていた。ニードルパンチングでの損傷についてはパンチング前後における基布の経糸方向の強力がより高い保持率を示した。
【０１１８】
実施例３は実施例１〜２と同じ織組織にウェブ繊維を少な目に表面側のみに積層して、厚みを薄くして、経糸方向に一層柔軟性が優れた（経糸方向の３点曲げ剛性は２７０ｃＮ／３ｃｍ）フェルトになった。
【０１１９】
実施例４は実施例１〜３の織組織に、表層および裏層の緯糸に直径寸法が０．４０ｍｍの断面円形高収縮ポリエステルモノフィラメント、中層緯糸にスパン糸を織成した緯３重織りであり、緯糸の高収縮モノフィラメントにより高い経糸充填率とし、中層緯糸のスパン糸により表層のみの積層で積層量を極力少なくしたウェブ繊維との交絡性を確保したので、実施例１〜３に比較して経糸方向の柔軟性（経糸方向の３点曲げ剛性は２５０ｃＮ／３ｃｍ）に優れると共に、厚さが１．９２ｍｍと薄くなっているが、緯糸方向の剛性（緯糸方向の３点曲げ剛性は１，０４０ｃＮ／３ｃｍ）、耐ズレ性（加熱後のズレ角度θ２は４．４６°）で同等の性能となった。また、通気度も１，８２０ｃｍ³/ｃｍ²・分と低く出来、シングルラン形式で広幅、高抄速の乾燥部に充分な適用性を示した。
【０１２０】
（実施例５）
実施例５のドライヤーフェルトを表９に示す仕様と図４（Ｄ）に示す基布の織組織に基づいて織成、ヒートセット加工を施し、表９に示す仕様のウェブを積層ニードリングして基布と絡合一体化した後、ヒートセット加工を施して作成した。
【０１２１】
すなわち、経糸１１に寸法が厚さ０．３ｍｍ×幅０．４６ｍｍの「厚さ方向に直線部の無い断面形状」（ＡＴＮ形）ポリエステルモノフィラメント｛図１（Ｂ）の断面形状｝、表層の緯糸１２に寸法が直径０．５ｍｍの断面円形ポリエステルモノフィラメント、裏層の緯糸１３ａにアクリルスパンの綿番手６^Sの５本撚りの糸を用い、表２／２破れ斜文裏３／１破れ斜文緯２重織組織で基布１０ｄを織成し、ヒートセット加工を施した上、基布１０ｄの表層に表９の仕様に示す繊度６．６dtexのナイロン６６繊維ステープルのウェブ１５を１００ｇ／ｍ²の積層量で積層し、ニードリングにて絡合一体化して表層に不織布層１５を形成した後、ヒートセット加工を施して、経糸密度が７４．０本／２．５４ｃｍ、緯糸密度が１５．３×２本／２．５４ｃｍのドライヤーフェルト１００Ｄを作成した。
構成の概念を図８（Ｄ）に示す。この時の経糸充填率は１３４．０％であり、基布１０ｄの厚さは１．６８ｍｍとなった。ドライヤーフェルト１００Ｄの厚さは１．８７ｍｍ、通気度は２，０８０ｃｍ³/ｃｍ²・分であった。また、接紙面側の不織布層１５の表面の平滑性は非常に良好であった。ニードリング前の基布の経糸強度に対するニードリングの傷付きでの強度保持率は、従来の断面円形モノフィラメントを経糸とした基布のドライヤーフェルトに比べ差がなかった。
【０１２２】
（実施例６）
実施例６のドライヤーフェルトを表９に示す仕様と図４（Ｄ）に示す基布の織組織に基づいて織成、ヒートセット加工を施し、表９に示す仕様のウェブを積層ニードリングして基布と絡合一体化した後、ヒートセット加工を施して作成した。
【０１２３】
すなわち、経糸１１に寸法が厚さ０．３０ｍｍ×幅０．４６ｍｍの「厚さ方向に直線部の無い断面形状」（ＡＴＮ形）ポリエステルモノフィラメント｛図１（Ｂ）の断面形状｝、表層の緯糸１２に直径寸法が０．５０ｍｍの断面円形高収縮ポリエステルモノフィラメント、裏層の緯糸１３ａにアクリルスパンの綿番手６^Sの５本撚り糸を用い、表２／２破れ斜文裏３／１破れ斜文緯２重織組織で基布１０ｄを織成し、ヒートセット加工を施した上、基１０ｄの表層に表９に示す仕様の繊度６．６dtexのナイロン６６繊維ステープルのウェブ１５を１００ｇ／ｍ²の積層量で積層し、ニードリングにて絡合一体化して表層に不織布層１５を形成した後、ヒートセット加工を施して、経糸密度が７８．０本／２．５４ｃｍ、緯糸密度が１５．５×２本／２．５４ｃｍのドライヤーフェルト１００Ｄを作成した。構成の概念を図８（Ｄ）に示す。この時の経糸充填率は１４１．３％であり、基布１０ｄの厚さは１．６６ｍｍとなった。ドライヤーフェルト１００Ｄの厚さは１．８０ｍｍ、通気度は１，９５０ｃｍ³/ｃｍ²・分であった。また、接紙面側の不織布層１５の表面の平滑性は非常に良好であった。ニードリング前の基布の経糸強度に対するニードリングの傷付きでの強度保持率は、従来の断面円形モノフィラメントを経糸とした基布のドライヤーフェルトに比べ差がなかった。
【０１２４】
実施例５〜６は、共に経糸１１に寸法が厚さ０．３０ｍｍ×幅０．４６ｍｍの「厚さ方向に直線部の無い断面形状」（ＡＴＮ形）ポリエステルモノフィラメントを用い、実施例５、６共に表層の緯糸１２には直径寸法が０．５０ｍｍの断面円形ポリエステルモノフィラメントを用い、裏層の緯糸１３ａにはアクリルスパン糸６^Sの５本撚りの糸を用いている。織組織は経糸１１が長浮きになっていて表面性は良いが、緯糸１２，１３の交絡点が少なく耐ズレ性が比較的少ない図４（Ｄ）の表２／２破れ斜文裏３／１破れ斜文緯２重織組織で基布１０ｄを織成している。実施例６は表層の緯糸１２に乾熱収縮率の高いポリエステルモノフィラメントを使用したので、織成後の熱加工で経糸充填率を、実施例５の１３４．０％に対し１４１．３％と高くすることが出来て、耐ズレ性を一層補強することが出来た。
【０１２５】
また、実施例５〜６は基布１０ｄの厚さが１．６６ｍｍ〜１．６８ｍｍであったので、ドライヤーフェルト１００Ｄの厚さが１．８０ｍｍ〜１．８７ｍｍで、通気度が１，９５０〜２，０８０ｃｍ³/ｃｍ²・分で、シングルラン形式の乾燥部に適した厚さ、通気度が得られた。
【０１２６】
また、後述の同じ織組織で表面側にのみウェブ繊維を積層した比較例３〜４と比べると、経糸１１に直径寸法が０．４０ｍｍの断面円形ポリエステルモノフィラメントを使用した比較例３に対しては、経糸方向の柔軟性（経糸方向の３点曲げ剛性は実施例５では１０４ｃＮ／３ｃｍ、実施例６では１４６ｃＮ／３ｃｍに対し、比較例３では２１９ｃＮ／３ｃｍ）は優れており、緯糸方向の剛性（緯糸方向の３点曲げ剛性は、実施例５では５０４ｃＮ／３ｃｍ、実施例６では５１７ｃＮ／３ｃｍに対し、比較例３では５８７ｃＮ／３ｃｍ）は若干優れていた。耐ズレ性（加熱後のズレ角度θ２は、実施例５では６．３０°、実施例６では５．２０°に対し、比較例３では６．１４°）は同等ないし優れており、不織布層１５面からの感触は平滑であった。経糸に寸法が厚み０．２８ｍｍ×幅０．５６ｍｍの断面四角形ポリエステルモノフィラメントを使用した比較例４に対しては、経糸方向の柔軟性（経糸方向の３点曲げ剛性は１５２ｃＮ／３ｃｍ）はほぼ同等であり、緯糸方向の剛性（緯糸方向の３点曲げ剛性は４７５ｃＮ／３ｃｍ）および耐ズレ性（加熱後のズレ角度θ２は１１．３６°）は同等ないし優れている。
不織布層１５の表面の平滑性は非常に良好であった。
【０１２７】
次に、基布にウェブを積層し、ニードルパンチングしたドライヤーフェルトの状態での比較例について、表１０〜表１１に基づいて説明する。各表でのウェブ仕様欄における記号Ｎはナイロン６６、ＡＣはアクリル、Ｔはポリエステルと、それぞれウェブの材質を表し、その後の数字はウェブの繊度（単位はdtex、表中では繊度の数字に続けて上付きの「Ｔ」と表記する）を示す。
【０１２８】
（比較例）
（比較例１）
比較例１のドライヤーフェルトを表１０に示す仕様と図４（Ａ）に示す基布の織組織に基づいて織成、ヒートセット加工を施し、表１０に示す仕様のウェブを積層ニードリングして基布と絡合一体化した後、ヒートセット加工を施して作成した。
【０１２９】
すなわち、経糸１１に直径寸法が０．４０ｍｍの断面円形ポリエステルモノフィラメント、表層，裏層の緯糸１２，１３に直径寸法が０．４０ｍｍの断面円形ポリエステルモノフィラメントを用い、表１／３破れ斜文裏３／１破れ斜文緯２重織組織で基布１０ａを織成し、ヒートセット加工を施した上、基布１０ａの表層に表１０の仕様に示す繊度６．６dtexのナイロン６６繊維ステープルと繊度１１dtexのアクリル繊維ステープルとを重量比６０％：４０％で混合したウェブ１５を３２０ｇ／ｍ²、裏層に表層と同様の配合のウェブ１６を１００ｇ／ｍ²の積層量で積層し、ニードリングにて絡合一体化して表層，裏層に不織布層１５，１６を形成した後、ヒートセット加工を施して、経糸密度が８５．１本／２．５４ｃｍ、緯糸密度が１５．５×２本／２．５４ｃｍのドライヤーフェルト１００Ａを作成した。この時の経糸充填率は１３４．０％であり、基布の厚さは１．９３ｍｍとなった。構成の概念図を図８（Ａ）に示す。ドライヤーフェルトの厚さは４．２７ｍｍ、通気度は５，５４０ｃｍ³/ｃｍ²・分であった。
【０１３０】
【表１０】

【０１３１】
比較例１のドライヤーフェルトは、広幅、高抄速の抄紙機乾燥部に従来から使用実績の豊富なドライヤーフェルトである。
【０１３２】
（比較例２）
比較例２のドライヤーフェルトを表１０に示す仕様と図４（Ａ）に示す基布の織組織に基づいて織成、ヒートセット加工を施し、表１０に示す仕様のウェブを積層ニードリングして基布と絡合一体化した後、ヒートセット加工を施して作成した。
【０１３３】
すなわち、経糸１１に直径寸法が０．３０ｍｍの断面円形ポリエステルモノフィラメント、表層および裏層の緯糸１２，１３に直径寸法が０．５０ｍｍの断面円形ポリエステルモノフィラメントを用い、表１／３破れ斜文裏３／１破れ斜文緯２重織組織で基布１０ａを織成し、ヒートセット加工を施した上、基布１０ａの表層に表１０の仕様に示す繊度１６．５dtexのナイロン６６繊維ステープルと繊度１１dtexのアクリル繊維ステープルを重量比６０％：４０％で混合したウェブ１５を３３０ｇ／ｍ²、裏層に表層と同様の配合のウェブ１６を１００ｇ／ｍ²の積層量で積層し、ニードリングにて絡合一体化して表層，裏層にそれぞれ不織布層１５，１６を形成した後、ヒートセット加工を施して、経糸密度が１２６．１本／２．５４ｃｍ、緯糸密度が１４．４×２本／２．５４ｃｍのドライヤーフェルト１００Ａを作成した。この時の経糸充填率は１４８．９％であり、基布１０ａの厚さは１．８９ｍｍとなった。構成の概念図を図８（Ａ）に示す。ドライヤーフェルト１００Ａの厚さは４．７１ｍｍ、通気度は５
，７００ｃｍ³/ｃｍ²・分であった。
【０１３４】
比較例２のドライヤーフェルトは、上質紙や塗工用原紙のような高度な品質水準が要求される用途の抄紙機乾燥部において、従来から使用実績の豊富なドライヤーフェルトである。
【０１３５】
（比較例３）
比較例３のドライヤーフェルトを表１１に示す仕様と図４（Ｄ）に示す基布の織組織に基づいて織成、ヒートセット加工を施し、表１１に示す仕様のウェブを積層ニードリングして基布と絡合一体化した後、ヒートセット加工を施して作成した。
【０１３６】
すなわち、経糸１１に直径寸法が０．４０ｍｍの断面円形ポリエステルモノフィラメント、表層の緯糸１２に直径寸法が０．４０ｍｍの断面円形ポリエステルモノフィラメント、裏層の緯糸１３ａにアクリルスパンの綿番手６^Sの４本撚りの糸を用い、表２／２破れ斜文裏３／１破れ斜文緯２重織組織で基布１０ｄを織成し、ヒートセット加工を施した上、基布１０ｄの表層に表１１の仕様に示す繊度６．６dtexのポリエステル繊維ステープルと繊度６．６dtexのナイロン６６繊維ステープルを重量比６０％：４０％で混合したウェブを１００ｇ／ｍ²の積層量で積層し、ニードリングにて絡合一体化して表層に不織布層１５を形成した後、ヒートセット加工を施して、経糸密度が８５．２本／２．５４ｃｍ、緯糸密度が１５．１×２本／２．５４ｃｍのドライヤーフェルト１００Ｄを作成した。この時の経糸充填率は１３４．２％であり、基布１０ｄの厚さは１．７７ｍｍとなった。構成の概念図を図８（Ｄ）に示す。ドライヤーフェルト１００Ｄの厚さは２．１９ｍｍ、通気度は２０２０ｃｍ³/ｃｍ²・分であった。
【０１３７】
【表１１】

