US3392942A - Woven wire cloth for fourdrinier machines - Google Patents

Woven wire cloth for fourdrinier machines Download PDF

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US3392942A
US3392942A US536545A US53654566A US3392942A US 3392942 A US3392942 A US 3392942A US 536545 A US536545 A US 536545A US 53654566 A US53654566 A US 53654566A US 3392942 A US3392942 A US 3392942A
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warp
wires
shute
copper
fourdrinier
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US536545A
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Vincent A Stanton
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Cheney Bigelow Wire Works Inc
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Cheney Bigelow Wire Works Inc
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21FWORKING OR PROCESSING OF METAL WIRE
    • B21F27/00Making wire network, i.e. wire nets
    • B21F27/12Making special types or portions of network by methods or means specially adapted therefor
    • B21F27/18Making special types or portions of network by methods or means specially adapted therefor of meshed work for filters or sieves
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21FPAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F1/00Wet end of machines for making continuous webs of paper
    • D21F1/10Wire-cloths
    • D21F1/12Seams thereof
    • D21F1/14Seams thereof welded

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  • ABSTRACT OF THE DISCLOSURE A seam for seaming adjacent ends of warp wires of Fourdrinier cloth to form the latter into an endless loop in which the warp wires are composed of metal coated cores in which the seam is characterized by brazing material having a melting temperature in excess of 1,500 P. diffused through the coatings or bonded to the Cores of the warp wires.
  • the present invention relates to Woven wire cloth of the type which is seamed at its ends to form a continuous wire belt for use on Fourdrinier papermaking machines.
  • Such known Fourdrinier wire and seaming material are not particularly well adapted, however, to withstand the hard wear which is encountered when using a Fourdrinier machine and the operational life of such Fourdrinier wire cloth is relatively short, usually wearing from one week to a few months depending upon the speed of operation of the machine and the type of paper being manufactured.
  • the warp Wires extend lengthwise in the direction of movement of the endless belt while the weft or shute wires are transverse to such direction of movement. It is the warp wires which are subjected to the greatest wear and abrasion and which necessitate the replacement of known Fourdrinier wire cloth at rather frequent intervals.
  • the cross-sectional area of the hard stainless steel core is significantly less than the overall cross-sectional area of the warp wires, the relatively high modulus of elasticity of the stainless in much less of a problem insofar as fatigue failure is concerned, since the effective modulus of the composite wire is reduced.
  • the weaving characteristics of the composite wire having a relatively hard core and a relatively soft outer layer are considerably improved over the characteristics of solid stainless, and even over the usual phosphorous bronze, while offering substantially the same advantages as solid stainless insofar as longer life is concerned.
  • Gold-copper alloys Gold-nickel alloys Gold-copper-nickel alloy Gold-nickel-chromium alloy Gold-copper-silver alloys Nickel-chromiumboron-silicon-iron alloys Nickel-chromium-boron-silicon alloys Nickel-chromium-silicon alloys Copper-m an ganese-nickel alloys Nickel-chromium-phosphorous alloys Nickel-phosphorous alloys.
  • Permabraze 129 composed of 35% gold, 3% nickel and balance copper and characterized by a melting temperature of 1,742 F. to 1,886 F.;
  • Permabraze 402 composed of 50% gold and 50% copper having a melting temperature of 1,742 F. to 1,787 F.
  • Permabraze 050 composed of 75% gold, 5% silver and balance copper, having a melting temperature of 1,625 F. to 1,640 F.
  • brazing materials of the aforementioned class could be satisfactorily employed for seaming by using materials having weaving characteristics similar to the conventional copper alloy shute wires or suitable for weaving with copper coated stainless warp wires characterized by a melting temperature in excess of 1,850 F. or greater in that the copper coating serves as a heat sink protecting both the stainless steel of the warp and the shutes adjacent the seam from the seaming temperature of the brazing material.
  • Such shute material may be used at opposite end portions of the Fourdrinier wire without being deleteriously affected during seaming, and indeed, such new shute material if sufficiently economical as compared with conventional copper alloys could be used as shute wires throughout the Fou'rdrinier cloth.
  • nickel-silver alloy is composed of 65% copper, 18% nickel and 17% zinc. Such alloy is characterized by a melting point of about 2,030 F. The weaving characteristics of such nickel-silver all-0y are somewhat different than that of brass in view of which it is preferable when used to be employed throughout the whole of the Fourdrinier cloth.
  • known brass shute wire is characterized by a 17 l0 p.s.i. modulus, and if the shute material employed in the present invention is any greater than 21 l0 the material will not crimp satisfactorily and the mesh count will change.
