US20120175009A1 - Method of manufacturing industrial textiles by minimizing warp changes and fabrics made according to the method - Google Patents

Method of manufacturing industrial textiles by minimizing warp changes and fabrics made according to the method Download PDF

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Publication number
US20120175009A1
US20120175009A1 US13/378,401 US201013378401A US2012175009A1 US 20120175009 A1 US20120175009 A1 US 20120175009A1 US 201013378401 A US201013378401 A US 201013378401A US 2012175009 A1 US2012175009 A1 US 2012175009A1
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Prior art keywords
warp
fabrics
fabric
yarns
group
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US13/378,401
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Roger Danby
Dale Johnson
Derek Chaplin
John Clinton Vanderkolk
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AstenJohnson Inc
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AstenJohnson Inc
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Assigned to ASTENJOHNSON, INC. reassignment ASTENJOHNSON, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHAPLIN, DEREK, DANBY, ROGER, JOHNSON, DALE, VANDERKOLK, JOHN CLINTON
Publication of US20120175009A1 publication Critical patent/US20120175009A1/en
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    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D23/00—General weaving methods not special to the production of any particular woven fabric or the use of any particular loom; Weaves not provided for in any other single group
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03C—SHEDDING MECHANISMS; PATTERN CARDS OR CHAINS; PUNCHING OF CARDS; DESIGNING PATTERNS
    • D03C19/00—Methods or devices concerned with designing or making patterns, not provided for in other groups of this subclass
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F1/00—Wet end of machines for making continuous webs of paper
    • D21F1/0027—Screen-cloths
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/06—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyethers
    • D10B2331/061—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyethers polyetherketones, polyetheretherketones, e.g. PEEK
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/10—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyurethanes
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/30—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polycondensation products not covered by indexing codes D10B2331/02 - D10B2331/14
    • D10B2331/301—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polycondensation products not covered by indexing codes D10B2331/02 - D10B2331/14 polyarylene sulfides, e.g. polyphenylenesulfide
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/04—Heat-responsive characteristics
    • D10B2401/041—Heat-responsive characteristics thermoplastic; thermosetting
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D10B2401/062—Load-responsive characteristics stiff, shape retention
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial

Definitions

  • This invention relates to the manufacture of industrial textiles, and in particular to a method of operating looms in such manufacture and to fabrics produced according to the method. More particularly, the invention relates to a method of improved manufacturing of such textiles by reducing the number of different meshes (number of warp yarns per unit width of fabric across the loom, e.g. yarns/in. or yarns/cm) and warp yarn sizes required, and thus the number of warp yarn changes required for such looms to produce in sequence a number of different fabrics each having similar properties to those of fabrics previously woven at differing meshes and using differing warp yarn sizes, so as to thereby minimize the idle time, or down time, of looms.
  • number of different meshes number of warp yarns per unit width of fabric across the loom, e.g. yarns/in. or yarns/cm
  • warp yarn sizes e.g. yarns/in. or yarns/cm
  • Industrial fabrics such as are used in papermaking, filtration and like applications are generally woven structures made using very wide industrial looms which can be 30 ft. (10 m) in width or wider. Certain of these fabrics, particularly those used in papermaking to initially form and drain the sheet (referred to as forming fabrics), are frequently woven at very high mesh counts, meaning that the number of warp yarns per unit of fabric width is relatively high in comparison to other papermaking fabrics, and can be in the range of up to 200 yarns per inch (78.7 yarns/cm) or more.
  • These yarns can be very small in size, with diameters ranging from as low as about 0.08 mm or less up to about 0.30 mm or more; other fabrics, such as those used in the press or dryer sections of papermaking machines, or in similar industrial filtration applications, may have warp yarn sizes in the range from about 0.3 mm up to about 0.7 mm or higher.
  • These larger yarns are frequently woven to provide a mesh of from 20 yarns/inch (7.87 yarns/cm) up to about 70 yarns/inch (27.6 yarns/cm).
  • Selection of appropriate weave designs for these industrial fabrics, and selection of warp and weft yarn diameters and cross-sectional shapes for use in these industrial fabrics is generally based on the type of product to be made, the environment in which the fabric is to be used, and characteristics of the machine for which the fabric is intended.
  • Papermakers forming fabrics are currently manufactured using carefully selected yarn sizes and materials which, when woven to provide one of the above textile structures, with a chosen mesh and knock (number of weft yarns per unit length of fabric, e.g. yarns/in. or yarns/cm), are intended to best suit the grade or type of product that is to be manufactured on a specific papermaking machine having unique performance characteristics.