【０１３８】
比較例３のドライヤーフェルトは、シングルラン形式の乾燥部において上質紙や塗工用原紙のような高度な品質水準が要求される用途の抄紙機乾燥部に従来から使用実績の豊富なドライヤーフェルトである。
【０１３９】
（比較例４）
比較例４のドライヤーフェルトを表１１に示す仕様と図４（Ｄ）に示す基布の織組織に基づいて織成、ヒートセット加工を施し、表１１に示す仕様のウェブを積層ニードリングして基布と絡合一体化した後、ヒートセット加工を施して作成した。
【０１４０】
すなわち、経糸１１に寸法が厚さ０．２８ｍｍ×幅０．５６ｍｍの断面四角形ポリエステルモノフィラメント、表層の緯糸１２ａにアクリルスパンの綿番手２０^Sの８本撚りの糸、裏層の緯糸１３に寸法が直径０．４０ｍｍの断面円形ポリエステルモノフィラメント用い、表２／２破れ斜文裏３／１破れ斜文緯３重織組織で基布１０ｄ’を織成し、ヒートセット加工を施した上、基布１０ｄ’の表層に表１１の仕様に示す繊度６．６dtexのポリエステル繊維ステープルと繊度６．６dtexのナイロン６６繊維ステープルを重量比６０％：４０％で混合したウェブ１５を１００ｇ／ｍ²の積層量で積層し、ニードリングにて絡合一体化して不織布層１５を形成した後、ヒートセット加工を施して、経糸密度が５５．３本／２．５４ｃｍ、緯糸密度が１７．３×２本／２．５４ｃｍのドライヤーフェルト１００Ｄ’を作成した。この時の経糸充填率は１２１．９％であり、基布の厚さは１．６５ｍｍとなった。構成の概念図は図８（Ｄ）において、表層の緯糸１２ａを撚り糸に、裏層の緯糸１３をモノフィラメンントに置換したものである。ドライヤーフェルト１００Ｄ’の厚さは１．９７ｍｍ、通気度は１，１４０ｃｍ³/ｃｍ²・分であった。
【０１４１】
【発明の効果】
本発明によれば、経糸および緯糸を用いて織成した基布と、基布の片面もしくは両面に、短繊維ウェブをニードルパンチングにより絡合した不織布層とで構成した製紙機械用ドライヤーフェルトにおいて、経糸に「厚さ方向に直線部の無い断面形状」の合成繊維モノフィラメントを用いたので、また、経糸の充填率を１２５％〜１７５％という高い範囲としたので、さらには基布を構成する少なくとも１層の緯糸に乾熱収縮率の高いモノフィラメントを用いて、経糸充填率を１３０％〜１７５％の範囲としたので、特に高度の品質水準が要求される、例えば上質紙や塗工用原紙の抄紙の抄紙用多筒式乾燥機の乾燥部のうち、湿紙水分率の高い前半部の第１〜２群において特に好適に使用できる、湿紙との密着性、クッション性を確保しつつ、特に経糸方向の柔軟性に優れ、かつ、緯糸方向の剛性に優れると共に、ニードルパンチングでの傷付きが少なく耐久性を有し、形態保持性、走行安定性に優れた製紙機械用ドライヤーフェルトを実現することが出来る。
【０１４２】
また、その基布が緯２重織りもしくは緯２．５重織もしくは３重織のいずれかの織組織で織成し、基布の少なくとも表層および裏層に用いる緯糸に断面円形の直径寸法が０．３ｍｍ〜０．７ｍｍの範囲内の合成繊維モノフィラメントを用いたので、広幅、高抄速で稼働される抄紙用多筒式乾燥装置の用途に好適に使用できる形態保持性、走行安定性に優れた製紙機械用ドライヤーフェルトを実現することが出来る。
【０１４３】
さらには、その基布が緯２重織りもしくは緯２．５重織もしくは３重織のいずれかの織組織で織成し、基布の少なくとも表層および裏層に用いる緯糸に断面円形の直径寸法が０．３ｍｍ〜０．７ｍｍの範囲内の合成繊維モノフィラメントを用い、または、基布の表層または裏層に用いる緯糸に断面円形の直径寸法が０．３ｍｍ〜０．７ｍｍの範囲内の合成繊維モノフィラメントを用い、他の一層の緯糸にウェブ繊維との交絡接着性の良いスパン糸等を使用したので、前記乾燥シリンダーが単列に配置された形式の抄紙用多筒式乾燥装置に使用可能な、特に前記乾燥部の全群またはサイズプレスまでが乾燥シリンダーが単列に配置された形式の乾燥部で、例えば上質紙や塗工用原紙の抄紙のような、高度な品位水準が要求される用途の抄紙用多筒式乾燥機における乾燥部のうち湿紙水分率の高い前半部の第１〜２群において特に好適に使用可能な、厚み寸法の範囲と低い通気度を含む広い通気度調整範囲を有し、良好な表面平滑性、ならびに、経糸方向での柔軟性と緯糸方向での剛性を兼ね備える製紙機械用ドライヤーフェルトを実現することが出来る。
【０１４４】
また、前記乾燥シリンダーが単列に配置された形式の抄紙用多筒式乾燥装置のうち、例えばフェルト幅５ｍ〜９ｍの範囲内、抄速ｍａｘ１，０００ｍ／ｍｉｎ〜１，５００ｍ／ｍｉｎの広幅・高抄速の抄紙用多筒式乾燥機に適用可能な緯糸方向の剛性、および形態保持性、走行安定性を有する製紙機械用ドライヤーフェルトを実現することが出来る。
【図面の簡単な説明】
【図１】（Ａ）は断面形状が楕円形状の経糸の断面図、
（Ｂ）は本発明に係る断面形状を有する経糸の一例の断面図、
（Ｃ）は本発明に係る断面形状を有する経糸の異なる例の断面図である。
【図２】（Ａ）は従来の断面が四角形状の経糸を用いた基布の接紙面側における要部拡大断面図、
（Ｂ）は本発明の断面形状を有する経糸を用いた基布の接紙面側における要部拡大断面図である。
【図３】（Ａ）は本発明の経糸に対してニードルを押し込む場合のズレや逃げについて説明するニードル押し込み前の要部拡大断面図、
（Ｂ）は本発明の経糸に対してニードルを押し込む場合のズレや逃げについて説明するニードル押し込み時の要部拡大断面図である。
【図４】（Ａ）〜（Ｅ）は基布の織組織の各種形態の概略説明図を示し、
（Ａ）は表１／３破れ斜文裏３／１破れ斜文緯２重織基布の説明図、
（Ｂ）は表１／３破れ斜文裏３／１破れ斜文緯２．５重織基布の説明図、
（Ｃ）は表１／３破れ斜文裏３／１破れ斜文緯３重織基布の説明図、
（Ｄ）は経糸が長浮きする表２／２正則斜文や表２／２破れ斜文緯２重織基布の説明図、
（Ｅ）は経糸が長浮きする表３／３正則斜文や表３／３破れ斜文緯２重織基布の説明図である。
【図５】ドライヤーフェルトの３点曲げ剛性の試験方法の説明図である。
【図６】（Ａ）はドライヤーフェルトのズレ角度測定装置における荷重時の斜視図、
（Ｂ）はドライヤーフェルトのズレ角度測定装置におけるズレ角度測定時の斜視図、
（Ｃ）は（Ａ）のズレ角度測定装置におけるズレ角度の測定方法の説明図である。
【図７】ドライヤーフェルトの摩擦係数測定装置の概略構成図である。
【図８】（Ａ）〜（Ｄ）はドライヤーフェルトの各種実施態様を示し、
（Ａ）は図４（Ａ）の基布１０ａの表裏両面にウェブを積層したドライヤーフェルトの要部拡大断面図、
（Ｂ）は図４（Ａ）の基布１０ａの表側のみにウェブを積層したドライヤーフェルトの要部拡大断面図、
（Ｃ）は図４（Ｃ）の基布１０ｃの表側のみにウェブを積層したドライヤーフェルトの要部拡大断面図、
（Ｄ）は図４（Ｄ）の基布１０ｄの表側のみにウェブを積層したドライヤーフェルトの要部拡大断面図である。
【符号の説明】
１０ａ，１０ｂ，１０ｃ，１０ｄ，１０ｅ 基布
１１ 経糸
１２，１３，１３ａ 緯糸
１４ 中層の緯糸
１５，１６ 不織布層（ウェブ）
２０ ３点曲げ剛性の試験機
３０ ズレ角度測定装置
４０ 摩擦係数測定装置
１００Ａ，１００Ｂ，１００Ｃ，１００Ｄ ドライヤーフェルト[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an improvement of a dryer felt for a papermaking machine used in a drying section of a paper machine, particularly in applications where a high quality level is required, for example, in a multi-cylinder dryer for papermaking of high-quality paper and coating base paper. Dryer felt for papermaking machine that has good warp direction flexibility that can be suitably used and has rigidity in the weft direction in the first and second groups of the first half of the wet paper web having a high moisture content. About.
[0002]
[Prior art]
A dryer felt for a paper machine used in a drying section of a paper machine usually needs a synthetic fiber web on one or both sides of a woven fabric made of synthetic fibers such as monofilament, multifilament twisted yarn and spun twisted yarn. As a result, the base fabric and the web are intertwined and manufactured. The dryer felt made by needling this web is smooth and flexible to the wet paper on its paper-contacting surface, has excellent adhesion and cushioning properties, and various conditions such as air permeability are optimized. Widely used for paper, coating base paper, etc.
[0003]
Because the durability and dimensional stability of dryer felt are often borne by the base fabric, monofilaments with excellent durability and rigidity have been mainly used as the constituent yarn of the base fabric for both warp and weft. . In addition, various combinations are used, such as the use of a multifilament twisted yarn or a spun yarn as a part of securing the entanglement adhesiveness with the web fiber in needling and air permeability adjusting yarn.
[0004]
Incidentally, a dryer felt for a papermaking machine is usually used as an endless belt by forming joints at both ends in the flow direction and placing the joints in a paper machine, then connecting the joints at both ends.
Due to recent demands for improving paper quality, warp loop joints using warps of the base fabric body with few joint marks are often used as joints. In this case, the warp of the base fabric is composed of a monofilament single yarn that can form a good warp loop joint.
[0005]
The dryer felt in the drying section of the paper machine presses wet paper against a heated cylinder and dries it. At this time, if the pressing force is not uniform, uneven drying occurs and the paper quality is impaired. In applications that require a high level of quality, such as high-quality paper or base paper for coating, not only does not cause quality defects such as wet paper marks, but also the flow direction and width of wet paper. The demand for uniformity of drying in the direction is severe.
Therefore, it is necessary to bring the wet paper into contact with the cylinder uniformly, and uniform adhesion to the wet paper and the pressing force in the flow direction and the width direction are required for the dryer felt. Therefore, it is necessary to have both good surface smoothness and flexibility in the warp direction, and at the same time sufficient rigidity in the weft direction.
[0006]
On the other hand, in recent years, paper machines have become wider and higher in speed, and for example, there is a track record of speeds up to a maximum of 1500 m / min beyond the range of a maximum speed of 1,000 m / min to 1,500 m / min. Since the felt width of paper machines is in the range of 5m to 9m, the development of dryer felt that can ensure stable operation of paper machines in response to these higher speeds and wider widths. In addition to the conventional dryer felt, it is more important to improve the flexibility in the warp direction and the rigidity in the weft direction, as well as improve the form retention and running stability. It is becoming.
[0007]
In order to obtain a uniform pressing force in the warp direction, flexibility in the warp direction is required along with sufficient tensile strength in the warp direction. In order to obtain a sufficient tensile strength, a certain fineness per unit width dimension of the dryer felt is required in addition to the characteristics of the material used for the warp of the base fabric. In addition, in order to obtain flexibility, it is generally desirable that the thickness of the dryer felt or the base fabric is thin along with the characteristics of the material. On the other hand, in order to obtain a uniform pressing force in the weft direction, rigidity in the weft direction is required. For that purpose, it is generally desirable that the thickness of the dryer felt or the base fabric is thick in addition to the rigidity of the weft. .
[0008]
Various fabric substrates have been used for these conflicting demands. In order to ensure a warp fineness of a certain level or more per width dimension and an appropriate thickness, weft double weave, 2.5 double weave or triple weave is generally adopted as the base fabric.
[0009]
In order to ensure flexibility in the warp direction, it is conceivable to use monofilaments with a fine fineness for the warp of the base fabric. In this case, since the warp is thin and lacks in rigidity, the bond due to the crossing with the woven weft is loose, the constraint between the crossing yarns is weak, and the displacement resistance is poor. Here, the “deviation resistance” is a characteristic representing the degree of resistance against the deformation of the dryer felt in the oblique direction. The dryer felt has a problem that the width dimension decreases when the oblique deformation progresses, and the form retainability and running stability as a dryer felt for a papermaking machine cannot be secured.
[0010]
There is a proposal to use a so-called flat cross-sectional monofilament (hereinafter referred to as “cross-sectional square monofilament”) having an appropriate thickness dimension for the warp of the base fabric and a width dimension larger than the thickness dimension. When a monofilament with a square cross section is used for the warp warp, the warp direction is flexible, but it has been found that there are the following problems. In other words, with the recent increase in demand for paper quality, higher speed of paper machines, and wider width, weft material characteristics and weft weaving structure, that is, weaving structure is simply double weaving, 2.5 weaving, A triple weave is not sufficient, and it is necessary to increase the warp density and reinforce the rigidity and shape retention characteristics of the weft. For example, it is also necessary to set the warp filling rate to a high range exceeding 100%. However, in that case, adjacent monofilaments with cross-sections interfere with each other, making it difficult to secure the desired high filling rate, and the resistance to misalignment cannot be improved. It was difficult to further improve the running stability.
[0011]
Furthermore, if the filling rate is increased to a certain extent, the flat surface of the monofilament with a cross section cannot be maintained parallel to the surface of the base fabric even if a fabric having a good surface property is selected. The corners of the cross-sectional square of the warp are exposed on the surface of the base fabric, especially if the amount of web lamination is reduced, the surface properties of the dryer felt will be affected, and the warp during weaving It has been found that there are problems such as a decrease in weaving efficiency due to the effect of the milling.
[0012]
For example, the applicant has experienced that a warp filling ratio of 125% to 130% is a practical upper limit when using a square polyester monofilament having a size of 0.3 mm × 0.55 mm for warp of a base fabric. Have. The “warp filling rate” refers to a percentage per unit length expressed using the product of the warp density in the width direction of the base fabric and the width dimension of the warp cross section.
[0013]
In addition, a base fabric woven with a monofilament having a square cross section as a warp is a needle punching needle with a flat cross-sectional shape parallel to the substantial width direction of the warp when the web is entangled with the base fabric by needle punching. And / or the needle (needle) penetrates the warp without causing warp deviation or escape, and the warp is easily damaged. Therefore, there is a problem that the strength reduction is larger than that of other forms of the base fabric.
[0014]
In terms of the base fabric structure, it is preferable to increase the thickness in order to obtain rigidity in the weft direction. However, if the thickness is increased, flexibility in the warp direction is impaired. On the other hand, if the thickness is reduced in order to ensure flexibility in the warp direction, the rigidity in the weft direction is impaired. On the surface of the base fabric constituent yarn, if a flexible yarn is used for the warp, the binding force against the weft is reduced, and it is not possible to sufficiently secure the displacement resistance, the shape retention, and the running stability. In addition, if a thick thread is used to obtain rigidity in the weft direction, the thickness of the base fabric increases, which affects the flexibility in the warp direction. Thus, the stiffness in the weft direction and the flexibility in the warp direction influence each other. In order to obtain these conflicting characteristics together, a new technology is required.
[0015]
On the other hand, as the structure of the drying section in the multi-cylinder dryer for papermaking, the upper and lower canvas system in the conventional upper and lower two-stage arrangement dryer, the single run canvas system as an improvement plan thereof, and the further improvement plan The Berlan system (trademark of Beloit, USA) and Shimlan system (trademark of Valmet, Finland), etc., in which cylinders are arranged in a single row have been proposed, and improvements have been made to prevent sheet fluttering due to higher papermaking speed. It has been.
[0016]
In the single-run canvas system, wet paper runs on the outer periphery of the dryer canvas or dryer felt on the lower cylinder, and in the Berlan system on the suction roller between the cylinders. Due to the difference in peripheral speed corresponding to the thickness of the canvas or felt with the cylinder part, the tension on the wet paper and the loosening of the wet paper are repeated as the wet paper travels, adversely affecting the wet paper. Deterioration of the paper surface, slight vibration of the sheet, severe paper breakage, etc. may occur. For this reason, it is indispensable that the canvas or felt is thin particularly in the single run canvas method, the bell run method, and the shim run method that perform high-speed papermaking.
[0017]
To reduce the thickness, it is necessary to reduce the amount of web lamination and / or to use a thin base fabric. When the amount of web lamination is reduced, the convex part of the warp that appears on the fabric surface at the intersection of the warp and the weft, that is, the knuckle part, comes into contact with the wet paper through the thin nonwoven layer made of the web with less dryer felt surface. It is conceivable that For this reason, the surface of the base fabric on the paper contact surface side needs to be as smooth as possible. Further, when the amount of laminated web is reduced, the entanglement joining force with the base fabric is reduced, and the possibility that the nonwoven fabric layer or the web fiber is peeled off during use of the dryer felt is increased.
It is possible to increase the needle punching amount, that is, the number of needle insertions and the insertion density, in order to ensure the entanglement bonding force between the base fabric and the web, but in the use of the above-mentioned single run, bell run type, shim run type drying section In order to obtain these functions, the base fabric woven with warp yarns at high density can be used while ensuring a wide adjustment range of air permeability including the low air permeability described later. In addition, an increase in the amount of needle punching leads to a decrease in strength, which significantly impairs the durability of the dryer felt.
[0018]
The dryer felt used in the single-run multi-cylinder dryer for papermaking including the above-described configuration in which the drying cylinders are arranged in a single row, particularly the drying unit before the size press or the entire group of drying units of the dryer. As a dryer felt suitable for a drying section of a row arrangement type, the applicant has proposed a dryer felt for papermaking described in Japanese Patent Publication No. 7-91798 and put it into practical use.
[0019]
This dryer felt has a thickness as thin as 1.7 mm to 2.2 mm, but when the thickness is reduced, the amount of laminated web is 80 g / m. ² ~ 120g / m ² At the same time, high shrinkage fibers are mixed into the web, and the heat shrinkage action of the high shrinkage fibers compensates for the decrease in the entanglement between the base fabric and the web due to the reduced amount of web lamination, Further, by using a yarn having a lot of fluff like a spun yarn or a multifilament yarn, a fine monofilament assortment yarn for one layer of a weft double woven base fabric, entanglement and adhesion between the base fabric and the surface layer web To improve the performance, suppress the damage of the base fabric due to the needling without increasing the number of needle insertions and the density during the needling, the entanglement between the web and the base fabric required for the dryer felt It is possible to reduce the thickness without impairing the properties and the like. Further, the base fabric has a structure in which the warp on the surface is long-floating to prevent a decrease in the smoothness of the dryer felt surface due to a decrease in the amount of web lamination, and further improve the smoothness of the surface.
[0020]
In this Japanese Patent Publication No. 7-91798, in its example, the warp of the base fabric is a circular circular cross-section having a diameter of 0.30φmm to 0.40φmm, or a minor axis × major axis is 0.20 mm to 0.35 mm × 0. Synthetic resin monofilaments such as polyester having a flat cross section of 50 mm to 0.60 mm are used with a warp density of 50 / 2.54 cm to 130 / 2.54 cm, and a warp length floating structure is formed on the front side where the web is laminated. Is disclosed.
[0021]
In this case, in order to ensure sufficient adhesive entanglement with the insufficient base fabric by reducing the amount of web fibers laminated, in addition to using web fibers with high dry heat shrinkability, It is necessary to use a yarn in which a plurality of multi-yarns, spun yarns, thin monofilament yarns are aligned or a yarn obtained by mixing and twisting these yarns on at least one of the front and back layers of the weft. This is also necessary to obtain the limited air permeability of the dryer felt. These yarns are inferior in rigidity to monofilaments of the same fineness, and a dryer felt using a base fabric in which these yarns are used as at least one weft of the surface layer and the back layer is inferior in rigidity in the weft direction. Further, the bonding force due to the crossing is loose and the binding force is small, and sufficient misalignment resistance cannot be obtained.
[0022]
[Problems to be solved by the invention]
In view of the above-mentioned problems, the present invention is particularly suitable for applications requiring a high quality level, for example, the first half having a high wet paper web moisture content in the drying section of paper-making multi-cylinder dryers for high-quality paper and coating base paper. Can be suitably used in the first and second groups of the part, while ensuring the adhesion to the wet paper and cushioning properties, while being excellent in the flexibility in the warp direction and in the rigidity in the weft direction, damage due to needle punching It is an object of the present invention to obtain a dryer felt for a papermaking machine that has less durability and has excellent shape retention and running stability.
[0023]
Furthermore, the drying cylinder can be used in a multi-cylinder dryer for papermaking in a form in which the drying cylinders are arranged in a single row, and in particular, the whole group of the drying section or the size press is in a form in which the drying cylinders are arranged in a single row. Of the drying section in the multi-cylinder dryer for papermaking for applications that require a high level of quality, such as papermaking of high-quality paper and coating base paper, It has a wide air permeability adjustment range including thickness range and low air permeability, which can be suitably used in the first and second groups, and has good surface smoothness, flexibility in the warp direction and weft direction. It is an object of the present invention to provide a dryer felt for a papermaking machine that also has rigidity.
[0024]
In addition, among the multi-cylinder dryers for papermaking in the form in which the drying cylinders are arranged in a single row, for example, within a range of felt width 5 m to 9 m (preferably within a range of 6 m to 9 m), papermaking speed max1, Applicable to wide and high speed multi-cylinder dryers for papermaking within the range of 000m / min to 1,500m / min (preferably including a range of papermaking speed exceeding 1,500m / min) Another object of the present invention is to provide a dryer felt for a papermaking machine having flexibility in the warp direction, rigidity in the weft direction, shape retention and running stability.
[0025]
[Means for Solving the Problems]
The present invention is characterized by the following configuration.
That is, the present invention relates to a dryer felt for a paper machine comprising a base fabric woven using warps and wefts, and a nonwoven fabric layer in which a synthetic fiber web of short fibers is entangled on one or both sides of the base fabric by needle punching. In the warp, the warp yarn is inscribed in a quadrilateral whose thickness direction dimension is smaller than the width direction dimension, and consists of one continuous curve, or consists of one straight line and one continuous curve in the thickness direction. A synthetic fiber monofilament having a cross-sectional shape having no straight portion and a cross-sectional area larger than the area of a regular ellipse inscribed in the quadrangle is used, and a filling rate of warp is 100% to 175%, preferably 125. % To 175%.
[0026]
Alternatively, in the present invention, the warp yarn having a cross-sectional shape having no straight portion in the thickness direction constituting the base fabric has a thickness direction dimension in the range of 0.25 mm to 0.35 mm, and the thickness direction dimension and the width direction dimension. Is a synthetic fiber monofilament having a cross-sectional shape inscribed in a quadrangle having a ratio of 1: 1.3 to 1: 2.0.
[0027]
In addition, the present invention is characterized in that a monofilament with a high dry heat shrinkage rate is used for at least one of the wefts constituting the base fabric, and the filling rate of the warp yarn is within the range of 130% to 175%.
[0028]
Further, according to the present invention, the base fabric is woven with a weft double, 2.5 double or triple woven structure, and the weft used for at least the surface layer and the back layer of the base fabric has a circular cross section and a diameter of 0. . Synthetic fiber monofilament within a range of 3 mm to 0.7 mm is used.
[0029]
Furthermore, according to the present invention, the base fabric is woven with a weft structure of either double, 2.5 or triple, and the weft used for the surface layer or the back layer of the base fabric has a circular cross section and a diameter of 0. . Synthetic fiber monofilament within a range of 3 mm to 0.7 mm is used.
[0030]
Furthermore, the present invention relates to a dryer felt for a papermaking machine used in a drying section of a type in which the entire drying section of a multi-cylinder dryer for papermaking or a drying cylinder before a size press is arranged in a single row. The thickness of the cloth is in the range of 1.3 mm to 1.8 mm (preferably 1.3 mm to 1.6 mm), and the thickness of the dryer felt is in the range of 1.7 mm to 2.2 mm. .
[0031]
DETAILED DESCRIPTION OF THE INVENTION
The dryer felt of the present invention is a dryer for a papermaking machine comprising a base fabric woven using warps and wefts, and a nonwoven fabric layer in which a synthetic fiber web of short fibers is entangled by needle punching on one or both sides of the base fabric. In the felt, the warp yarn is inscribed in a quadrangle in which the dimension in the thickness direction is smaller than the dimension in the width direction, and consists of one continuous curve, or consists of one straight line and one continuous curve. A synthetic fiber monofilament having a cross-sectional shape having no straight part and a cross-sectional area larger than the area of a regular ellipse inscribed in the quadrangle, and a filling rate of warp is 100% to 175%, preferably The range is from 125% to 175%.
[0032]
Here, “the thickness direction dimension is inscribed in a square smaller than the width direction dimension, and is composed of one continuous curve, or is composed of one straight line and one continuous curve. A synthetic fiber monofilament having a cross-sectional shape with no cross-section and having a cross-sectional area larger than a mathematically defined regular oval area inscribed in the square is as shown in FIG. In addition, a regular oval shape in which the cross section having the minor axis a and the major axis b is mathematically defined is not included, and in addition, the cross-sectional shape in which the four corners of the square of the cross section are smoothly chamfered also has a straight portion in the thickness direction. Since it remains, it is excluded from the “cross-sectional shape having no straight portion in the thickness direction” of the present invention, and has a cross-sectional shape as shown in FIG. 1 (B) and FIG. 1 (C).
[0033]
That is, FIG. 1 (B) is composed of a single curve m inscribed in a quadrilateral having a width direction dimension X and a thickness direction dimension Y, and a curve representing its outer shape in a cross section. It passes through each point included in the side, for example, the middle points c, c ′, d, d ′, and is closer to the circumscribed rectangle side than the mathematically defined normal ellipse of FIG. , Having a cross-sectional shape having a larger cross-sectional area. Further, FIG. 1C approximates the cross-sectional shape shown in FIG. 1B, and a single straight line p is formed at a position overlapping one curve n and the side (long side) of the circumscribed rectangle in the width direction. Having a cross-sectional shape.
In this case, the length Z of the straight portion p is preferably 1/2 to 3/4 of the width direction dimension X. Hereinafter, in the present invention, these shapes are abbreviated as “a cross-sectional shape having no straight portion in the thickness direction” or “ATN type”.
[0034]
As described above, the monofilament having a “cross-sectional shape having no straight portion in the thickness direction” of the present invention does not include a regular cross-sectional ellipse that is mathematically defined, and the curve representing its outer shape is closer to the circumscribed rectangle. Therefore, when the width direction dimension of the circumscribed square is X and the thickness direction dimension is Y, the cross-sectional area of the cross-sectional square is XY> the cross-sectional area having no straight portion in the thickness direction. > Mathematically defined normal cross-sectional elliptical cross-sectional area ≈ 0.79XY, covering the defects of the cross-sectional square monofilament and having a larger cross-sectional area than the mathematically defined normal elliptical monofilament . That is, the strength per yarn can be increased, and the durability of the dryer felt can be increased.
[0035]
The range of the cross-sectional area of the monofilament of “cross-sectional shape having no straight part in the thickness direction” used for the warp of the dryer felt base fabric of the present invention is less than the cross-sectional area (XY) of the circumscribed square as described above, The range exceeds the normal elliptical cross-sectional area (πXY / 4≈0.79XY) inscribed in the quadrangle, but a preferable range can be exemplified by a minimum value of 0.81XY and a maximum value of 0.89XY. . That is, as a cross-sectional shape having a cross-sectional area corresponding to the minimum value, for example, the lower side (or upper side) of the cross section in the thickness direction is a regular elliptical shape mathematically defined and the upper side in the thickness direction A cross-sectional shape having a cross-sectional area corresponding to a shape in which two corners on the upper side (or lower side) of the circumscribed square (or the lower side) are smoothly chamfered with a radius corresponding to ½ of the thickness direction dimension Y can be exemplified. . Moreover, as a cross-sectional shape having a cross-sectional area corresponding to the maximum value, for example, it has a cross-sectional area corresponding to a shape in which the four corners of the circumscribed square are smoothly chamfered with a radius corresponding to 1/2 of the thickness direction dimension. A cross-sectional shape can be illustrated.
[0036]
If a monofilament having a cross-sectional area with a cross-sectional shape having no straight portion in the thickness direction is used for the warp of the base fabric, the strength per warp is at least 81% of the circumscribed square made of the same material. Since it is possible to ensure a range of 89%, the filling rate of the warp is 1 / 0.89 to 1 / 0.0 .0 with respect to the upper limit of 125% or 130% in the case of a monofilament having a circumscribed square cross section. 81 times, that is, 140% to 154% or 146% to 160%, or 140% to 160%, if the warp filling ratio corresponding to the cross-sectional area ratio with the circumscribed square is set, the sectional shape of the circumscribed square Thus, it is possible to realize a base fabric having a warp direction strength equivalent to that when the monofilament is used for warp. If the warp filling ratio is set to a high value of at least 160% to 175% (upper limit), it is possible to realize a base fabric having a warp direction strength greater than that when a circumscribed square cross-sectional monofilament is used for warp. Become.
[0037]
In the present invention, by using the monofilament 11 having a “cross-sectional shape without straight portions in the thickness direction” for warp of the base fabric, for example, as shown in FIG. The curved surface shape acts effectively, and the side surfaces of the adjacent monofilaments interfere with each other, which is a problem when the warp is a monofilament 110 having a square section as shown in FIG. The problem that it was difficult to ensure a high warp filling rate is solved.
[0038]
When the warp filling ratio is 100% or less, the stiffness in the weft direction is insufficient, and the reinforcing effect of form retention and running stability does not appear. In order to expect a reinforcing effect suitable for a paper machine having a width of 5 to 9 m or more, a high warp filling rate of 125% or more is required. The upper limit of the warp filling rate is set to 175% because, depending on the woven structure of the applied base fabric and the rigidity of the applied monofilament of warp, the warp yarns overlap when the warp filling rate exceeds this value, and the surface smooth base fabric that can be used practically. This is because it becomes difficult to obtain.
[0039]
In the present invention, since the synthetic fiber monofilament having a “cross-sectional shape having no straight portion in the thickness direction” is smaller than the width-direction dimension, warp yarns of the base fabric have the same cross-sectional area, for example, a circular monofilament cross-section. Compared to the conventional dryer felt used for the warp, the size in the thickness direction of the warp is smaller. In addition to increasing the flexibility in the thickness direction of the warp itself, the thickness of the base fabric is reduced. The flexibility of the dryer felt in the warp direction can be improved. In addition, when the thickness of the base fabric is the same, the thickness direction dimension (for example, diameter) of the weft is increased and the flexibility in the warp direction is improved at the same time as the warp thickness dimension is reduced. It is possible to improve the rigidity in the weft direction.
[0040]
A dryer felt made by laminating the same amount of web as a conventional base fabric, for example, a base fabric using a monofilament with a circular cross-section, as a warp, has the same adhesion and cushioning properties to wet paper as a conventional base fabric product. At the same time, it has superior warp direction flexibility and excellent uniformity of the pressing force in the warp direction. Of course, it is possible to increase the amount of web lamination as the thickness of the base fabric is reduced. As the nonwoven fabric layer becomes thicker due to the increase in the amount of web lamination, the adhesion to the wet paper and the cushioning properties are improved, and it becomes possible to cope with the high quality of the wet paper. Even if the thickness is the same as that of the dryer felt, the flexibility in the warp direction is more greatly contributed by the base fabric, so that it becomes more flexible than the dryer felt of the conventional base fabric.
[0041]
In addition, by using a monofilament having a “cross-sectional shape without a straight portion in the thickness direction” for warp of the base fabric, when the web to be laminated is entangled with the base fabric by needle punching, as shown in FIG. The smooth curved surface shape of the side surface of the warp 11 having no straight portion in the vertical direction works effectively, and the needle ND and / or the warp 11 is displaced or escaped during needle punching, and the monofilament 110 having a quadrangular cross section is formed. Since it is more likely to occur than in the case of the base fabric used for the warp, the possibility that the needle ND pierces and damages the warp 11 of the base fabric is reduced, and the strength of the dryer felt increases the cross-sectional shape of the warp. It can be expected to be held at the same retention rate as the base fabric using the monofilament.
[0042]
4A to 4E are schematic explanatory views showing various aspects of the woven structure of the base fabric. These will be described below.
FIG. 4 (A) is a table 1/3 broken oblique back 3/1 broken oblique weft double woven base fabric 10a, in which the diameter yarn 11 is sequentially woven into the surface weft 12 and the back weft 13. . FIG. 4B shows the above-mentioned table 1/3 broken oblique back 3/1 broken oblique weft double weave, in which every other weft 14 is placed in the intermediate layer between the surface weft 12 and the back weft 13. It is a woven base fabric 10b having a weaved front 1/3 torn oblique back and 3/1 torn oblique weft. FIG. 4 (C) shows that in the above-mentioned table 1/3 broken oblique back 3/1 broken oblique weft double weave, wefts 14 are woven one by one into the intermediate layer between the surface weft 12 and the back weft 13 It is the front 1/3 broken oblique back 3/1 broken oblique weft triple woven base fabric 10c. FIG. 4 (D) shows a table 2/2 regular oblique text or a table 2/2 broken oblique text weft double weave base in which the warp 11 is woven with the weft 12 of the surface layer and the weft 13 of the back layer floating only on the surface layer side. The cloth 10d. FIG. 4 (E) shows a table 3/3 regular syllabary or a table 3/3 broken slant that weaves the warp yarn 11 with the surface weft 12 and the back layer weft 13 floated on both sides of the surface layer and the back layer side. This is a double weave base fabric 10e.
[0043]
Sample A, Sample B, and Sample C in Table 1 have the same woven structure using monofilaments having a “cross-sectional shape without a straight portion in the thickness direction” (cross-sectional shape ATN), a circular cross-section, and a square cross-section {Fig. 4 (D) The warp on the surface side of the surface layer is long floating Table 2/2 regular oblique weft double weave}, needle punching the base fabric woven with almost the same weft filling rate, the resulting strength decline tendency It is what I saw. As can be seen, the cross-sectional ATN type product of sample A has a strength retention of 53% in the first punching and 51% in the second punching, and the first 49% and the second in the cross-sectional square product of sample C. It is superior to 44% and has the same strength retention as 58% for the first round and 51% for the second round of the sample B. This table shows data in the state of the base fabric when needle punching is performed without laminating the web, but this tendency is the same for the felt with web laminated. The strength retention rate is based on the woven fabric strength test method of JIS L-1096: 1999. The measured strength of the base fabric before punching is measured with a felt needling machine with a # 32 needle (vegetable needle). Density 160 / cm ² It was determined from the residual strength of the base fabric after punching once and after punching twice under the condition of a needle depth of 13 mm.
[0044]
[Table 1]