  • the aforementioned yield point lies in the range of 15,00030,000 p.s.i., the modulus a maximum of 21 X10 p.s.i., the shear strength a minimum of 24,000 p.s.i. that such material is satisfactory for practicing the present invention if the tensile is of a minimum of 30,000 psi. and the elongation a minimum of 2%.
  • shute materials may, if desired, be used only at the adjacent end portions of the loop of the woven wire at opposite sides of a seaming shute of the aforementioned brazing materials as a substitute for the brass shutes conventionally used at such opposite ends of the Fourdrinier cloth, and indeed such shute materials of the invention, as above mentioned, if economically competitive with brass or other conventionally used copper alloys, could be used throughout the Fourdrinier cloth.
  • shute wire of uniform chemical composition throughout the cross section as aforenoted
  • FIGURE 1 is a fragmentary plan view of a portion of a Fourdrinier wire cloth constructed in accordance with the principles of the present invention and showing greatly enlarged seaming of the warp wires of the cloth to a seaming shute with shutes adjacent the seaming shute being of the materials of the present invention.
  • FIGURE 2 is a detail vertical sectional view taken substantially along the line 2-2 of FIGURE 1 and illustrating seaming of opposite ends of warp wires to the seaming shute;
  • FIGURE 3 is an enlarged detail cross sectional view of one of the warp wires of the Fourdrinier clot-h of FIG- URE 1;
  • FIGURE 4 is a schematic elevational view showing a Fourdrinier wire cloth mounted on the rolls of a paper making machine and disposed adjacent a suction box over which the cloth is adapted to be driven.
  • FIG- URE 1 a portion of Fourdrinier wire cloth comprising a plurality of warp wires 12, a shute seam 13 for seaming adjacent opposed ends of the warp wires, a plurality of shute wires 14 of the characteristics aforementioned adjacent the shute seam 13 for withstanding the seaming temperature in forming the seam, and a plurality of shute wires 15 which may be of known conventional copper materials such as brass or bronze. -It will be understood as already noted the shute wires 15, if desired, could be composed of the same or similar materials from which the chutes 14 are fabricated.
  • the warp and shute wires may be woven in accordance with conventional expedients and seamed to form an endless loop.
  • the Fourdrinier wire cloth 10 may typically have meshes in the range of 40 to 100', i.e., 40' to 100 warp wires per inch.
  • a 55 mesh wire cloth has 55 warp wires per inch and about 32 to 36 shute wires per inch
  • an 80 mesh wire cloth has 80 warp wires per inch and about 62 to 72 shute wires per inch.
  • the diameters of the warp and shute wires may vary in accordance with the mesh and for -a 40 mesh the warp should have a diameter of approximately 0.014 inch and the shute would have a diameter of approximately 0.0165 inch, whereas with a 100 mesh, the warp would have a diameter of approximately 0.00475-000525 inch and the shute would have a diameter of approximately 0.00 6- 0.0065 inch.
  • the diameter of the warp wires lies in the approximate range of 0.00475- 0.014 inch, and the diameter of the shute wires in the approximate range of 00062-00165 inch.
  • the warp wires 12 thus lie in a range of .000i01257 to .0002011 square inch in cross-sectional area.
  • the warp wires 12 are composite wires composed of a hard inner stainless steel core 16 and a relatively soft outer layer 18.
  • the inner core 16 is preferably stainless steel, although in certain instances other materials such as carbon steel may be used as a core material. Various types of stainless steel may be used depending upon the particular application, but the core material should have an annealed tensile strength of at least 80,000 p.s.i. and must have adequate corrosion resistance to the papermaking solution.
  • the outer coating 18 of the warp wires may be of substantially pure copper which can be electrolytically plated on the stainless at a reasonable cost.
  • the seam shute 13 may be composed of seaming or brazing materials as aforenoted over, for example, a 50% by weight nickel core.
  • the amount of the copper coating on the warp wires is not critical and very thin coating-s could be used, although it is preferable that the copper coating should comprise at least 10% by weight of the overall composite warp wires.
  • the copper coating of the warp wires functions as a heat sink dissipating the heat during the seaming operation to effect brazing of the adjacent ends of the warp wires to each other.
  • the diameter of the stainless steel core is significantly less than the overall diameter of the composite warp wire and the outer layer of the warp is relatively soft copper.
  • the effective modulus of elasticity of the copper coated wrap is substantially less than 223x10 which would be the modulus if solid stainless were used.