  • Each papermaking machine and each type of stock that is, the highly aqueous mixture of water, papermaking fibers and chemicals
  • the fabric itself must be extremely rugged and provide a stable structure which will withstand, without distorting or catastrophically failing, the speeds and environmental conditions in which it is expected to operate.
  • the fabric surface upon which the papermaking fibers are deposited referred to as the paper side or PS, must be constructed so as to uniformly support the fibers and form the sheet, while providing adequate drainage of fluid from the papermaking stock deposited thereon.
  • the opposite fabric surface referred to as the machine side or MS, must be rugged and dimensionally stable so as to provide a secure and robust base below the fine papermaking surface. While in operation, the fabric will be running in an endless loop through the papermaking machine at speeds as high as 1,500 m/min or more and will be in moving contact with various stationary dewatering devices (such as blades, foils and suction box covers) in the machine.
  • the fabric manufacturer must strike a balance between the papermaking properties (e.g.: fiber support and drainage capabilities of the PS layer), and the mechanical properties of the fabric (e.g.: elastic modulus, shear stability, caliper and seam strength) while providing a textile product which is suitable for the manufacture of a particular grade of paper on the machine for which it is intended. In the past, this was frequently done by changing one or more of the fabric mesh, knock, yarn size and structure.
  • the papermaking properties e.g.: fiber support and drainage capabilities of the PS layer
  • the mechanical properties of the fabric e.g.: elastic modulus, shear stability, caliper and seam strength
  • Woven industrial textiles are typically manufactured from polymeric monofilament or multifilament yarns as each of the warp and weft materials.
  • the warp is paid off from a yarn supply at the back of the loom (from what is referred to as a back beam), passed through reed openings mounted in the loom heddles, and then around a take-up roll at the front of the loom.
  • the individual warp yarns are thus moved to create so-called shed openings.
  • the weft yarns are shot, or carried, across the shed openings from one side of the fabric to the other by means of a shuttle, rapier or similar mechanism, depending on the loom type.
  • weft yarns are paid off from a storage canister or bobbin located at each side of the fabric.
  • the weave pattern of the fabric is created by controlling the movement of the heddles and thus the individual warp yarns so that selected ones are positioned either above or below a specific weft yarn, thereby creating interlacing locations across the width of the fabric.
  • cans large individual spools
  • cans which are about 3 ft (1 m) in diameter and range from about 4 to 12 inches (10 cm to 30.5 cm) in width.
  • These cans are usually made of steel or a similar rugged material and, when full of yarn (which has been carefully wound onto the can at predetermined tension) they are then mounted in succession along the back beam of the loom to provide the supply of warp material for the fabrics that are to be woven.
  • a 10 m wide loom equipped with 4 inch (10.2 cm) wide cans might have more than 100 of such cans mounted in succession along its back beam. If the loom is a double beam loom, meaning it is equipped with two such back beams, then the number of cans would be double that of a single beam loom, or 200 such cans or more.
  • Warp changes on a loom are typically made to accommodate fabrics having either different textile structures or meshes, or both, than those made previously on the same loom.
  • the warp change will usually be made to allow the manufacturer to weave other fabrics having differing mechanical properties and constructions from those previously produced.
  • a warp change would be made to allow the production of a fabric with a different mesh, or larger or smaller warp yarn sizes than previously used, or yarns having a different cross-sectional shape, or made from a different material, than was previously made on the same loom.
  • a warp change will be made when the manufacturer wishes to weave a different textile structure on the same loom previously used to weave another structure (e.g.
  • a simple warp change (that is, a material replenishment that does not require a mesh change) is effected as follows when there is no fabric structure change.
  • the original warp yarns are cut before (i.e. on the can side of) the heddles so as to leave trailing ends, and the cans containing the old warp material are removed from the back beam; cans containing the new warp material are then mounted onto a new or the existing back beam at the back of the loom.
  • the old beam or cans are removed from the loom and the new beam or cans are then suitably positioned.
  • the trailing ends of the existing warp yarns are then joined onto those from the new beam and the loom is advanced (i.e.
  • the take-up roll is advanced so that the existing warp is wound onto it) and the yarns from the new beam are passed through the heddles following the previous ones. Weaving can then re-commence once all of the new yarns are in position and placed under suitable tension. This relatively simple change can be executed quickly compared to a complete warp and mesh change.
  • the loom must be completely re-drawn or re-threaded, meaning that the old warp must be removed and the new warp must be individually and manually threaded through the eyelets of each of the heddles.
  • warp platform specifies all of the requirements needed to specifically define the warp of the fabric to be woven.