[0045]
On the other hand, when a monofilament with a circular cross section is used for the warp of the base fabric (Sample B), the contact area at the intersection with the weft is small, and the restraint with the intersecting weft is small. Little contribution to strengthening. In addition, when the cross-sectional square monofilament (sample C) has a high warp filling rate, the side faces of the adjacent cross-sectional square yarns interfere with each other and the filling rate is increased to a certain extent. The parallel surface in the width direction of the base fabric cannot be maintained {see FIG. 2 (A)}, and in a part of the surface of the base fabric, the corner of the warp cross-sectional square appears on the base fabric surface 110 ′ and is thin. It affects the surface properties of the dryer felt through the nonwoven fabric layer. In addition, when weaving the base fabric, it affects the warp warping and causes a decrease in weaving efficiency.
[0046]
However, since the present invention uses a monofilament having a “cross-sectional shape without a straight portion in the thickness direction” for the warp of the base fabric, the cross-sectional shape is flat, and the intersecting wefts are in contact with each other over a wide area on the major axis side and intersect. It is strongly restrained with the weft and greatly contributes to the enhancement of rigidity and displacement resistance in the weft direction. Further, even if the warp filling rate is increased, the smooth curved surface shape of the side surface of the cross section maintains the smooth surface property on the base fabric surface 10 '{see FIG. 2 (B)}, and the warp between the warp yarns is good and the weaving property is good. There is no loss.
[0047]
Sample D, Sample E, Sample F, and Sample G in Table 2 have the same woven structure using monofilaments having a “cross-sectional shape without straight portions in the thickness direction” (ATN type), a circular cross-section, and a square cross-section, respectively. Table 2/2 is a data obtained by measuring the warp direction and the weft direction coefficient of friction of the surface of the base fabric woven with a torn and weft double weave). The friction coefficient in the warp direction is 0.176 for sample D, 0.195 for sample E, 0.203 for sample F, 0.201 for sample G, and the order of sample F> sample G> sample E> sample D Becomes smaller. The coefficient of friction in the weft direction is 0.179 for sample D, 0.189 for sample E, 0.214 for sample F, and 0.207 for sample G. Sample F> Sample G> Sample E> Sample D The coefficient of friction decreases in order. Thus, the sample D having the ATN cross section has the smallest friction coefficient. The friction coefficient of the sample G having a square cross section belongs to the larger one. Although the measured friction coefficient of the base fabric is not a numerical value that directly represents the surface property of the needling felt, for example, when webs of the same material, fineness, and lamination amount are laminated under the same conditions, the web thickness is particularly thin. It goes without saying that the correlation with the surface property of the needle felt becomes higher. In other words, it can be said that the “cross-sectional shape having no straight portion in the thickness direction” (ATN type) product can improve the surface property of the needling felt more than the quadrilateral cross-sectional product.
[0048]
[Table 2]