  • the copper coating lessens reed wear and makes weaving easier than would be the case of solid stainless, since the lubricating effect of the copper decreases the tendency for the stainless to seize and gall the reed.
  • the composite warp wires above noted have been found to provide weaving characteristics superior to the phosphorousbronze warp heretofore used.
  • the copper outer layer will wear off on the machine side of the wire cloth so as to expose the stainless core after a relatively short time, for example, 24 hours or less, so that the advantages of the stainless core relative to hardness and longer life are at present substantially the same as if a solid stainless warp was used, but without the several disadvantages of the latter.
  • a further advantage of the copper coating on the stainless of the warp is that the stainless core for the warp wires will not adversely affect the shute wires of the present invention whether employed adjacent the seam or throughout the Fourdrinier cloth, nor brass or bronze shutes should such be used in the main body of the Fourdrinier cloth with the shutes of this invention suitable for such purpose at adjacent end portions of the cloth at the seam.
  • the several shutes, except those adjacent the opposite ends of the seaming shute 13 and subject to the seaming temperature may be of the known brass or bronze materials. It will be recognized that according to the present invention brass may, if desired, be used for the shutes 15 throughout the Fourdrinier wire cloth except for the shutes 14 adjacent the seam.
  • shutes 15 where a corrosion problem exists.
  • Various other materials may also be use-d for the shutes 15, but it is preferable that such shutes be of material which is substantially softer than the stainless steel core of the warp and which has a substantially lower modulus elasticity than the stainless and the maximum tensile strength of 75,000 psi.
  • the outer copper coating for the Warp wires preferably comprises 10 to 5.0% by Weight of the composite warp wires, the remainder comprising the stainless core.
  • the copper is in a range of 20-30% by weight for rea- SOns of economy so as not to use substantially more copper than is required to achieve satisfactory warp wire and yet provide enough copper to lower the modulus of elasticity of the composite warp wires sufiiciently to produce optimum weaving characteristics, resist the fatigue failure, and function as a heat sink.
  • the modulus there is less load applied to the seam shute 13, and this is important particularly with high Thickness of Copper Coating (inch) 'lotal Diameter of Warp Wire. (inch) (10% by by (50% by Weight) Weight.) Weight)
  • the warp wires need not necessarily be of true circular cross-section.
  • the warp wires may, for example, be flat or oval like in cross-section.
  • warp wire of an original diameter of .0085 inch may be flattened to provide a cross-section measuring .0075 x .00975 inch.
  • An advantage of fiat warp is that it provides lateral stability and overcomes the tendency of developing longitudinal ridges especially in high speed papermaking machines.
  • Typical Fourdrinier wire cloth embodying flat warp may, for example, comprise 59 warp wires and 51 shute wires per inch in an over one and under two weave.
  • the shute wires may be of any of the foregoing materials of the present invention and may typically be of a diameter of .011 inch.
  • the foregoing flat warp wire may be used as a replacement for Fourdrinier wire embodying 68 warp wires and 52 shute wires per inch in which the warp wires measure .00775 inch in diameter and the shute wires measure .008 inch in diameter.
  • the volume of metal in the first warp is about 45% greater in the shute direction than round warp and the flat warp Fourdrinier cloth is much stiffer in the lateral direction.
  • flat warp constructions may comprise 63 warp wires and 57 shute Wires per inch with the warp wires measuring .00725 x .009 inch in cross-section and the shute wires .009 inch in diameter, and 68 warp wires and 65 shute wires per inch with the warp wires measuring .00675 x .0075 inch in cross-section and the shute wires .0085 inch in diameter.
  • round warp wires of the present invention lie in a range of .016 to .004 inch in diameter or in a range of .0002011 to .00001257 square inch in cross-sectional area.
  • the flat warp wires of Fourdrinier cloth of the present invention also lie in the foregoing range of cross-sectional areas of .0002011 to .00001257 square inch.
  • shute or weft wires at end portions of the Fourdrinier cloth adjacent the seaming shute may be of any suitable material characterized by having a melting point of 1,850 F. or greater, a maximum modulus elasticity of 21 X 10 a tensile of a minimum of 30,000 p.s.i., a yield point between 15,00030,000 p.s.i., percent of elongation a minimum of 2% and shear strength of a minimum of 24,000 p.s.i,
  • One such material responding to the aforementioned characteristics are copper-nickel alloys consisting essentially of 10% nickel and balance copper.
  • such material embodied as shutes in the Fourdrinier wire cloth is similar in most physical characteristics to brass.
  • shutes adjacent the seaming shute may be of the aforementioned materials or indeed all the shutes may be of such material if economically competitive with known shute materials.