  • SWP single warp platform
  • the weaving parameters for all fabrics previously made, and new fabrics compatible therewith, and previously using a variety of warp sizes and meshes can now be modified so that the warps can be selected from no more than four configurations, and preferably as few as three.
  • Adjustments to fabric properties are then made by selection of any or all of the weft yarn parameters of size, shape, material and density (knocking) prior to and during weaving as well as the subsequent fabric processing parameters, such as heatsetting and tensioning.
  • a single loom can be provided for each of one or more chosen warp platforms, each including yarns having a specified composition, cross-sectional shape and size, threaded to a chosen mesh.
  • Each one can then be used to weave a group of fabrics, the different groups having differing structures, each of which is intended for use in the production of paper products of differing grades or having differing basis weights.
  • one or more of the weft yarn size, cross-sectional shape, polymer composition and knocking is adjusted in the design of the fabric (in comparison to a corresponding substantially equivalent known fabric), or provided in new designs for fabrics in the specific group, so as to provide a textile product with both comparable papermaking properties including drainage area, fiber support, frame length and air permeability, and mechanical properties including elastic modulus, shear stability and stiffness sufficient to accommodate the production of paper products having differing basis weights.
  • the fabrics woven using the warps on that one loom will, of necessity, all have the same mesh in each of the PS and MS layers and will be woven using the same number of sheds in the loom.
  • the set of warp yarns can be divided into two groups, to weave upper and lower fabrics, each of which would have one-half the mesh of the previous single layer fabric. Adjustments to physical properties are then made by changing the weft yarn material and subsequent heatsetting/processing parameters.
  • the invention seeks to provide a method for optimizing industrial fabric production, and fabrics produced by the method, comprising reducing or minimizing the number of times the warp yarn material on a loom must be changed, by providing a manufacturing method whereby a number of different textile products, having some equivalent or closely related characteristics, can be made in sequence using the same loom and warp platform, thus minimizing the number of warp changes necessary between production of the different fabrics, in comparison to the present practice.
  • the physical characteristics of the fabrics can be selected to closely match the requirements necessary for the end consumer to manufacture a range of cellulosic products whose basis weights range from at least 15 to 80 gsm (grams per square meter) or more.
  • the fabrics of the invention comprise groups of at least two industrial fabric structures, each of which is woven using the same warp platform including polymeric warp yarns of the same composition, size, cross-sectional area and shape, and each of which is woven to the same mesh.
  • a group of industrial fabrics produced in accordance with the method of optimizing industrial fabric production can include any two or more of the following textile structures: single layer fabrics, semi duplex fabrics, double layer fabrics, extra support double layer fabrics, triple weft fabrics, standard triple layer fabrics, triple layer sheet support binder (SSB) fabrics, triple layer warp tie fabrics, and triple layer warp integrated sheet support binders (WISS).
  • Each fabric in a group of fabrics of the invention will include warp yarns having the same polymeric composition, cross-sectional shape and area, and number of yarns per unit of CD fabric width as the other fabrics in the group.
  • warp yarns having the same polymeric composition, cross-sectional shape and area, and number of yarns per unit of CD fabric width as the other fabrics in the group.
  • textile structures which include in their constructions two layers of warp yarns, in particular double layer fabrics, extra support double layer, standard triple layer, triple layer sheet support binder (SSB), triple layer warp tie fabrics, and triple layer warp integrated sheet support binders (WISS)
  • the warp yarn cross-sectional shape, size, material composition and mesh used in each layer will be substantially the same.
  • the invention therefore seeks to provide a method of manufacturing woven fabrics from warp yarns and weft yarns for industrial uses, the method comprising the steps of:
  • step (a) identifying optimal fabric characteristics to correspond with at least one selected industrial use to determine at least one group of fabrics suitable for each selected industrial use; (b) selecting a set of shedding options for a loom and providing the loom with a shedding arrangement to provide the selected options; (c) selecting a first group of fabrics and identifying selected fabric properties to produce the optimal fabric characteristics for the first group of fabrics; (d) identifying optimal properties for warp yarns for the first group of fabrics; (e) selecting a fabric structure type and a weave design for each fabric of the first group; (f) installing warp yarns on the loom to correspond with the optimal properties identified in step (d); (g) selecting a first fabric of the first group, identifying properties for weft yarns to correspond with a first weave design for the first fabric, setting the loom to correspond with the first weave design, and weaving the first fabric according to the first weave design; and (h) selectively repeating step (g) for selected other ones of the fabrics in the first group.