[0049]
In carrying out the present invention, the “cross-sectional shape having no straight portion in the thickness direction” monofilament used for the warp has a thickness direction dimension of 0.25 mm to 0.35 mm and a ratio with the width direction dimension of 1: 1.3. It is a cross-sectional shape inscribed in a square within a range of ˜1: 2.0. The upper limit of the width direction dimension is 0.35 mm in order to maintain good flexibility in the warp direction, and if it is increased beyond this, it becomes difficult to develop preferable flexibility. On the other hand, if it is less than 0.25 mm, sufficient warp rigidity cannot be secured, it is not possible to cross deeply at the intersection of wefts, and even if the filling rate is increased, improvement in shape retention and running stability is expected. Can not.
[0050]
On the other hand, in order to effectively exhibit the smoothness of the dryer felt of the “cross-sectional shape having no straight portion in the thickness direction” monofilament used for the warp, the ratio of the thickness direction dimension to the width direction dimension is 1: 1. 3 is the lower limit. In addition, the upper limit of the ratio between the thickness direction dimension and the width direction dimension is set to 1: 2.0, so that the curved surface shape of the side surface is substantially secured, and a high filling rate of warp and an effect of avoiding damage from needle punching are exhibited. In order to ensure the durability of the base fabric.
[0051]
In order to increase the filling rate of warps, in addition to setting the warp density during weaving, we will select and use processing conditions that increase the amount of shrinkage in the weft direction during heat setting and high weft shrinkage . When using a weft having a high dry heat shrinkage rate, it is used for at least one weft. The use of all the weft layers can increase the filling rate of the warp. When wefts having a high dry heat shrinkage rate are used, it is possible to achieve a warp filling rate of 130% to 175%.
[0052]
In the practice of the present invention, the monofilament with high dry heat and high shrinkage used for the weft is 12% to 26% at 160 ° C, 14% to 30% at 180 ° C, more preferably 12% at 160 ° C. 21.4%, which has a dry heat shrinkage in the range of 14% to 24% at 180 ° C., and is generally available for dryer canvas. For example, as a polyester monofilament, PX-405 manufactured by Shakespeare is commercially available.
[0053]
Monofilament yarns applicable to the present invention include polyester fibers such as PET and PBT, polyamide fibers such as nylon 6, nylon 46 and nylon 66, polyolefin fibers such as polypropylene fibers, and PPS and PEEK having excellent heat resistance. A monofilament yarn as a main component is used as warp and / or weft alone or in combination. Polyester fibers such as PET and PBT are preferable from the viewpoints of dimensional stability, wear resistance, and bending fatigue resistance, and PPS and PEEK yarns are preferable from the viewpoint of heat resistance.
[0054]
As the woven structure of the base fabric, a weft double weave or a weft triple weave is used to ensure flexibility in the warp direction and particularly to require rigidity in the weft direction. In particular, when placing emphasis on the stiffness in the direction of the weft, it is based on the double weave {Fig. A weaving 2.5 double weave {FIG. 4 (B)} and a triple weaving {FIG. 4 (C)} in which wefts are woven one by one in the middle layer are used. Of course, a double weaving can be used as well. Further, in order to improve the flatness of the surface, a weft double weave in which the warp floats long and a table 2/2 regular oblique or table 2/2 broken oblique weft 2 as shown in FIGS. Weaving structures such as heavy weaving {FIG. 4 (D)}, Table 3/3 regular weft and Table 3/3 broken weft weft {FIG. 4 (E)} can be used.
[0055]
When higher stiffness in the weft direction is particularly required, for example, when the felt width is 5 m or more, the wefts of both the front layer and the back layer have a diameter of 0.3 mm to 0.7 mm. A monofilament with a circular cross section is used. Adjacent warps are obtained by using a monofilament having a “cross-sectional shape without a straight portion in the thickness direction” as the warp and setting the warp filling rate to 100% to 175%, preferably 125% to 175%. The restraint between the two becomes stronger, the crossing with the weft becomes deeper and stronger, the stiffness in the direction of the weft is further reinforced and the displacement resistance is improved, and the dryer felt has excellent shape preservation and running stability. It becomes. For the weft yarns in the middle layer, multi yarns, spun yarns and the like can be appropriately used for adjusting the entanglement adhesiveness with the web fibers and the air permeability. Furthermore, it is desirable to use a monofilament with a circular cross section for the purpose of further increasing the rigidity in the weft direction for the weft yarn of the intermediate layer. In this case, the weft diameter is preferably in the range of 0.3 mm to 0.7 mm.
[0056]
The required amount of web to be laminated on the base fabric is set depending on the adhesion to the wet paper and the cushioning property. In order to ensure sufficient entanglement adhesion between the web and the base fabric, or to obtain low air permeability, we woven a monofilament with a circular cross section on one of the weft yarns on the front and back layers, and multifilaments and span yarns on the other weft yarns. Can be used. When a yarn with poor rigidity other than a monofilament is used for one weft layer, the stiffness in the weft direction naturally decreases, but the warp filling rate is preferably increased to 130% to 170%, and the resistance to misalignment In order to improve the shape preservability and running stability, the rigidity in the weft direction is reinforced by the rigid cross-sectional monofilament having a diameter dimension of 0.3 mm to 0.7 mm in the single layer weft. As a result, rigidity in the weft direction that can be applied to applications in which the felt width is 5 m or more can be obtained.
[0057]
In addition to the material and diameter of the weft, in the weft surface, in order to obtain preferable weft rigidity, misalignment resistance, and air permeability, and considering the production efficiency of the warp loop joint, weft density In the range of 12 x 2 / 2.54 cm to 20 x 2 / 2.54 cm for a double weft and 12 x 3 / 2.54 cm to 20 x 3 / 2.54 cm for a triple weft. You can choose.
[0058]
In the part used in the so-called single run type, as described above, it is essential that the dryer felt is thin, so that the amount of web fibers laminated is also limited. When the amount of web fibers laminated is small, the entanglement adhesiveness with the base fabric tends to decrease, and in the case of wide and high speed applications in a single run type drying section, further rigidity and resistance in the weft direction. Since misalignment is required, weaving cross-section circular monofilaments with excellent rigidity on the front and back layers, and using a yarn with good entanglement with web fibers such as spun yarn in the middle layer. A triple weave is preferred.
[0059]
Also, in the case of a single run type drying section, especially when the surface property is important, the web fiber is used with a limited amount of lamination, so that the nonwoven fabric layer becomes thin and the surface layer of the base fabric has a thin surface property. Therefore, it is preferable to use a weft texture structure having a double weft in which the warp on the surface of the paper contact surface, which is excellent in surface smoothness, floats for a long time. The surface smoothness as a base fabric can be obtained due to the flatness of the monofilament “cross-sectional shape having no straight portion in the thickness direction” used for the warp.
[0060]
The thickness of the fibers used in the web should be 11dtex or more and 22dtex when felt cushioning and high air permeability are placed heavily, and 11dtex or less and 2dtex when thin thickness and low air permeability are required. It is selected as appropriate by mixing single or plural kinds of fine fibers. The amount of web lamination is usually 300 g / m ² The front and rear are used, but in order to reduce the thickness, 100 g / m ² A degree or less is also selected. As the material of the web, polyester fiber, polyamide fiber, acrylic fiber, aromatic polyamide fiber, and other fibers can be used.
[0061]
In the present invention, a "cross-sectional shape having no straight portion in the thickness direction" monofilament is used for the warp, and the warp filling rate is set to be high so that adjacent warps in the width direction are sufficiently adhered to each other. In combination with the rigidity of the cross-section circular monofilament of the above-mentioned diameter size range used for the weft, the effect of reducing the flexibility in the width direction is reduced, compared with the case of using the cross-section circular or cross-section square monofilament. It is possible to improve the misalignment resistance as well as the rigidity.
[0062]
In the present invention, a “cross-sectional shape having no straight portion in the thickness direction” monofilament is used for the warp of the base fabric, so that a high warp filling rate can be realized. Table weaving 2.5 / 3 weave or weft triple weave in the back 1/3 torn weave, weaving structure with sufficient rigidity and misalignment resistance for wide width and high speed A dryer felt having a surface smoothness with no problem and a thickness of the base fabric of 1.3 mm to 1.8 mm, and a thickness within the range of 1.7 mm to 2.2 mm suitable for a single run type application. Can be realized.
[0063]
In addition, a warp long floating weft double weave structure using monofilaments with a circular cross section for the front layer or the back layer and a yarn having excellent entanglement with the web such as multifilament yarns and spun yarns for the remaining one layer is sufficient. Reinforce the rigidity in the weft direction, and even with a small amount of web lamination, the surface of the base fabric has excellent surface smoothness due to the smooth surface of the base fabric, and the thickness of the base fabric is preferably 1.3 mm to 1.8 mm. A dryer felt having a thickness in the range of 1.3 mm to 1.6 mm and a thickness in the range of 1.7 mm to 2.2 mm suitable for a single run type application can be realized.
[0064]
In the present invention, a monofilament having a “cross-sectional shape without a straight portion in the thickness direction” is used for the warp of the base fabric, and a high warp filling ratio can be realized. , Spun yarn, etc. can be used, so that a dryer felt with excellent surface smoothness even with a small amount of web lamination is suitable for applications of single run type, 1,000 to 6,000 cm. ^Three / cm ² ・ Minute, preferably 1,000-4,500cm ^Three / cm ² ・ Dryer felt with air permeability within minutes can be realized.
[0065]
In addition, about the method of each test in connection with implementation of this invention, it is based on the following.
(1) Dry heat shrinkage
Five samples obtained by cutting the raw yarn into a length of 300 mm are treated in a hot air dryer for 20 minutes. The sample taken out is left in a room in a standard state (temperature 20 ° C., relative humidity 65%) for about 30 minutes or more, then its length is measured and expressed as an average value of five samples obtained by the following formula. .