  • only a few of the shutes subject to the seaming operation adjacent the seam shute may be composed of the aforementioned material.
  • such shute material need not be of uniform chemical composition throughout its cross-section, it being possible to employ, for example, a 20% nickel and copper core material, or of many other alloys, and plate 15% to 30% copper by weight thereon to the end of providing such composite material with the physical characteristics above noted.
  • a nickel-silver alloy of 65% copper, 18% nickel and 17% Zinc has utility as weft wires throughout the whole cloth.
  • the shute seam as above mentioned may be composed of any of the aforementioned brazing materials over a nickel or other suitable core and characterized by a melting point in the range of 1,500 F. to 2,100 F.
  • the brazing material diffuses through the copper coating of the warp wires and bonds with the stainless core providing a strong seam.
  • the copper coating of the stainless steel warps dissipates the heat of the seaming operation protecting not only the shutes adjacent the seam from damage but also the stainless steel cores of the warp.
  • the seaming temperature of the brazing material which is in excess of the temperature of conventional seaming solders effects a strong bond between abutting ends of the stainless steel cover of the warp wires.
  • the copper coatings of the warps also importantly serve to keep the outer surfaces of the stainless steel cores clean so as to form a good brazed seam between adjacent opposed ends of the warps.
  • a Fourdrinier wire cloth comprising warp wires having a relatively hard core made of a material having a modulus of elasticity of at least 25 10 p.s.i., and an outer metal coating on said hard core made of a material having a modulus of elasticity which does not exceed 20 10 p.s.i., said outer coating comprising approximately 10-50 percent by weight of said warp wires, and a plurality of shutes extending transversely of said warp wires, the combination therewith of a seam seaming opposed ends of said warp wires to form said cloth into an endless loop comprising brazing material characterized by a melting temperature in excess of 1,500 F. diffused through the coatings of and bonded to the cores of said warp wires.
  • shutes adjacent said seam are characterized by a melting point in excess of 1,850 P. a maximum modulus of elasticity of 21 10 p.s.i., a tensile of a minimum of 30,000 p.s.i., a yield point between 15,000 to 30,000 p.s.i., percent of elongation a minimum of 2%, and shear strength of a minimum of 24,000 p.s.i.
  • shutes adjacent said seam comprise a core consisting essentially of 20% nickel and 80% copper and having a copper coating in the range of 15% to 30% by weight thereon.
  • shutes adjacent said seam are composed of an alloy consisting essentially of 10% nickel and the balance copper.
  • shutes are composed of an alloy consisting essentially of 65% copper, 18% nickel and 17% zinc.
  • shutes adjacent said seam are characterized by a melting point in excess of 1,850 F.

Description

July 16, 1968 v. A. STANTON WOVEN WIRE CLOTH FOR FOURDRINIER MACHINES m 60 mmfl m mm MU mm Inf/872i? 7." lfz'nceni Cl '5 uu;uuwuw-uu-u United States Patent 3,392,942 WOVEN WIRE CLOTH FOR FOURDRINIER MACHINES Vincent A. Stanton, Springfield, Mass, assignor to Cheney Bigelow Wire Works Inc., Springfield, Mass, at corporation of Delaware Continuation-impart of application Ser. No. 481,017, Aug. 19, 1965. This application Mar. 4, 1966, Ser. No. 536,545 The portion of the term of the patent subsequent to July 4, 1984, has been disclaimed 9 Claims. (Cl. 245-10) ABSTRACT OF THE DISCLOSURE A seam for seaming adjacent ends of warp wires of Fourdrinier cloth to form the latter into an endless loop in which the warp wires are composed of metal coated cores in which the seam is characterized by brazing material having a melting temperature in excess of 1,500 P. diffused through the coatings or bonded to the Cores of the warp wires.
The present application is a continuation-in-part of my earlier application Ser. No. 481,017 filed Aug. 19, 1965, now abandoned.
The present invention relates to Woven wire cloth of the type which is seamed at its ends to form a continuous wire belt for use on Fourdrinier papermaking machines.
In the manufacture of paper on a Fourdrinier machine, it is common to utilize a woven wire cloth in the form of a continuous endless belt which is mounted over a pair of rolls, one of which is rotated to drive the woven wire cloth around the rolls and across a suction box disposed between the rolls. Fourdrinier wire cloth is thus subjected to continuous stress and abrasion and must be replaced with some frequency due to Wear, fatigue failure and the like, and such replacement is an expensive operation due to the fact that the high costs of such papermaking machinery must be taken out of service to permit the removal of the old wire cloth and the installation of a new one.