  • Two or more fabrics made according to the manufacturing method herein disclosed will have the same mesh as woven, and will include warp yarns of the same composition, size and warp yarn cross-sectional configuration regardless of the chosen fabric structure. Further, in fabrics having two layers of warp yarns in their structure, the warp yarn size and mesh used in each layer will be substantially the same.
  • step (d) comprises the steps of
  • identifying the properties for weft yarns in step (g) comprises determining weft yarn size and knocking measured as number of weft yarns per unit length of the fabric.
  • step (b) comprises providing a loom equipped with a number of back beams selected from one, two and three; and generally the loom will be equipped with two back beams.
  • the warp yarns are constructed of a material selected from polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyetheretherketone (PEEK), polyphenylene sulphide (PPS) and blends and copolymers thereof.
  • PET polyethylene terephthalate
  • PEN polyethylene naphthalate
  • PEEK polyetheretherketone
  • PPS polyphenylene sulphide
  • the weft yarns are constructed of a material selected from PET, polybutylene terephthalate (PBT), a polyamide selected from polyamide 6, 6/6, 6/10, and 6/12, and blends of thermoplastic polyurethane and PET.
  • step (a) comprises determining a maximum of four groups of fabrics.
  • the identifying properties in step (g) comprises selection of adjustable properties selected from at least one of weft yarn material, cross-section shape, size and knocking; more preferably, the selection of adjustable properties is performed to correspond with product criteria for a paper product to be manufactured using the first fabric, wherein the product criteria comprise at least one of the basis weight and the paper grade of the paper product.
  • the identified optimal properties for warp yarns comprises warp sizes in ranges between 0.08 mm and 0.50 mm, and more preferably between 0.1 mm and 0.35 mm.
  • the step of selecting a weave design in step (e) can comprises modifying an existing design, or preparing a new design.
  • the shedding options in step (b) comprise using an integer multiple of 2, 3, 4, 6, 8, 12 or 24 sheds on the loom, and more preferably the shedding arrangement requires 24 sheds.
  • the selecting fabric structure type of step (e) comprises selecting a type from single layer fabrics, semi-duplex fabrics, double layer fabrics, extra support double layer fabrics, triple weft fabrics, standard triple layer fabrics, triple layer sheet support binder fabrics, triple layer warp tie fabrics, and triple layer warp integrated sheet support binder fabrics, and more preferably from extra support double layer fabrics, triple layer sheet support binder fabrics, triple layer warp tie fabrics, and triple layer warp integrated sheet support binder fabrics.
  • the selecting a weave design of step (e) comprises selecting a design requiring two systems of warp yarns, wherein the warp yarn material, size, cross-sectional shape and mesh in each system is substantially the same.
  • the warp yarns are polymeric monofilaments; alternatively they can be polymeric multifilaments, and optionally in either case they can be plied or cabled.
  • single monofilaments are preferred for use in the papermaking fabrics made in accordance with the teachings of this invention.
  • the paper product is selected from a member of one of three groups of paper products, wherein a first group has a basis weight in a range between 15 and 35 gsm, a second group has a basis weight in a range between 35 and 80 gsm, and a third group has a basis weight greater than 80 gsm.
  • the paper product is selected from a member of one of three groups of paper product grades, wherein a first group comprises towel and tissue, a second group comprises printing and writing, and a third group comprises packaging and linerboard.
  • the size of the PS weft yarns is in a range of between 0.08 mm and 0.50 mm, and more preferably between 0.1 mm and 0.35 mm.
  • the PS weft yarns are polymeric monofilaments; alternatively they can be polymeric multifilaments, and optionally in either case they can be plied or cabled.
  • the PS weft yarns should be compatible with the warp yarns, and in general, as for the warp yarns, single monofilaments are preferred for use in the papermaking fabrics made in accordance with the teachings of this invention.
  • the warp yarns have a diameter which exceeds a diameter of the PS weft yarns by less than 0.10 mm, and more preferably by less than 0.05 mm.
  • the method further comprises after step (g) the step of (g.1) heatsetting the first fabric.
  • the invention further seeks to provide a group of at least two industrial textiles, wherein each industrial textile comprises a woven structure of polymeric warp and weft yarns, wherein
  • the warp yarns have warp yarn properties comprising size, shape, polymeric composition, and together have a mesh value; and (ii) the warp yarn properties and mesh value of each industrial textile are substantially identical to the warp yarn properties and mesh value of each other industrial textile in the group.
  • the woven structure of each industrial textile is selected from one of a single layer, semi duplex, double layer, extra support double layer, triple weft, standard triple layer, triple layer sheet support binder, triple layer warp tie, and triple layer integrated sheet support binder fabric construction.