[0066]
▲ 2 ▼ Air permeability
Measured by using a measuring device conforming to JIS L-1096: 1999 Frazier method.
[0067]
(3) 3-point bending rigidity
By using the testing machine 20 in FIG. 5, the upper surfaces of both ends of the sample S having a width of 3 cm (dimension in the front and back direction in FIG. 5)
The central portion of the sample S is pulled upward via a 10 mm diameter roller 22 and a load meter (not shown). Although the display value increases with the amount of pulling up of the roller 22, the display value of the load meter does not increase when the roller 22 is pulled up to some extent. The maximum display value at this time is referred to as a rigidity value and is expressed in a unit cN / 3 cm.
[0068]
When testing the three-point bending stiffness in the warp direction, the longitudinal direction of the sample S (the direction perpendicular to the width of 3 cm) is the warp direction.
When measuring the stiffness in the weft direction, the longitudinal direction of the sample S is the weft direction.
[0069]
(4) Misalignment angle
6 (A) and 6 (B) show a deviation angle measuring device 30, and one end of the lateral arms 32 and 33 can be swung up and down by pivot pins 34 and 35 at the upper end and the base end of the fixed column 31, respectively. The other ends of the horizontal arms 32, 33 are connected in a link shape by a connecting arm 36, and the upper horizontal arm 32 is normally fixed to a fixed horizontal arm 37 by a pin 38. In addition, a pointer 39 that indicates the inclination angle is attached to the base of the lateral arm 32 on the upper end side.
[0070]
The upper end of the sample S having a predetermined length and width is fixed by the horizontal arm 32 and the fixed horizontal arm 37, and a load of 1 kg per 1 cm width of the sample S is suspended from the lower end. In this state, the lower end of the sample S is fixed to the lower horizontal arm 33, and then the load is removed. In this way, the sample S is fixed as shown in FIG. 6 (A), the pin 38 is pulled out, and a downward moment is applied as shown in FIG. 6 (B). After leaving in this state for a certain period of time, the displacement dimension x1 (before heating) in FIG. Thereafter, the displacement dimension x2 (after heating) is again measured with the pointer 39.
The displacement angles θ1 (before heating) and θ2 (after heating) are calculated as shown in FIG. 6C by the displacement dimension x (mm) and the length L (from the center point of the pivot pin 34 to the tip of the pointer 39). = 120 mm), it is calculated by the following formula.
tan θ = x / 120, θ = tan ^-1 (X / 120)
The deviation of the woven structure during the running of the dryer felt is estimated from the deviation angle θ obtained from the above and used for the evaluation of the running stability of the dryer felt.
[0071]
(5) Friction coefficient
The apparatus 40 shown in FIG. 7 is used for the measurement of the friction coefficient. The apparatus 40 is configured to place a pull string 43 tied to a weight 42 on a pulley 44 while a weight 42 is placed on a sample S on a fixed contact member 41 and a load W is applied in a vertical direction. Measure the frictional force F when it starts to move (speed: 50 mm / min) (eg; install a spring balance in the middle of the pull string 43 and see the value) Based on friction force F and load (W = 5kg)
Subsequently, the friction coefficient was calculated from the relational expression of friction coefficient (μ) = friction force (F) / load (W). A sample S having a width of 10 cm and a length of 15 cm is used. When obtaining the friction coefficient in the warp direction, the length direction of the sample S is set as the warp direction, and when obtaining the friction coefficient in the weft direction, the length of the sample S is obtained. The direction is the weft direction.
[0072]
▲ 6 ▼ Thickness
Measured with a thickness measuring instrument in accordance with JIS L-1096: 1999 thickness measurement method. However, the measurement pressure was measured at 14.7 kPa.
[0073]
(Stiffness check in the flow direction (warp direction) and width direction (weft direction) of the base fabric)
The dryer felt that laminates the web on the base fabric, needsling and entangles and integrates it, the specifications such as the web material, etc., depending on the function such as adhesion to wet paper, cushioning, moisture absorption, air permeability, etc. The amount of lamination, needle punching conditions, resin processing after needling and heat set processing conditions are appropriately selected, and these specification conditions are the main improvement objectives of the present invention, the flexibility in the warp direction and the direction in the weft direction. It also affects the rigidity and misalignment resistance.
[0074]
In order to explain the effects of the present invention in comparison with the claims of the present invention, first, Tables 3 to 3 for the prototypes 1, 2, and 3 of the base fabric, which is the main element of the present invention, and the prototypes 4 to 7 as comparative examples thereto. This will be described with reference to Table 5. Depending on the configuration of the base fabric and the characteristics from the configuration, it is possible to clearly confirm the action and effect of the dryer felt that is entangled and integrated with the web on the base fabric.
[0075]
[Table 3]

[0076]
[Table 4]

[0077]
[Table 5]

[0078]
Trials 1 to 3 (Table 3) are all prototypes of the base fabric used for the dryer felt of the present invention before the webs are laminated. Moreover, trial manufacture 4-7 (Table 4 and Table 5) is also a prototype of the base fabric before laminating | stacking a web, Comprising: It prototyped as a comparative example of trial manufacture 1-3.
[0079]
In each table, TM represents a polyester monofilament, and AC represents a spun yarn of acrylic fiber. High shrinkage yarn represents a monofilament with a high dry heat shrinkage.
[0080]
(Prototype 1)
The base fabric of Prototype 1 was woven based on the specifications shown in Table 3 and the weave structure shown in FIG.
That is, a warp having a thickness of 0.30 mm × width of 0.46 mm “cross-sectional shape without a straight portion in the thickness direction” (ATN type) polyester monofilament {cross-sectional shape of FIG. 1B}, surface layer and back layer The weft yarn used was a high-shrinkage yarn with a diameter of 0.50 mm and a circular polyester monofilament with a cross section. It was prepared with a weft density of 16.6 pieces × 2 / 2.54 cm. The prepared base fabric had a thickness of 1.80 mm.
[0081]
(Prototype 2)
The base fabric of Prototype 2 was woven based on the specifications shown in Table 3 and the weave structure shown in FIG.
That is, a warp having a thickness of 0.30 mm × width of 0.46 mm “cross-sectional shape having no straight portion in the thickness direction” (ATN type) polyester monofilament {cross-sectional shape of FIG. 2 (B)}, surface layer and back layer The weft yarns were circular polyester monofilaments with a diameter of 0.50 mm and had a 1/3 torn diagonal back and 3/1 torn diagonal weft double weave structure, a warp filling rate of 134.1% and a weft density of 16. 2 pieces × 2 / 2.54 cm. The prepared base fabric had a thickness of 1.84 mm.
[0082]
(Prototype 3)
The base fabric of Prototype 3 was woven based on the specifications shown in Table 3 and the weave structure shown in FIG.
That is, a warp having a thickness of 0.30 mm and a width of 0.46 mm having a “cross-sectional shape having no straight portion in the thickness direction” (ATN type) polyester monofilament {cross-sectional shape of FIG. 2 (B)}, surface weft Cross section circular polyester monofilament with a diameter of 0.40mm is used as the weft of the back layer. ^S 5/2 acrylic spun yarns with a twisted double weft structure with a 2/2 broken oblique back, a warp filling rate of 133.3%, a weft density of 15.1 × 2/2 .54 cm. The prepared base fabric had a thickness of 1.68 mm.
[0083]
(Prototype 4)
The base fabric of Prototype 4 was woven based on the specifications shown in Table 4 and the weave structure shown in FIG.
That is, a circular polyester monofilament having a cross-sectional diameter of 0.40 mm is used for the warp, and a circular polyester monofilament having a cross-sectional diameter of 0.40 mm is used for the wefts of the front and back layers. It was prepared with a weft double weave structure, a warp filling ratio of 132.6%, and a weft density of 15.5 yarns × 2 / 2.54 cm. The prepared base fabric had a thickness of 1.86 mm.
[0084]
(Prototype 5)
The base fabric of Prototype 5 was woven based on the specifications shown in Table 4 and the woven structure shown in FIG.
That is, a circular polyester monofilament having a cross-sectional diameter of 0.30 mm is used for the warp yarn, and a circular polyester monofilament having a cross-sectional diameter of 0.50 mm is used for the wefts of the surface layer and the back layer. It was made of a weft double weave structure with a warp filling ratio of 148.9% and a weft density of 14.3 pieces × 2 / 2.54 cm. The prepared base fabric had a thickness of 1.83 mm.
[0085]
(Prototype 6)
The base fabric of prototype 6 was woven based on the specifications shown in Table 5 and the weave structure shown in FIG.
That is, a circular polyester monofilament with a cross-sectional diameter of 0.40 mm for the warp yarn, a circular polyester monofilament with a cross-sectional diameter of 0.40 mm for the surface weft, and a cotton count 6 for the weft of the back layer. ^S The twisted yarn of 5 acrylic spun yarns of the above, with a 2/2 broken diagonal weft back 3/1 broken oblique weft double weave structure, warp filling rate 133.5%, weft density 13.9 × 2/2 .54 cm. The prepared base fabric had a thickness of 1.66 mm.
[0086]
(Prototype 7)
The base fabric of Prototype 7 was woven based on the specifications shown in Table 5 and the weave structure shown in FIG.
That is, a square polyester monofilament having a cross section of 0.28 mm in thickness and a width of 0.56 mm is used for the warp, a circular polyester monofilament having a diameter of 0.40 mm is used for the weft of the surface layer, and the cotton count 20 is used for the weft of the back layer. ^S 12 twisted yarns of acrylic spun yarn, 2/2 broken back and back 3/1 broken oblique weft double weave structure, warp filling rate of 121.3%, weft density of 15.0 × 2/2 .54 cm. The prepared base fabric had a thickness of 1.60 mm.
[0087]
The rigidity in the flow direction (warp direction) and the width direction (weft direction) of the above-described prototypes 1 to 3 of the present invention and the prototype fabrics 4 to 7 of the comparative examples 4 to 7 are shown in FIG. The bending rigidity was checked with a testing machine 20. The load is applied from the paper contact surface side (the lower side in FIG. 5). This corresponds to a state in which the wet paper is pressed on the cylinder when the dryer felt is used. The measurement is carried out at three points on each base fabric, and the average value of the measurement results is shown in Table 6, prototypes 1, 2, 4, and 5 for the base fabric of the woven structure in FIG. ) Of the woven fabrics shown in Tables 6 and 6 and 7 respectively.
[0088]
[Table 6]