It has been common practice to weave Fourdrinier wire cloth from warp and shute or weft wires wherein the warp wires are made of phosphorous bronze containing approximately 92% copper and 8% tin, and the shute or weft wires are made of brass containing approximately 85% copper and zinc. The foregoing known warp and weft wires for Fourdrinier cloth have reasonably satisfactory weaving characteristics and can be usually seamed with good results by using a conventional seaming material in the form of a shute comprising a bronze core coated with a silver alloy composed of 54% silver, 22% copper and 24% zinc and having a melting temperature of 1,223 F. Such known Fourdrinier wire and seaming material are not particularly well adapted, however, to withstand the hard wear which is encountered when using a Fourdrinier machine and the operational life of such Fourdrinier wire cloth is relatively short, usually wearing from one week to a few months depending upon the speed of operation of the machine and the type of paper being manufactured. In Fourdrinier wire cloth, the warp Wires extend lengthwise in the direction of movement of the endless belt while the weft or shute wires are transverse to such direction of movement. It is the warp wires which are subjected to the greatest wear and abrasion and which necessitate the replacement of known Fourdrinier wire cloth at rather frequent intervals.
The art has sought to extend the life of Fourdrinier wire cloth by utilizing warp wires made of stainless steel which is harder than the conventional phosphorous bronze material usually used for the warp wires as above noted and which will tend to wear longer. However, such efforts have not met with much success due to several problems which more than offset the greater hardness provided by the stainless steel. For example, where stainless steel warp Wires are utilized, it is generally necessary to also use stainless steel shute wires, even though the latter are not subjected to excessive wear, because if a softer alloy, such as brass or bronze is used for the shute, the stainless warp wires will adversely affect the shute during the weaving operation and cause the shute wires to be powdered out or cut in two. Accordingly, there is a significant additional expense of providing stainless steel shute wires even though the latter are not subjected to any particular problem of wear.
In the last noted Fourdrinier wire cloth, another problem arises due to the fact that stainless steel has a relatively high modulus of elasticity of 28 X10 and when a solid stainless Fourdrinier wire cloth is run around the rolls of a papermaking machine, the wire has a greater tendency to fail by cracking due to fatigue stresses than the phosphorous bronze warp wires normally used for Fourdrinier machines. In addition, as indicated hereinabove, the Fourdrinier wire cloth is seamed at its ends to form a continuous endless belt, and the stainless cloth is more difficult to seam than the usual bronze cloth, and some tests have shown that there is more than a normal tendency for stainless steel Fourdrinier wire cloth to fail at the seam.
It is now known that certain of the aforementioned advantages of stainless steel for the warp wires may be achieved by providing such warp wires with a relatively soft outer layer or coating, such as of copper. The outer copper layer will wear ofi on the machine side during use of the wire cloth on the papermaking machine sufficiently to expose the inner core of stainless steel. Such exposure of the hard inner core usually occurs within about 24 hours of use or less, because initially there is a line contact between the warp wires and machine components such as a suction box, causing relatively rapid reduction in the wire diameter, and as the bearing area increases, the effective wear and the diameter of the wire is lessened. Because the copper will wear primarily on the machine side of the wire cloth, such wear will not normally have any significant effect on the mesh of the cloth and yet the hard stainless core will be exposed in the area which is subjected to the greatest wear in order to substantially extend the life of the cloth.
In addition, because the cross-sectional area of the hard stainless steel core is significantly less than the overall cross-sectional area of the warp wires, the relatively high modulus of elasticity of the stainless in much less of a problem insofar as fatigue failure is concerned, since the effective modulus of the composite wire is reduced. For much the same reason the weaving characteristics of the composite wire having a relatively hard core and a relatively soft outer layer are considerably improved over the characteristics of solid stainless, and even over the usual phosphorous bronze, while offering substantially the same advantages as solid stainless insofar as longer life is concerned. In the Fourdrinier wire last noted, it is not necessary to use stainless steel shute wires in combination with the stainless steel warp wires and instead softer and less expensive materials, such as brass or bronze can be used for the shute. The latter use is possible because the copper outer layer on the stainless steel warp wire will prevent the shute wires from being powdered cut or cut in two by the stainless during the weavmg operation.
In connection with Fourdrinier wire cloth as last described, diflicult problems have been encountered in effecting seaming of the opposite ends of the warp wires. In use of the aforementioned conventional silver alloy of 54% silver, 22% copper and 24% zinc over a bronze core and having a melting point of l,223 F. it was found that the bond was through the copper to the stainless steel core of the warp and that the copper is a weak link at which fatigue failure readily takes place. The seaming temperature of this alloy, however, is such that the shutes adjacent to the seam are not deleteriously affected and on that score were satisfactory but as aforenoted the bond was inadequate.