  • the composition of the warp yarns comprises polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyetheretherketone (PEEK), polyphenylene sulphide (PPS) and blends and copolymers thereof.
  • PET polyethylene terephthalate
  • PEN polyethylene naphthalate
  • PEEK polyetheretherketone
  • PPS polyphenylene sulphide
  • each industrial textile is woven according to a pattern having a loom requirement for a number of sheds selected from an integer multiple of 2, 3, 4, 6, 8, 12 and 24.
  • the industrial textiles can be woven according to patterns having a loom requirement for the less usual numbers of sheds, such as selected from an integer multiple of 5, 7, 9, 11, 13, 17, 19 and 23.
  • Fabrics made in accordance with the teachings of this invention can be made on a loom equipped with one, two or more warp beams.
  • the weave design of the MS of the fabric differs substantially from that of the PS, it may be necessary to weave the fabric using a two or three beam warp configuration due to the differing path lengths of the warp yarns in each of the PS and MS layers.
  • FIGS. 1A to 1C together comprise a flow chart of the steps in an embodiment of the method of the invention.
  • the invention provides the important advantage that all, or substantially all, fabrics presently manufactured from a multiplicity of differing warp types, each having differing warp yarn materials, cross-sectional shape or areas, or mesh from the other, and targeted for a generic paper grade (e.g. tissue and towel, printing and writing, packaging and linerboard) can now be made using a minimal number, possibly only one, warp platform, whose yarn size (i.e. diameter, for substantially circular yarns) is selected from the range of from 0.08 mm to about 0.50 mm such as would be optimal for a range of these textile products. Selection of a specific warp yarn size and mesh is determined primarily by the basis weight of the products to be manufactured, and characteristics of the papermaking machine for which the fabric is intended.
  • a generic paper grade e.g. tissue and towel, printing and writing, packaging and linerboard
  • Table 1 a wide range of paper products have been grouped by basis weight into three general grade designations: packaging and linerboard which are generally heavier products and require a high basis weight of about 80 gsm or more; printing and writing grades such as newsprint, magazine and similar papers intended for the application of ink and which have a lower basis weight range of between about 35 and 80 gsm; and towel and tissue which are relatively light basis weight products ranging from about 15 to 35 gsm.
  • packaging and linerboard which are generally heavier products and require a high basis weight of about 80 gsm or more
  • printing and writing grades such as newsprint, magazine and similar papers intended for the application of ink and which have a lower basis weight range of between about 35 and 80 gsm
  • towel and tissue which are relatively light basis weight products ranging from about 15 to 35 gsm.
  • Each of these products will require a fabric the papermaking and mechanical properties of which are optimized for the manufacturing requirements and machine conditions to which they will be exposed.
  • fabric manufacturers would conventionally produce differing fabrics for a much smaller range of basis weights, so that within each of the above general grade designations, multiple fabric designs would be used, each having a different warp platform, to satisfy a narrower basis weight range. It has now been found that fabric products can be grouped within e.g. the categories identified in Table 1, so that a single warp platform can be used for each fabric within a specific group, i.e. utilizing one set of warp yarns in each of the PS and MS woven structures for the fabrics of the particular group, to satisfy the requirements of each grade.
  • weft yarn size and knocking number of weft yarns per unit length of fabric used in combination with the warp will be selected to correspond with the warp yarn sizes.
  • appropriate PS weft yarn sizes would generally range from about 0.08 mm to about 0.50 mm, with the actual size and knocking being selected in combination with the warp yarn mesh, size and cross-sectional shape available.
  • a round cross-section warp yarn having a diameter of about 0.11 mm intended for a fabric for the manufacture of low basis weight products such as tissue would generally utilize a weft yarn size of from about 0.08 mm to 0.20 mm at a PS knocking of from about 50 to 100 yarns/inch (19.7-39.4 yarns/cm). Selection of an appropriate weft yarn size, shape, material and knocking will provide a fabric having the necessary physical and mechanical properties within the range appropriate for the product to be made.
  • the MS weft yarns can be selected to provide the required properties for the intended end use, and can be as large as required.
  • the warp yarn size range in Table 1 would be appropriate for any of these fabric structures and designs, and such fabrics could be woven on a loom provided with one, two or three beams as required.
  • the invention is based on the understanding that selection of a warp platform, i.e. preferred mesh, warp size and cross-sectional shape appropriate for a range of fabrics, is made by evaluating the mechanical properties requirements of the resulting fabrics in combination with the papermaking properties of the fabric.