[0089]
In addition, the woven structure of the table 1/3 torn oblique back and back 3/1 torn oblique weft double weave in FIG. 4A is easy to obtain the rigidity in the weft direction and the resistance to misalignment, and it is difficult to obtain the flexibility. Weaving organization. The woven structure of Table 2/2 torn diagonal back 1/3 torn oblique weft double weave in FIG. 4 (D) is a woven structure which is easy to obtain the warp direction flexibility but difficult to obtain the slip resistance.
[0090]
(3-point bending stiffness in the radial direction)
The results of the three-point bending stiffness in the warp direction are 60 cN / 3 cm for prototype 1, 65 cN / 3 cm for prototype 2, 35 cN / 3 cm for prototype 3, 120 cN / 3 cm for prototype 4, 70 cN / 3 cm for prototype 5, 105 c for prototype 6.
N / 3cm, and in trial production 7, it was 45cN / 3cm.
[0091]
Accordingly, the three-point bending stiffness in the warp direction is 60 cN / 3 cm for prototype 1 and 65 cN / 3 cm for prototype 2 in the case of the woven structure shown in FIG. 4A. It was found that the flexibility was very good as compared with a conventional dryer felt base fabric using 120 (120 cN / 3 cm in trial production 4). In addition, it was found to be equivalent to or more flexible than a conventional dryer felt base fabric (70 cN / 3 cm in trial production 5) using a circular monofilament with a diameter of 0.30 mm having a small fineness for the warp.
[0092]
In the case of the woven structure shown in FIG. 4D, the prototype 3 is 35 cN / 3 cm, which is more flexible than the prototype 1 and the prototype 2. Further, it is much more flexible than a conventional dryer felt base fabric (105 cN / 3 cm in trial production 6) using a circular monofilament with a diameter of 0.40 mm for the warp. The thickness of the base fabric is 1.68 mm for the conventional dryer felt base fabric (45 cN / 3 cm in trial production 7) using a square monofilament with a cross section of thickness 0.28 mm x width 0.56 mm. Although it was slightly thicker than 1.60 mm of prototype 7, it was found that the flexibility in the warp direction was equal to or greater.
[0093]
(3-point bending stiffness in the weft direction)
The results of the three-point bending stiffness in the weft direction are 815 cN / 3 cm for trial 1, 775 cN / 3 cm for trial 2, 405 cN / 3 cm for trial 3, 445 cN / 3 cm for trial 4, 745 cN / 3 cm for trial 5, 355 cN for trial 6 / 3 cm, and in Prototype 7, it was 295 cN / 3 cm.
[0094]
Accordingly, the three-point bending stiffness in the weft direction is 815 cN / 3 cm for prototype 1 and 775 cN / 3 cm for prototype 2, and the weft has a circular cross section with a diameter of 0.50 mm. Although the monofilament was used, it was almost the same thickness as the conventional dryer felt base fabric (445 cN / 3 cm in prototype 4) that used a 0.40 mm diameter circular monofilament for the weft. A conventional dryer felt base fabric using a circular monofilament with a cross-sectional diameter of 0.30 mm for the warp and a diameter of 0.30 mm for the warp, and a circular monofilament with a cross-section of 0.50 mm for the weft, which is 745 cN / 3 cm) or more. Prototype 1 uses high-shrinkage monofilaments for the wefts, so that the warp filling rate can be as high as 145.1%, so that the three-point bending rigidity (815 cN / 3 cm) in the weft direction is a circular monofilament cross section. This is even higher than the three-point bending rigidity (775 cN / 3 cm) in the weft direction in trial production 2 having a warp filling ratio of 134.1%.
[0095]
In the case of the woven structure shown in FIG. 4D, the three-point bending stiffness in the weft direction of the prototype 3 is 405 cN / 3 cm, which is lower than those of the prototype 1 and the prototype 2. The configuration using a cross-sectional monofilament with a diameter of 0.40 mm for the weft of the surface layer and a twisted yarn of the spun yarn for the weft of the back layer is almost the same in both prototypes 3, 6, and 7, and the warp has a thickness of 0 Dryer felt base fabric (prototype 3) using 30mm x width 0.46mm "cross-sectional shape with no straight part in the thickness direction" (ATN type) monofilament has a cross-sectional circular monofilament with a diameter of 0.40 mm as the warp. Dryer felt base fabric (355cN / 3cm in trial production 6) and dryer felt base fabric using a square monofilament having a cross section of 0.28mm in the thickness direction and 0.56mm in the width direction as the warp 7 and 295 cN / 3 cm), the three-point bending stiffness in the weft direction was found to be approximately the same or slightly higher.
[0096]
(Evaluation of running stability on the base fabric)
The deviation angle before heating (after 2 minutes after mounting) and after heating (after 3 minutes after treatment) in the above-described prototypes 1 to 3 of the present invention and prototypes 4 to 7 as comparative examples is shown in FIG. Measured by the measuring device 30 shown in Fig. 1 to estimate the displacement of the woven structure during dryer felt traveling, and evaluated traveling stability. The measurement was performed on each base fabric for three samples, and the average value of the measurement results is shown in Table 7.
[0097]
[Table 7]

[0098]
The deviation angle θ1 before heating (2 minutes after mounting) is 2.58 ° in prototype 1, 3.42 ° in prototype 2, 4.08 ° in prototype 3, 5.25 ° in prototype 4, and 9 in prototype 5. 0.08 °, prototype 6 was 11.92 °, prototype 7 was 5.92 °.
[0099]
The deviation angle θ2 after heating (3 minutes after the treatment) is 6.67 ° in prototype 1, 7.75 ° in prototype 2, 8.25 ° in prototype 3, 10.83 ° in prototype 4, and 14 in prototype 5. .33 °, Sample 6 was 16.08 °, and Sample 7 was 11.17 °.
[0100]
Therefore, in the case of the woven structure shown in FIG. 4A, the deviation angle θ is 2.58 ° before heating and 6.67 ° after heating in the prototype 1, and 3.42 ° before heating and 7.7 after the heating in the prototype 2. Degree of deviation from the dryer felt base fabric (5.25 ° before heating and 10.83 ° after heating in Prototype 4) using a circular monofilament with a cross section of 75 °, each having a large warp fineness and a diameter of 0.40 mm. θ is small. In addition, each of the deviation angles θ is considerably smaller than the dryer felt base fabric using the monofilament having a cross-section with a small warp fineness of 0.30 mm in diameter (9.08 ° before heating and 14.33 ° after heating in Prototype 5), It was found that running stability was improved. Further, it was found that in trial 1 and trial 2, trial 1 with a higher warp filling rate had a smaller deviation angle θ before and after heating, and was more excellent in running stability.
[0101]
In the case of the woven structure of FIG. 4 (D), in the trial production 3, 4.08 ° before heating and 8.25 ° after heating, and each used a circular monofilament having a large warp fineness and a diameter of 0.40 mm. Use a square monofilament with a cross section of smaller diameter θ than the dryer felt base fabric (Prototype 6: 11.92 ° before heating and 16.08 ° after heating), and the dimensions are 0.28mm thickness x 0.56mm width. It was found that the deviation angle θ was smaller than the conventional dryer felt base fabric (5.92 ° before heating and 11.17 ° after heating) in the prototype 7, and the running stability and shape retention were excellent.
[0102]
As described above, in the case of the woven structure of FIG. 4 (A) Table 1/3 broken oblique back 3/1 broken oblique weft double weave, FIG. 4 (D) Table 2/2 broken oblique back 3 / Also in the case of a weave structure with 1 tear oblique weft and double weave, the dryer felt base fabrics of prototypes 1 to 3 of the present invention have a warp direction in comparison with the prototype 4 to 7 dryer felt base fabrics as comparative examples. It was found that the fabric was excellent in flexibility, and the stiffness in the weft direction was also superior to the prototype dryer felt base fabric of the comparative example when viewed with the same weft configuration. It was also found that deviation resistance, which is an evaluation of running stability and form retention, is improved in trial productions 1 to 3 of the present invention compared to trial productions 4 to 7.
[0103]
Next, the Example of this invention in the state of the dryer felt which laminated | stacked the web on the base fabric and needle-punched is demonstrated based on Table 8-Table 9. FIG. The symbol N in the web specification column in each table represents nylon 66, AC represents acrylic, and the material of the web. The subsequent numbers are the fineness of the web (unit is dtex, in the table, the superscript following the fineness number) ("T").
[0104]
(Example)
Examples 1 and 2 are examples of a dryer felt in which a web is laminated on both front and back sides of a base fabric. Examples 3 to 6 are examples of a dryer felt in which a web is laminated on one side (surface) of the base fabric. This is an example. Hereinafter, each example will be described based on Tables 8 to 9.
[0105]
[Table 8]

[0106]
[Table 9]