In order to attempt to solve the problem last noted, seaming material of a form to serve as a shute at the opposite ends of the Fourdrinier wire and composed of a nickel core with a flush alloy coating of 82% gold and 18% nickel was tried. This seaming alloy, known in the trade as Handy and Harman alloy Permabraze 130 is characterized by having a melting point of about 1,740 F. In effecting a seam of such Permabraze 130 material, it was found the seaming alloy diffuses through the copper coating of the stainless steel warp and bonds with the stainless core thus avoiding the problem of the weak copper bond of the conventional silver alloys last above noted. It has now been further discovered that conventional brazing materials characterized by melting temperatures in a range of 1,500 F. to 2,100 F. have utility in the present invention in addition to the aforementioned Permabraze 130. Typical of such additional conventional and known brazing materials may be grouped as follows:
Gold-copper alloys Gold-nickel alloys Gold-copper-nickel alloy Gold-nickel-chromium alloy Gold-copper-silver alloys Nickel-chromiumboron-silicon-iron alloys Nickel-chromium-boron-silicon alloys Nickel-chromium-silicon alloys Copper-m an ganese-nickel alloys Nickel-chromium-phosphorous alloys Nickel-phosphorous alloys.
Specific and typical alloys of the aforementioned groups comparable to Permabraze 130 are:
(1) Permabraze 129 composed of 35% gold, 3% nickel and balance copper and characterized by a melting temperature of 1,742 F. to 1,886 F.;
(2) Permabraze 402 composed of 50% gold and 50% copper having a melting temperature of 1,742 F. to 1,787 F.; and
(3) Permabraze 050 composed of 75% gold, 5% silver and balance copper, having a melting temperature of 1,625 F. to 1,640 F.
The last three above mentioned brazing compositions and many others are commercially available from sandy & Harm-an of New York City, NY. However, in making the seams at these higher temperatures of the foregoing brazing materials, the shutes adjacent the seam if composed of the conventional copper alloys of bronze or brass melt during the seaming.
In order to overcome the last noted problem, applicant conceived that brazing materials of the aforementioned class could be satisfactorily employed for seaming by using materials having weaving characteristics similar to the conventional copper alloy shute wires or suitable for weaving with copper coated stainless warp wires characterized by a melting temperature in excess of 1,850 F. or greater in that the copper coating serves as a heat sink protecting both the stainless steel of the warp and the shutes adjacent the seam from the seaming temperature of the brazing material. Such shute material may be used at opposite end portions of the Fourdrinier wire without being deleteriously affected during seaming, and indeed, such new shute material if sufficiently economical as compared with conventional copper alloys could be used as shute wires throughout the Fou'rdrinier cloth.
In approaching the problem last noted, alloys of stainless steel (T304) and Monel were tried as shutes for the Fourdrinier cloth at the beginning and end of the Pourdrinier wire, but because of the higher yield, tensile and modulus of elasticity they did not weave in a manner similar enough to bronze or brass. Pure copper was tried with some success and could be made to work, but its shear strength was enough lower than the brass so some powdering was encountered. However, its melting point was high enough that it did not melt out during seaming with the foregoing brazing materials.
In view of the shortcomings of the last noted materials, applicant further conceived of utilizing commercial copper alloys having greater shear strength than copper and of an equal or higher melting point. It was discovered one such group of alloys are the copper-nickel alloys and it was found that an alloy of 10% nickel and balance of copper is similar in most of its physical characteristics to brass from the view point of shear, tensile and modulus with the result that it could be woven in a manner similar enough to brass so it could be substituted for the brass shutes at least at portions adjacent the seam of the Fourdrinier cloth without having to make excessive loom adjustments. It has further been discovered that nickelsilver alloys have utility with the copper coated stainless warp wires for use as Weft wires. One such nickel-silver alloy is composed of 65% copper, 18% nickel and 17% zinc. Such alloy is characterized by a melting point of about 2,030 F. The weaving characteristics of such nickel-silver all-0y are somewhat different than that of brass in view of which it is preferable when used to be employed throughout the whole of the Fourdrinier cloth.
Accordingly it is an object of the present invention to provide Fourdrinier wire cloth having stainless steel core and copper coated warp wires seamed at their opposite ends by a seaming alloy or bronze material diffused through the copper coating of the warp wires to form a strong bond with the stainless steel cores, and shute wires adjacent the joined end portions of the warp wires which are resistant to destruction at temperatures for seaming of the seaming material at the joined ends of the warp wires.