  • the fabric must provide adequate physical properties appropriate for the environment for which it is intended, which are primarily dictated by the elastic modulus of the warp materials and the resulting stability (as dictated by the shear values of the fabric). Selection of appropriate weft yarn cross-sectional shape and size, material composition and knocking thus become much more important variables that which will allow for adjustment of fabric properties to suit the intended end use of the product.
  • high modulus warp yarn materials particularly polyethylene naphthalate (PEN) and blends thereof such as are described for example in PCT/US2009/034850, or high modulus polyethylene terephthalate (PET) yarns allows the use of smaller diameter warp at lower mesh while still maintaining adequate elastic modulus in the resulting fabric, so these materials are thus particularly suitable for use in fabrics made according to the invention.
  • PEN polyethylene naphthalate
  • PET high modulus polyethylene terephthalate
  • other materials may also be suitable.
  • warp yarns having a smaller cross-sectional area can provide adequate elastic modulus for the intended product, then greater freedom is available for the selection of an appropriate weft yarn size and knocking which will, in turn, allow for a wider variety of paper grades to be manufactured using fabrics produced from the same warp.
  • Monofilaments formed from PEN may be more suited for use in fabrics where the chosen warp yarn size is relatively small or which may be subjected to higher than normally expected linear tensions.
  • Yarns made from polymers such as polyetheretherketone (PEEK), polyphenylene sulphide (PPS), various polyamides or similar materials may also be used.
  • the chosen weft yarn can be any of the thermoplastic polymeric monofilaments or multifilaments currently employed in the manufacture of industrial textiles. While polymers such as PET and polybutylene terephthalate (PBT), polyamides such as polyamide 6, 6/6, 6/10, 6/12, and blends of thermoplastic polyurethane and PET such as are described in U.S. Pat. No. 5,169,711 or U.S. Pat. No. 5,502,120 may be suitable; others may be effective as well and the invention is not limited in this way. Similarly, the weft yarns used in fabrics made according to this invention will generally have a substantially circular cross-sectional shape, but they could also be generally rectangular, square, ovate or otherwise depending on the desired fabric properties and its intended operating environment.
  • Drainage area as well as other papermaking properties of the PS including air permeability, frame length, fiber support index (FSI) can be adjusted by appropriate selection of weft yarn knocking, size and materials.
  • Weft yarn used in the fabrics of this invention can be of any size, shape or composition appropriate for the application.
  • fabric specifications e.g. fiber support or drainage area
  • the weft yarn material may also be changed to provide a monofilament which is either stiffer or more malleable, depending on the property change necessary to match specifications. Such adjustments to the weft yarn parameters would be readily apparent to the person skilled in the art of manufacture of these industrial textiles.
  • the warp yarn diameter should not be larger than about 0.5 mm, but preferably will generally be in the range of 0.08 to 0.35 mm, as indicated in Table 1 above, and more preferably will be in the range of 0.1 mm to 0.25 mm, so as to provide adequate PS surface properties and the PS weft should not be smaller than the warp by a difference of greater than 0.1 mm to 0.05 mm, to ensure that on heatsetting the weft provides sufficient crimp to the warp, to avoid the warp being unduly straight, which could lead to insufficient stability of the resulting fabric.
  • the weft can be as large as necessary or practical to provide the required properties.
  • Industrial fabric structures that can be woven using a single loom and warp platform include: single layer, semi duplex, double layer, extra support double layer, triple weft, standard triple layer, triple layer sheet support binder, triple layer warp tie, and triple layer integrated sheet support binder fabrics. Fabric properties are subsequently adjusted to meet operational requirements by appropriate selection of weft yarn materials and knocking.
  • warp platform is used to refer to the set of warp yarn parameters including: a) diameter (or cross-sectional area in the case of non-round cross-section yarns), b) material composition (e.g. the polymer from which the yarn is formed by thermoplastic extrusion process), c) warp yarn mesh as woven (i.e. the number of warp yarns per unit width in the textile as woven and prior to any subsequent treatment such as by heatsetting) and d) the number of sheds in a single loom required to weave the chosen fabric structure.
  • material composition e.g. the polymer from which the yarn is formed by thermoplastic extrusion process
  • warp yarn mesh as woven i.e. the number of warp yarns per unit width in the textile as woven and prior to any subsequent treatment such as by heatsetting
  • d the number of sheds in a single loom required to weave the chosen fabric structure.
  • single warp platform is used to refer to the combination of warp-related parameters for a group of different industrial textile structures, which using conventional methods would have been woven using different warp platforms for each of the different textiles.
  • the related terms “single warp platform product” and “single warp platform loom” refer respectively to industrial textiles woven using a single warp platform, and the loom on which they are or can be woven.