[0107]
Example 1
The dryer felt of Example 1 was woven and heat set based on the specifications shown in Table 8 and the base fabric woven structure shown in FIG. 4 (A), and a web having the specifications shown in Table 8 was laminated and needling. After entangled and integrated with the base fabric, it was created by heat setting.
[0108]
That is, the warp yarn 11 has a thickness of 0.30 mm × width of 0.46 mm “cross-sectional shape having no linear portion in the thickness direction” (ATN type) polyester monofilament {cross-sectional shape of FIG. 1B}, surface layer and back surface The weft yarns 12 and 13 are circular polyester monofilaments with a cross-sectional diameter of 0.50 mm, and the base fabric 10a is woven with a 1/3 torn diagonal back and 3/1 torn diagonal weft double weave structure, and heat set processing In addition, 320 g of web 15 obtained by mixing nylon 66 fiber staple having a fineness of 6.6 dtex and acrylic fiber staple having a fineness of 11 dtex shown in the specifications of Table 8 at a weight ratio of 60%: 40% on the surface layer of the base fabric 10a. / M ² In the back layer, 100 g / m of web 16 having the same composition as the surface layer ² The nonwoven fabric layers 15 and 16 are formed on the surface layer and the back layer respectively by entanglement and integration by needling, and then heat set to give a warp density of 73.6 pieces / 2.54 cm. A dryer felt 100A having a weft density of 17.2 × 2 pieces / 2.54 cm was prepared. The concept of the structure is shown in FIG. The warp filling rate at this time was 133.3%, and the thickness of the base fabric 10a was 1.77 mm. The thickness of the dryer felt 100A is 4.42mm, and the air permeability is 5,720cm. ^Three / cm ² ・ It was minutes. In addition, the strength retention ratio of the needling with respect to the warp strength of the base fabric 10a before needling was not different from that of a conventional dryer felt of a base fabric using a circular monofilament as a warp.
[0109]
(Example 2)
The dryer felt of Example 2 was woven and heat set based on the specifications shown in Table 8 and the woven structure of the base fabric shown in FIG. 4 (A), and a web having the specifications shown in Table 8 was laminated and needling. After entangled and integrated with the base fabric, it was created by heat setting.
[0110]
That is, the warp yarn 11 has a thickness of 0.30 mm × width of 0.46 mm “cross-sectional shape having no linear portion in the thickness direction” (ATN type) polyester monofilament {cross-sectional shape of FIG. 1B}, surface layer and back surface The weft yarns 12 and 13 are made of a high-shrinkage polyester monofilament with a circular cross section of 0.50 mm in diameter. After setting, 320 g of web 15 in which nylon 66 fiber staple having a fineness of 6.6 dtex and acrylic fiber staple having a fineness of 11 dtex shown in the specifications of Table 8 are mixed at a weight ratio of 60%: 40% on the surface layer of the base fabric 10a. / M ² In the back layer, 100 g / m of web 16 having the same composition as the surface layer ² After the nonwoven fabric layers 15 and 16 are formed on the surface layer and the back layer respectively by entanglement and integration by needling, heat set processing is performed, and the warp density is 80.4 pieces / 2.54 cm. A dryer felt 100A having a weft density of 16.8 × 2 pieces / 2.54 cm was prepared. The concept of the structure is shown in FIG. The warp filling rate at this time was 145.6%, and the thickness of the base fabric 10a was 1.80 mm.
Dryer felt 100A has a thickness of 4.25mm and air permeability of 4,890cm. ^Three / cm ² ・ It was minutes. Further, the strength retention ratio of the base fabric before needling with respect to the warp strength of the base fabric was not different from that of a conventional dryer felt of a base fabric using a circular monofilament as a warp.
[0111]
(Example 3)
The dryer felt of Example 3 was woven and heat set based on the specifications shown in Table 8 and the base fabric woven structure shown in FIG. 4 (A), and a web having the specifications shown in Table 8 was laminated and needling. After entangled and integrated with the base fabric, it was created by heat setting.
[0112]
That is, the warp yarn 11 has a thickness of 0.30 mm × width of 0.46 mm “cross-sectional shape having no linear portion in the thickness direction” (ATN type) polyester monofilament {cross-sectional shape of FIG. 1B}, surface layer and back surface The weft yarns 12 and 13 are made of a high-shrinkage polyester monofilament with a circular cross section of 0.50 mm in diameter. In addition to the set processing, 260 g / m of a nylon 66 fiber staple web 15 having a fineness of 6.6 dtex shown in the specifications of Table 8 is applied to the surface layer of the base fabric 10a. ² After forming the nonwoven fabric layer 15 on the surface layer by entanglement and integration by needling, heat set processing is performed to obtain a warp density of 80.5 pieces / 2.54 cm and a weft density of 17. A dryer felt 100B of 5 × 2 pieces / 2.54 cm was prepared. The concept of the structure is shown in FIG. The warp filling rate at this time was 145.8%, and the thickness of the base fabric 10a was 1.82 mm. The dryer felt 100B has a thickness of 2.66 mm and an air permeability of 3,240 cm. ^Three / cm ² ・ It was minutes. Further, the strength retention ratio of the base fabric before needling with respect to the warp strength of the base fabric was not different from that of a conventional dryer felt of a base fabric using a circular monofilament as a warp.
[0113]
Example 4
The dryer felt of Example 4 was woven and heat set based on the specifications shown in Table 9 and the woven structure of the base fabric shown in FIG. 4C, and a web having the specifications shown in Table 9 was laminated and needling. After entangled and integrated with the base fabric, it was created by heat setting.
[0114]
That is, the warp yarn 11 has a thickness of 0.30 mm × width of 0.46 mm “cross-sectional shape having no linear portion in the thickness direction” (ATN type) polyester monofilament {cross-sectional shape of FIG. 1B}, surface layer and back surface Layer wefts 12 and 13 are cross-sectionally circular high-shrinkage polyester monofilaments with a diameter of 0.40 mm, and middle layer wefts 14 are acrylic span cotton count 6 ^S The base fabric 10c was woven with a triple woven structure of 1/3 torn diagonally back and 3/1 broken oblique weft, and subjected to heat-set processing. 100 g / m of web 15 in which nylon 66 fiber staple having a fineness of 6.6 dtex and acrylic fiber staple having a fineness of 11 dtex shown in the specification of 8 are mixed at a weight ratio of 60%: 40%. ² The nonwoven fabric layer 15 is formed on the surface layer by entanglement and integration by needling, and then heat set to give a warp density of 80.6 pieces / 2.54 cm and a weft density of 16. A dryer felt 100C of 5 × 2 pieces / 2.54 cm was prepared. The concept of the structure is shown in FIG. The warp filling rate at this time was 146.0%, and the thickness of the base fabric 10c was 1.72 mm. Dryer felt 100C has a thickness of 1.92mm and air permeability of 1,820cm. ^Three / cm ² ・ It was minutes. Further, the smoothness of the surface of the nonwoven fabric layer 15 on the paper contact surface side was very good. There was no difference in the strength retention of the needling with respect to the warp strength of the base fabric before needling compared to the conventional dryer felt of the base fabric using a circular monofilament as a warp.
[0115]
In Examples 1 and 2, the warp 11 has a dimension of 0.30 mm thick × 0.46 mm wide “cross-sectional shape having no straight portion in the thickness direction” (ATN type) polyester monofilament, surface layer and back layer weft 12 , 13 is a circular polyester monofilament having a diameter of 0.50 mm, and the woven structure is strong in the crossing of warp and weft and has good misalignment resistance. / 1 The base fabric 10a was woven with a double weave texture. Fiber webs 15 and 16 having a proven record in cushioning and durability are laminated on the front and back surfaces of the base fabric 10a subjected to heat setting, and entangled and joined by needle punching. In particular, Example 2 used polyester monofilaments with high dry heat shrinkage for the wefts 12 and 13, so that the warp filling rate in the heat setting after weaving was 133.3% of Example 1 compared to Example 2 Can be as high as 145.6%, and the displacement resistance (deviation angle θ2 after heating) is 6.50 ° in Example 1 and further improved to 5.25 ° in Example 2. done. In both cases, the warp filling rate could be within the range of 130% to 175%.
[0116]
Further, compared to Comparative Examples 1 and 2 described later, which have the same woven structure and web specifications, the comparative example 1 using a circular polyester monofilament with a cross-sectional diameter of 0.40 mm for the warp is flexible in the warp direction. The results of the three-point bending stiffness in the warp direction are 340 cN / 3 cm in Example 1, 310 cN / 3 cm in Example 2, and 560 cN / 3 cm in Comparative Example 1. The stiffness in the weft direction (three-point bending in the weft direction) The result of rigidity is excellent in 1,230 cN / 3 cm in Example 1, 1,160 cN / 3 cm in Example 2 and 810 cN / 3 cm in Comparative Example 1), and the resistance to misalignment (the misalignment angle θ2 after heating is a comparison). In Example 1, 8.95 °) was very good. Regarding the damage caused by needle punching, the strength in the warp direction of the base fabric before and after punching was the same retention rate.
[0117]
For Comparative Example 2 using a circular polyester monofilament with a diameter of 0.30 mm for the warp, the warp direction flexibility (the result of the three-point bending stiffness in the warp direction is 440 cN / 3 cm in Comparative Example 2) Good, weft direction stiffness (3-point bending stiffness in the weft direction is 930 cN / 3 cm in Comparative Example 2) and displacement resistance (deviation angle θ2 after heating is 9.51 ° in Comparative Example 2) It was. Regarding the damage caused by needle punching, the tenacity in the warp direction of the base fabric before and after punching showed a higher retention rate.
[0118]
In Example 3, web fibers were laminated on the same woven structure as in Examples 1 and 2 only on the surface side, the thickness was reduced, and the flexibility in the warp direction was further improved (three-point bending rigidity in the warp direction). 270 cN / 3 cm) felt.
[0119]
Example 4 is a weft triple weaving in which the weft structure of Examples 1 to 3 is woven by weaving a cross-sectional circular high-shrinkage polyester monofilament with a diameter of 0.40 mm on the wefts of the front layer and the back layer, and a span yarn on the middle layer High warp filling ratio due to the high shrinkage monofilament of the weft, and the entanglement with the web fiber with the laminating amount reduced as much as possible by the lamination of only the surface layer by the span yarn of the middle layer weft, so warp compared to Examples 1-3 The flexibility in the direction (three-point bending rigidity in the warp direction is 250 cN / 3 cm) and the thickness is as thin as 1.92 mm, but the rigidity in the weft direction (three-point bending rigidity in the weft direction is 1,040 cN) / 3 cm) and resistance to deviation (deviation angle θ2 after heating is 4.46 °). The air permeability is 1,820cm ^Three / cm ² ・ It was able to be made low, and it showed sufficient applicability to a single-run, wide, high-speed drying section.
[0120]
(Example 5)
The dryer felt of Example 5 was woven and heat set based on the specifications shown in Table 9 and the base fabric woven structure shown in FIG. 4 (D), and the web having the specifications shown in Table 9 was laminated and needling. After entangled and integrated with the base fabric, it was created by heat setting.
[0121]
That is, the warp 11 has a dimension of a thickness of 0.3 mm × width of 0.46 mm, “cross-sectional shape having no straight portion in the thickness direction” (ATN type) polyester monofilament {cross-sectional shape of FIG. 1 (B)}, surface weft 12 is a circular polyester monofilament having a diameter of 0.5 mm, and a weft yarn 13a on the back layer is an acrylic span cotton count 6 ^S The base fabric 10d was woven with a double weave structure of 2/2 torn diagonal back and weft, and subjected to heat-set processing. 100 g / m of nylon 66 fiber staple web 15 with a fineness of 6.6 dtex shown in 9 specification ² The nonwoven fabric layer 15 was formed on the surface layer by entanglement and integration with a needling amount, and then heat set to give a warp density of 74.0 pieces / 2.54 cm and a weft density of 15. 3 × 2 pieces / 2.54 cm of dryer felt 100D was prepared.
The concept of the structure is shown in FIG. The warp filling rate at this time was 134.0%, and the thickness of the base fabric 10d was 1.68 mm. Dryer felt 100D has a thickness of 1.87mm and air permeability of 2,080cm. ^Three / cm ² ・ It was minutes. Further, the smoothness of the surface of the nonwoven fabric layer 15 on the paper contact surface side was very good. There was no difference in the strength retention of the needling with respect to the warp strength of the base fabric before needling compared to the conventional dryer felt of the base fabric using a circular monofilament as a warp.
[0122]
(Example 6)
The dryer felt of Example 6 was woven and heat set based on the specifications shown in Table 9 and the woven structure of the base fabric shown in FIG. 4D, and the web having the specifications shown in Table 9 was laminated and needling. After entangled and integrated with the base fabric, it was created by heat setting.
[0123]
That is, the warp 11 has a dimension of a thickness of 0.30 mm × width of 0.46 mm “cross-sectional shape having no straight portion in the thickness direction” (ATN type) polyester monofilament {cross-sectional shape of FIG. 1 (B)}, surface weft 12 is a circular high-shrinkage polyester monofilament with a diameter of 0.50 mm, and the back layer weft 13a is an acrylic span cotton count 6 ^S The base fabric 10d was woven with a double weave structure of Table 2/2, broken back and back, 3/1 broken oblique weft, and heat-set, and the surface layer of the base 10d is shown in Table 9 100 g / m of nylon 66 fiber staple web 15 with a specified fineness of 6.6 dtex ² After the nonwoven fabric layer 15 is formed on the surface layer by entanglement and integration by needling, heat set processing is performed, the warp density is 78.0 pieces / 2.54 cm, and the weft density is 15. A dryer felt 100D of 5 × 2 pieces / 2.54 cm was prepared. The concept of the structure is shown in FIG. The warp filling rate at this time was 141.3%, and the thickness of the base fabric 10d was 1.66 mm. Dryer felt 100D has a thickness of 1.80mm and air permeability of 1,950cm. ^Three / cm ² ・ It was minutes. Further, the smoothness of the surface of the nonwoven fabric layer 15 on the paper contact surface side was very good. There was no difference in the strength retention of the needling with respect to the warp strength of the base fabric before needling compared to the conventional dryer felt of the base fabric using a circular monofilament as a warp.
[0124]
In each of Examples 5 to 6, a warp 11 having a thickness of 0.30 mm and a width of 0.46 mm using “a cross-sectional shape having no straight portion in the thickness direction” (ATN type) polyester monofilament is used. In both cases, a circular polyester monofilament having a diameter of 0.50 mm is used for the surface weft 12, and an acrylic spun yarn 6 is used for the back weft 13a. ^S Are used. In the woven structure, the warp yarn 11 is long floating and the surface property is good, but the entanglement points of the weft yarns 12 and 13 are few and the displacement resistance is relatively small. The base fabric 10d is woven with a 1-tear oblique weft double woven structure. In Example 6, a polyester monofilament having a high dry heat shrinkage rate was used for the weft 12 of the surface layer, so that the warp filling rate by heat processing after weaving was as high as 141.3% compared to 134.0% in Example 5. It was possible to reinforce the displacement resistance.
[0125]
In Examples 5 to 6, since the thickness of the base fabric 10d was 1.66 mm to 1.68 mm, the thickness of the dryer felt 100D was 1.80 mm to 1.87 mm, and the air permeability was 1,950. 2,080cm ^Three / cm ² ・ In minutes, a thickness and air permeability suitable for a single-run dry section were obtained.
[0126]
Moreover, compared with Comparative Examples 3 to 4 in which web fibers are laminated only on the surface side in the same woven structure described later, for Comparative Example 3 using a circular polyester monofilament with a cross-sectional diameter of 0.40 mm for the warp 11 , Flexibility in the warp direction (three-point bending rigidity in the warp direction is 104 cN / 3 cm in Example 5, 146 cN / 3 cm in Example 6, 219 cN / 3 cm in Comparative Example 3), and rigidity in the weft direction (The three-point bending stiffness in the weft direction was slightly superior at 504 cN / 3 cm in Example 5, 517 cN / 3 cm in Example 6, and 587 cN / 3 cm in Comparative Example 3). Displacement resistance (displacement angle θ2 after heating is 6.30 ° in Example 5, 5.20 ° in Example 6, 6.14 ° in Comparative Example 3) is equivalent or excellent, and the nonwoven fabric layer The touch from the 15th surface was smooth. Compared to Comparative Example 4 in which a warp yarn has a thickness of 0.28 mm and a width of 0.56 mm and a rectangular polyester monofilament having a cross section, the warp direction flexibility (three-point bending rigidity in the warp direction is 152 cN / 3 cm) is almost the same. The weft-direction stiffness (3-point bending stiffness in the weft direction is 475 cN / 3 cm) and displacement resistance (deviation angle θ2 after heating is 11.36 °) are equivalent or excellent.
The smoothness of the surface of the nonwoven fabric layer 15 was very good.
[0127]
Next, the comparative example in the state of the dryer felt which laminated | stacked the web on the base fabric and was needle punched is demonstrated based on Tables 10-11. The symbol N in the web specification column in each table represents nylon 66, AC is acrylic, T is polyester, and the web material represents the web fineness (the unit is dtex, in the table following the fineness number). And a superscript “T”).
[0128]
(Comparative example)
(Comparative Example 1)
The dryer felt of Comparative Example 1 was woven and heat-set based on the specifications shown in Table 10 and the base fabric woven structure shown in FIG. 4 (A), and a web having the specifications shown in Table 10 was laminated and needling. After entangled and integrated with the base fabric, it was created by heat setting.
[0129]
That is, a circular polyester monofilament having a cross-sectional diameter of 0.40 mm is used for the warp yarn 11, and a circular polyester monofilament having a cross-sectional diameter of 0.40 mm is used for the weft yarns 12 and 13 for the front and back layers. / 1 Weaving the base fabric 10a with a double weave texture, heat setting, and nylon 66 fiber staple with a fineness of 6.6 dtex shown in Table 10 on the surface of the base fabric 10a and a fineness of 11 dtex 320 g / m of web 15 mixed with acrylic fiber staples at a weight ratio of 60%: 40% ² In the back layer, 100 g / m of web 16 having the same composition as the surface layer ² After the nonwoven fabric layers 15 and 16 are formed on the surface layer and the back layer by entanglement integration by needling, heat set processing is performed, and the warp density is 85.1 pieces / 2.54 cm. A dryer felt 100A having a weft density of 15.5 × 2 / 2.54 cm was prepared. The warp filling rate at this time was 134.0%, and the thickness of the base fabric was 1.93 mm. A conceptual diagram of the structure is shown in FIG. The thickness of the dryer felt is 4.27mm and the air permeability is 5,540cm. ^Three / cm ² ・ It was minutes.
[0130]
[Table 10]