Shute wires according to the foregoing object and in accordance with the present invention are characterized by the following physical properties:
(1) A melting point of 1,850 F. or greater.
(2) A maximum modulus of elasticity of 21 X 10 psi (3) Tensile of a minimum of 30,000 p.s.i., a yield point between l5,00030,000 p.s.i., percent of elongation a minimum of 2%, and shear strength of a minimum of 24,000 p.s.i.
With respect to the foregoing modulus of elasticity of the shute materials of the present invention, known brass shute wire is characterized by a 17 l0 p.s.i. modulus, and if the shute material employed in the present invention is any greater than 21 l0 the material will not crimp satisfactorily and the mesh count will change.
In connection with the above, if the aforementioned yield point lies in the range of 15,00030,000 p.s.i., the modulus a maximum of 21 X10 p.s.i., the shear strength a minimum of 24,000 p.s.i. that such material is satisfactory for practicing the present invention if the tensile is of a minimum of 30,000 psi. and the elongation a minimum of 2%.
As aforementioned, certain of the above shute materials may, if desired, be used only at the adjacent end portions of the loop of the woven wire at opposite sides of a seaming shute of the aforementioned brazing materials as a substitute for the brass shutes conventionally used at such opposite ends of the Fourdrinier cloth, and indeed such shute materials of the invention, as above mentioned, if economically competitive with brass or other conventionally used copper alloys, could be used throughout the Fourdrinier cloth.
It will be understood that in addition to using a shute wire of uniform chemical composition throughout the cross section as aforenoted, it is possible to employ, for example, a 20% nickel and 80% copper core material or any of many other alloys and plate 15 to 30% copper by weight thereon, so that the composite material embodies the physical characteristics above noted.
A preferred embodiment of the invention will now be described in connection with the accompanying drawings in which:
FIGURE 1 is a fragmentary plan view of a portion of a Fourdrinier wire cloth constructed in accordance with the principles of the present invention and showing greatly enlarged seaming of the warp wires of the cloth to a seaming shute with shutes adjacent the seaming shute being of the materials of the present invention.
FIGURE 2 is a detail vertical sectional view taken substantially along the line 2-2 of FIGURE 1 and illustrating seaming of opposite ends of warp wires to the seaming shute;
FIGURE 3 is an enlarged detail cross sectional view of one of the warp wires of the Fourdrinier clot-h of FIG- URE 1; and
FIGURE 4 is a schematic elevational view showing a Fourdrinier wire cloth mounted on the rolls of a paper making machine and disposed adjacent a suction box over which the cloth is adapted to be driven.
Referring now to the drawings there is shown in FIG- URE 1 a portion of Fourdrinier wire cloth comprising a plurality of warp wires 12, a shute seam 13 for seaming adjacent opposed ends of the warp wires, a plurality of shute wires 14 of the characteristics aforementioned adjacent the shute seam 13 for withstanding the seaming temperature in forming the seam, and a plurality of shute wires 15 which may be of known conventional copper materials such as brass or bronze. -It will be understood as already noted the shute wires 15, if desired, could be composed of the same or similar materials from which the chutes 14 are fabricated. The warp and shute wires may be woven in accordance with conventional expedients and seamed to form an endless loop.
The Fourdrinier wire cloth 10 may typically have meshes in the range of 40 to 100', i.e., 40' to 100 warp wires per inch. By way of example, a 55 mesh wire cloth has 55 warp wires per inch and about 32 to 36 shute wires per inch, and an 80 mesh wire cloth has 80 warp wires per inch and about 62 to 72 shute wires per inch. The diameters of the warp and shute wires may vary in accordance with the mesh and for -a 40 mesh the warp should have a diameter of approximately 0.014 inch and the shute would have a diameter of approximately 0.0165 inch, whereas with a 100 mesh, the warp would have a diameter of approximately 0.00475-000525 inch and the shute would have a diameter of approximately 0.00 6- 0.0065 inch. Thus in a Fourdrinier cloth of the type to which the present invention relates, the diameter of the warp wires lies in the approximate range of 0.00475- 0.014 inch, and the diameter of the shute wires in the approximate range of 00062-00165 inch. The warp wires 12 thus lie in a range of .000i01257 to .0002011 square inch in cross-sectional area.