  • FIGS. 1A to 1C the steps taken in an exemplary embodiment of the invention, described here in relation to establishing a single warp platform for textiles for papermaking, are as follows.
  • Step 1 Select the intended target paper grade or basis weight for the product for which the textiles will be used (e.g. Tissue: 15-35 gsm; Printing: 35-80 gsm; Packaging/Linerboard: >80 gsm).
  • basis weight in Table 1 above, and throughout the following discussion, has the meaning commonly assigned to it in the papermaking arts and refers to the mass per unit area of the finished paper product that is to be made using the industrial textile.
  • Step 2 Review the mechanical and papermaking properties of existing industrial textile structures that are currently used or expected to be used in the manufacture of a cellulosic product for the target paper grade or basis weight, and which are intended to be consolidated into a SWP Platform, using the criteria of Table 1, so as to establish an appropriate group of fabrics.
  • the warp yarns have a substantially circular cross-section, which will generally be the shape selected for a new SWP Product; however, the same process would be used for other cross-sectional yarn shapes by determining their projected width on the PS.
  • Step 3 Determine the number of sheds used by looms to weave fabrics currently intended for use for the target paper grades and basis weights listed in Step 1, and the number of sheds which would be required for any new fabrics which would advantageously be included in the group under consideration, as identified in Step 2. Select an appropriate number of sheds to be provided.
  • Step 4 Select the different fabric structure types to be included in the group, e.g. single layer, double layer, triple layer, and others as listed above. From these fabric structure types, select those structures for which the weave designs will require a number of sheds which is equal to, or is an integer multiple of, the number of sheds selected in Step 3. For example, a 24 shed SWP loom can produce 2, 3, 4, 6, 8, 12 and 24 shed weave designs, but cannot produce 5 or 7 shed designs.
  • Step 5 From the fabrics identified in Step 4, select those with meshes within 20% (i.e. ⁇ 10%) of each other which, in addition, utilize warp yarn materials whose diameters (or projected widths on the PS of the fabric) are within ⁇ 25% of each other. It has been found that fabrics within such range of each other will be particularly amenable to the SWP process, primarily because the mesh will determine, to a great extent, both the mechanical and papermaking properties of the resulting SWP fabric.
  • the SWP Product must have sufficient modulus (i.e. MD strength), as well as air permeability, drainage and fiber support to enable the manufacture of the target paper grade.
  • Step 5 Use the set of fabrics identified in Step 5 to determine the PS warp fill of the new SWP product.
  • the warp fill of the SWP Product should preferably be within ⁇ 10% of the target fabrics identified in Step 6 whose platforms are to be consolidated into a single SWP platform, and more preferably it should be within ⁇ 5% of the target fabrics identified in Step 6. This will allow the SWP Product to more easily produce the papermaking characteristics required.
  • Step 8 Determine the ranges of concurrence for the fabrics identified and considered in each of Steps 6 and 7. From the set of fabrics identified in each of those Steps, select those fabrics whose total warp cross-sectional areas are between about ⁇ 15% of each other (Step 6), and whose PS warp fills are within about ⁇ 5% of each other (Step 7).
  • Step 9 Determine optimal warp yarn diameter and mesh for SWP Product by weighting fabric properties relative to their importance to the target paper grade, including at least:
  • the determination is performed by estimating the effect that warp diameter and mesh will have on the mechanical and papermaking qualities of the SWP Product. This can most easily be done by assigning a weighting factor (e.g. Low, Medium, High) to the importance of each property for the target basis weight and paper grade.
  • a weighting factor e.g. Low, Medium, High
  • Table 2 below provides an example of such weighting for various fabric properties used in fabrics intended for Packaging grades (Basis weight >80 gsm) and which are woven with warp yarns having circular cross-sections.
  • Step 9 two parallel groups of steps are conducted, the first group (Steps 10A, 11A) relating to providing and setting up the warp yarns on the loom, and the second group (Steps 10B, 11B and 12 ) relating to selecting the fabric to be woven, and determining the weft parameters required. These two groups of steps can be performed in any order or concurrently.
  • Step 10A Provide an industrial loom (the “SWP loom”) having the number of sheds determined as appropriate in Step 3.
  • Step 11A Provide the SWP loom with a set of warp yarns having the size and mesh determined at Step 9.
  • the warp yarns are mounted on at least one back beam, the warp yarns being threaded through the reed openings in the heddles of the loom to provide a desired mesh, and the heddles arranged to provide the required number of sheds.
  • the warp yarns may be threaded at a density of 1, 2, 3 or as many as 4 yarns per dent (reed opening) in the reed.