[0131]
The dryer felt of Comparative Example 1 is a dryer felt that has been used abundantly for a wide and high speed paper machine drying section.
[0132]
(Comparative Example 2)
The dryer felt of Comparative Example 2 was woven and heat-set based on the specifications shown in Table 10 and the base fabric woven structure shown in FIG. 4 (A), and a web having the specifications shown in Table 10 was laminated and needling. After entangled and integrated with the base fabric, it was created by heat setting.
[0133]
That is, a circular polyester monofilament having a cross-sectional diameter of 0.30 mm is used for the warp yarn 11, and a circular polyester monofilament having a cross-sectional diameter of 0.50 mm is used for the weft yarns 12 and 13 for the front and back layers. / 1 Weaving a base fabric 10a with a double weave texture, heat setting, and a nylon 66 fiber staple having a fineness of 16.5 dtex and a fineness of 11 dtex shown in Table 10 on the surface of the base fabric 10a 330 g / m of web 15 in which acrylic fiber staples are mixed at a weight ratio of 60%: 40%. ² In the back layer, 100 g / m of web 16 having the same composition as the surface layer ² After the nonwoven fabric layers 15 and 16 are formed on the surface layer and the back layer, respectively, and heat set processing is performed, the warp density is 126.1 pieces / 2.54 cm. A dryer felt 100A having a weft density of 14.4 × 2 pieces / 2.54 cm was prepared. The warp filling rate at this time was 148.9%, and the thickness of the base fabric 10a was 1.89 mm. A conceptual diagram of the structure is shown in FIG. The dryer felt 100A has a thickness of 4.71 mm and an air permeability of 5
700cm ^Three / cm ² ・ It was minutes.
[0134]
The dryer felt of Comparative Example 2 is a dryer felt that has been used abundantly in the past in the paper machine drying section for applications that require high quality standards such as high-quality paper and coating base paper.
[0135]
(Comparative Example 3)
The dryer felt of Comparative Example 3 was woven and heat set based on the specifications shown in Table 11 and the base fabric woven structure shown in FIG. 4 (D), and a web having the specifications shown in Table 11 was laminated and needling. After entangled and integrated with the base fabric, it was created by heat setting.
[0136]
That is, a circular polyester monofilament having a cross-sectional diameter of 0.40 mm on the warp 11, a circular polyester monofilament having a cross-sectional diameter of 0.40 mm on the weft 12 of the surface layer, and an acrylic span cotton count 6 on the weft 13 a of the back layer. ^S The base fabric 10d was woven with a double weave structure of 2/2 torn back and oblique weft, and subjected to heat-set processing. 100 g / m of a web in which polyester fiber staples having a fineness of 6.6 dtex and nylon 66 fiber staples having a fineness of 6.6 dtex shown in the specifications of No. 11 are mixed at a weight ratio of 60%: 40%. ² After the nonwoven fabric layer 15 is formed on the surface layer by entanglement and integration by needling, heat set processing is performed to obtain a warp density of 85.2 / 2.54 cm and a weft density of 15. A dryer felt 100D of 1 × 2 pieces / 2.54 cm was prepared. The warp filling rate at this time was 134.2%, and the thickness of the base fabric 10d was 1.77 mm. A conceptual diagram of the structure is shown in FIG. Dryer felt 100D has a thickness of 2.19mm and air permeability of 2020cm. ^Three / cm ² ・ It was minutes.
[0137]
[Table 11]

[0138]
The dryer felt of Comparative Example 3 is a dryer felt that has been widely used in the paper machine drying section where high quality standards such as high-quality paper and coating base paper are required in the single-run drying section. is there.
[0139]
(Comparative Example 4)
The dryer felt of Comparative Example 4 was woven and heat set based on the specifications shown in Table 11 and the base fabric woven structure shown in FIG. 4 (D), and a web having the specifications shown in Table 11 was laminated and needling. After entangled and integrated with the base fabric, it was created by heat setting.
[0140]
That is, the warp yarn 11 has a rectangular polyester monofilament with a cross section of 0.28 mm thickness × 0.56 mm width, and a cotton count 20 of acrylic span on the surface weft 12a. ^S 8/2 twisted yarns, and weft yarn 13 of the back layer is made of a polyester monofilament with a cross section of a diameter of 0.40 mm. Woven fabric, heat-set, and polyester fiber staples with a fineness of 6.6 dtex and nylon 66 fiber staples with a fineness of 6.6 dtex shown in the specifications of Table 11 on the surface layer of the base fabric 10d ′ at a weight ratio of 60%: 40% 100 g / m of web 15 mixed with ² The nonwoven fabric layer 15 is formed by entanglement and integration by needling, and then heat set to give a warp density of 55.3 / 2.54 cm and a weft density of 17.3 ×. A dryer felt 100D ′ of 2 / 2.54 cm was prepared. The warp filling rate at this time was 121.9%, and the thickness of the base fabric was 1.65 mm. The conceptual diagram of the configuration is obtained by replacing the surface weft 12a with twisted yarn and the back layer weft 13 with monofilament in FIG. 8D. The dryer felt 100D 'has a thickness of 1.97mm and an air permeability of 1,140cm. ^Three / cm ² ・ It was minutes.
[0141]
【The invention's effect】
According to the present invention, in a dryer felt for a papermaking machine comprising a base fabric woven using warps and wefts, and a nonwoven fabric layer in which a short fiber web is entangled by needle punching on one or both sides of the base fabric. Since a synthetic fiber monofilament having a “cross-sectional shape having no straight part in the thickness direction” was used, and the filling rate of the warp was set to a high range of 125% to 175%, at least one constituting the base fabric. A monofilament with high dry heat shrinkage is used for the weft of the layer, and the warp filling rate is in the range of 130% to 175%, so a particularly high level of quality is required. For example, paper making of high-quality paper or coating base paper Among the drying sections of the multi-cylinder dryer for papermaking, while being able to be used particularly preferably in the first and second groups of the first half with a high moisture content of the wet paper, while ensuring the adhesion with the wet paper and the cushioning property, In addition, it has excellent flexibility in the warp direction, rigidity in the weft direction, durability with little scratching by needle punching, and excellent form retention and running stability. I can do it.
[0142]
Further, the base fabric is woven with either a weft double weave, a weft 2.5 double or a triple weave, and the weft used for at least the surface layer and the back layer of the base fabric has a circular cross-sectional diameter of 0. Since synthetic fiber monofilaments in the range of 3 mm to 0.7 mm were used, they were excellent in form retention and running stability, which can be suitably used for applications of paper making multi-cylinder dryers operating at high speeds. A dryer felt for a papermaking machine can be realized.
[0143]
Further, the base fabric is woven with either a weft double weave or a weft 2.5 double or triple weave, and the weft yarn used for at least the surface layer and the back layer of the base fabric has a circular cross-sectional diameter of 0. Synthetic fiber monofilament within the range of 3 mm to 0.7 mm, or synthetic fiber monofilament with a circular cross-sectional diameter of 0.3 mm to 0.7 mm for the weft used for the surface layer or the back layer of the base fabric Used, and other layers of weft yarns, such as spun yarn with good entanglement adhesiveness with web fibers, can be used in the multi-cylinder dryer for papermaking, in which the drying cylinders are arranged in a single row. The entire drying unit or size press is a drying unit of a type in which drying cylinders are arranged in a single row. For example, high-quality paper and paper for coating base paper are used for applications that require a high level of quality. For papermaking Among the drying parts in the type dryer, it has a wide air permeability adjustment range including a range of thickness dimensions and a low air permeability, which can be particularly suitably used in the first and second groups of the first half with high wet paper moisture content It is possible to realize a dryer felt for a papermaking machine that has excellent surface smoothness, flexibility in the warp direction and rigidity in the weft direction.
[0144]
Among the multi-cylinder dryers for paper making in which the drying cylinders are arranged in a single row, for example, within a felt width of 5 m to 9 m, a paper making speed of 1,000 m / min to 1,500 m / min, It is possible to realize a dryer felt for a papermaking machine having rigidity in the weft direction, shape retention, and running stability that can be applied to a high-speed papermaking multi-cylinder dryer.
[Brief description of the drawings]
FIG. 1A is a cross-sectional view of a warp having an elliptical cross-section,
(B) is a cross-sectional view of an example of a warp having a cross-sectional shape according to the present invention,
(C) is sectional drawing of the example from which the warp which has the cross-sectional shape which concerns on this invention differs.
FIG. 2A is an enlarged cross-sectional view of a main part on the paper contact surface side of a base fabric using a warp having a square cross section in the past,
(B) is a principal part expanded sectional view in the paper contact surface side of the base fabric using the warp which has the cross-sectional shape of this invention.
FIG. 3 (A) is an enlarged cross-sectional view of a main part before pushing in the needle, explaining the displacement and escape when the needle is pushed into the warp of the present invention;
(B) is an enlarged cross-sectional view of the main part at the time of pushing in the needle, explaining the displacement and escape when the needle is pushed into the warp of the present invention.
FIGS. 4A to 4E are schematic explanatory views of various forms of the woven structure of the base fabric,
(A) is an explanatory view of a double woven base fabric of a table 1/3 torn oblique back and 3/1 torn oblique weft
(B) is an explanatory diagram of a double woven base fabric of Table 1/3 torn oblique back 3/1 torn oblique weft
(C) is an explanatory view of a table 1/3 broken oblique back 3/1 broken oblique weft triple woven base fabric,
(D) is an explanatory diagram of a Table 2/2 regular oblique with a long warp and a Table 2/2 broken oblique weft double weave base fabric,
(E) is an explanatory diagram of Table 3/3 regular oblique and Table 3/3 broken oblique weft double woven base fabric in which the warp floats long.
FIG. 5 is an explanatory diagram of a test method for a three-point bending stiffness of a dryer felt.
FIG. 6A is a perspective view when a load is applied in a dryer felt misalignment angle measuring device;
(B) is a perspective view at the time of deviation angle measurement in the deviation angle measuring device of the dryer felt,
(C) is explanatory drawing of the measuring method of the deviation angle in the deviation angle measuring apparatus of (A).
FIG. 7 is a schematic configuration diagram of a friction coefficient measuring apparatus for a dryer felt.
FIGS. 8A to 8D show various embodiments of dryer felt,
(A) is an enlarged cross-sectional view of a main part of a dryer felt in which webs are laminated on both front and back surfaces of the base fabric 10a of FIG. 4 (A),
(B) is an enlarged cross-sectional view of a main part of a dryer felt in which a web is laminated only on the front side of the base fabric 10a of FIG.
(C) is an enlarged cross-sectional view of a main part of a dryer felt in which a web is laminated only on the front side of the base fabric 10c of FIG.
(D) is a principal part expanded sectional view of the dryer felt which laminated | stacked the web only on the front side of the base fabric 10d of FIG. 4 (D).
[Explanation of symbols]
10a, 10b, 10c, 10d, 10e
11 Warp
12, 13, 13a Weft
14 Middle weft
15,16 Non-woven fabric layer (web)
20 3-point bending stiffness testing machine
30 Deviation angle measuring device
40 Friction coefficient measuring device
100A, 100B, 100C, 100D Dryer felt

Claims (6)

In a dryer felt for a paper machine comprising a base fabric woven using warps and wefts, and a nonwoven fabric layer in which a synthetic fiber web of short fibers is entangled by needle punching on one or both sides of the base fabric,
The warp yarn is inscribed in a quadrangle whose thickness direction dimension is smaller than the width direction dimension, and consists of one continuous curve, or consists of one straight line and one continuous curve, and a straight line portion in the thickness direction. A synthetic fiber monofilament having a cross-sectional shape having no cross-section and having a cross-sectional area larger than the area of a regular ellipse inscribed in the quadrangle, and having a warp filling rate in the range of 100% to 175%. Featuring dryer felt for paper machines. The warp having a cross-sectional shape having no straight portion in the thickness direction constituting the base fabric has a thickness direction dimension within a range of 0.25 mm to 0.35 mm, and a ratio between the thickness direction dimension and the width direction dimension. 2. The dryer felt for papermaking machine according to claim 1, which is a synthetic fiber monofilament having a cross-sectional shape inscribed in a quadrangle within a range of 1: 1.3 to 1: 2.0. The warp filling rate is within a range of 130% to 175% by using a monofilament having a high dry heat shrinkage rate for at least one weft constituting the base fabric. Dryer felt for paper machines. The base fabric is woven with either a weft double weave, a 2.5 double weave or a triple weave, and at least wefts used for the surface layer and the back layer have a circular cross section and a diameter of 0.3 mm to 0 mm. 4. A dryer felt for a papermaking machine according to claim 1, wherein a synthetic fiber monofilament within a range of .7 mm is used. The base fabric is woven with either a weft double weave, a 2.5 double weave or a triple weave, and the weft used for the surface layer or the back layer has a circular cross section and a diameter of 0.3 mm to 0.00 mm. 4. A dryer felt for a papermaking machine according to claim 1, wherein a synthetic fiber monofilament within a range of 7 mm is used. A dryer felt for a papermaking machine that is used in a drying section of a type in which the entire drying unit of a multi-cylinder dryer for papermaking or a drying cylinder before size press is arranged in a single row, and the thickness of the base fabric The dryer for a papermaking machine according to any one of claims 1 to 5, wherein the thickness of the dryer felt is in the range of 1.7 mm to 2.2 mm. felt.

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