  • the SWP Loom is configured according to the desired SWP platform, enabling the fabric manufacturer to consolidate the production of a plurality of industrial fabric structures having similar mesh (which would previously have been woven on multiple looms) onto one loom.
  • Step 10B Select a fabric structure type, e.g. single layer, triple layer, for the first fabric to be woven.
  • Step 11B Select a weave design for the first fabric to be woven, from existing or new designs.
  • Step 12B Determine weft yarn diameters and knocking for the first fabric, having regard to the warp yarn size, mesh and total cross-sectional area selected for the SWP Product, to obtain the characteristics required for the fabric to be woven, to achieve the best compromise of fabric properties.
  • Step 13 Install weft yarn material selected in Step 12B into the loom, and adjust loom to provide appropriate knocking as determined in Step 12B.
  • Step 14 Weave and finish the first fabric, including heatsetting and seaming.
  • Step 15 Select a fabric structure type for a second fabric to be woven, in the same manner as for the first fabric in Step 10B.
  • Step 16 Select a weave design for the second fabric to be woven, from existing or new designs.
  • Step 17 Determine weft yarn diameters and knocking for the second fabric in the same manner as for the first fabric in Step 12B.
  • Step 18 Install weft yarn material selected in Step 17 into the loom, and adjust loom to provide appropriate knocking as determined in Step 17.
  • Step 19 Weave and finish the second fabric, including heatsetting and seaming.
  • Step 20 Repeat Steps 15 to 19 for third and subsequent fabrics.
  • Table 3 provides a comparison between two known textile products (Samples 1 and 3), and textiles of the same structural type made using an SWP platform (Samples 2 and 4). Samples 1 and 2 were woven as extra support double layer fabrics, and it can be seen from Table 3 that their mechanical and papermaking properties and characteristics are closely similar, despite the changes in the warp and weft yarn parameters resulting from using the SWP.
  • Samples 3 and 4 each woven as triple layer sheet support binder fabrics, can be seen to be closely similar.
  • each of Samples 2 and 4 produced from an SWP can be seen to be acceptable replacements for Samples 1 and 3.
  • Table 4 shows a similar comparison to that of Table 3, in relation to two further known textile products (Samples 5 and 7), and two textiles of the same structural type using an SWP platform (Samples 6 and 8). Samples 5 and 6 were woven as extra support double layer fabrics, and Samples 7 and 8 were woven as triple layer sheet support binder fabrics.
  • a primary control variable for the heatsetting process is the total width shrinkage.
  • differing width shrinkage targets of from about 5% to 15% may be required to achieve optimal fabric properties in the SWP Product. Therefore, although the as woven mesh of two fabrics may be the same, the finished (heatset) fabric mesh may differ by an amount in accordance with the 5% to 15% width shrinkage targets.
  • the SWP Process has resulted in the ability to consolidate two or more previously different warp platforms with differing warp yarn sizes into a single mesh and warp size, which eliminates the need for major changes to the loom set-up. This results in significantly reduced down time of the loom, in changing fabric production between the different fabrics in the group to which the platform is applicable.
  • the method of this invention is directed to looms equipped with at least one back beam; it can also be used in looms equipped with two or three back beams so as to accommodate differing warp path lengths in the fabric due to differing weave designs on each of the paper and machine side surfaces of the fabric.
  • the invention is directed to fabric designs which are woven using any number of sheds in the loom as are required to weave the chosen design; however fabric designs woven according to patterns requiring 2, 3, 4, 5, 6, 8, 10, 12, 16, 20, 24, 32, 36 and 48 sheds are particularly preferred.
  • the invention is in no way limited to numbers of sheds required to weave a given fabric design, or to fabric structure (i.e. single, double, triple layer, etc.).
  • the invention is also directed at fabrics whose structure requires the use of two warp yarn systems, such as triple layer sheet support binder fabrics and warp tie fabrics where the size and mesh of the warp on one fabric surface is different from that used on the other, however it is not so limited and has applicability to any industrial textile structure.

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  • Textile Engineering (AREA)
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US13/378,401 2009-07-24 2010-07-23 Method of manufacturing industrial textiles by minimizing warp changes and fabrics made according to the method Abandoned US20120175009A1 (en)

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CA2673846A CA2673846A1 (fr) 2009-07-24 2009-07-24 Procede de fabrication de textiles industriels en minimisant les changements de chaines
CA2,673,846 2009-07-24
PCT/US2010/043040 WO2011011676A1 (fr) 2009-07-24 2010-07-23 Procédé de fabrication de textiles industriels en minimisant les changements de chaîne, et étoffes fabriquées selon ledit procédé

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