The warp wires 12 are composite wires composed of a hard inner stainless steel core 16 and a relatively soft outer layer 18. The inner core 16 is preferably stainless steel, although in certain instances other materials such as carbon steel may be used as a core material. Various types of stainless steel may be used depending upon the particular application, but the core material should have an annealed tensile strength of at least 80,000 p.s.i. and must have adequate corrosion resistance to the papermaking solution. The outer coating 18 of the warp wires may be of substantially pure copper which can be electrolytically plated on the stainless at a reasonable cost.
As will become apparent copper coated stainless warp is of particular advantage in providing an effective seam through the seam shute 13. The seam shute 13 may be composed of seaming or brazing materials as aforenoted over, for example, a 50% by weight nickel core. Insofar as the seaming characteristics of the present invention are concerned, the amount of the copper coating on the warp wires is not critical and very thin coating-s could be used, although it is preferable that the copper coating should comprise at least 10% by weight of the overall composite warp wires. Importantly it has been discovered that the copper coating of the warp wires functions as a heat sink dissipating the heat during the seaming operation to effect brazing of the adjacent ends of the warp wires to each other. In the foregoing Fourdrinier Wire cloth, it is desirable to have a Warp having a hard core for efiicient wear characteristics and a soft outer coating to give good weaving characteristics and resistance to cracking due to fatigue stresses. Preferably, the diameter of the stainless steel core is significantly less than the overall diameter of the composite warp wire and the outer layer of the warp is relatively soft copper. Thus, the effective modulus of elasticity of the copper coated wrap is substantially less than 223x10 which would be the modulus if solid stainless were used. Such an arrangement increases the resistance of the Fourdrinier wire to fatigue failure during use, and it substantially improves the weaving characteristics of the warp. In addition, the copper coating lessens reed wear and makes weaving easier than would be the case of solid stainless, since the lubricating effect of the copper decreases the tendency for the stainless to seize and gall the reed. The composite warp wires above noted have been found to provide weaving characteristics superior to the phosphorousbronze warp heretofore used. As noted, the copper outer layer will wear off on the machine side of the wire cloth so as to expose the stainless core after a relatively short time, for example, 24 hours or less, so that the advantages of the stainless core relative to hardness and longer life are at present substantially the same as if a solid stainless warp was used, but without the several disadvantages of the latter.
A further advantage of the copper coating on the stainless of the warp is that the stainless core for the warp wires will not adversely affect the shute wires of the present invention whether employed adjacent the seam or throughout the Fourdrinier cloth, nor brass or bronze shutes should such be used in the main body of the Fourdrinier cloth with the shutes of this invention suitable for such purpose at adjacent end portions of the cloth at the seam. Thus if desired, within the scope of the present invention, the several shutes, except those adjacent the opposite ends of the seaming shute 13 and subject to the seaming temperature may be of the known brass or bronze materials. It will be recognized that according to the present invention brass may, if desired, be used for the shutes 15 throughout the Fourdrinier wire cloth except for the shutes 14 adjacent the seam. However, in such instances bronze may be preferred for shutes 15 where a corrosion problem exists. Various other materials may also be use-d for the shutes 15, but it is preferable that such shutes be of material which is substantially softer than the stainless steel core of the warp and which has a substantially lower modulus elasticity than the stainless and the maximum tensile strength of 75,000 psi. The outer copper coating for the Warp wires preferably comprises 10 to 5.0% by Weight of the composite warp wires, the remainder comprising the stainless core. Preferably, the copper is in a range of 20-30% by weight for rea- SOns of economy so as not to use substantially more copper than is required to achieve satisfactory warp wire and yet provide enough copper to lower the modulus of elasticity of the composite warp wires sufiiciently to produce optimum weaving characteristics, resist the fatigue failure, and function as a heat sink. In addition, by reducing the modulus there is less load applied to the seam shute 13, and this is important particularly with high Thickness of Copper Coating (inch) 'lotal Diameter of Warp Wire. (inch) (10% by by (50% by Weight) Weight.) Weight) It will be understood for purposes of the invention that the warp wires need not necessarily be of true circular cross-section. The warp wires may, for example, be flat or oval like in cross-section. For example, warp wire of an original diameter of .0085 inch may be flattened to provide a cross-section measuring .0075 x .00975 inch. An advantage of fiat warp is that it provides lateral stability and overcomes the tendency of developing longitudinal ridges especially in high speed papermaking machines.
Typical Fourdrinier wire cloth embodying flat warp may, for example, comprise 59 warp wires and 51 shute wires per inch in an over one and under two weave. The shute wires may be of any of the foregoing materials of the present invention and may typically be of a diameter of .011 inch. The foregoing flat warp wire may be used as a replacement for Fourdrinier wire embodying 68 warp wires and 52 shute wires per inch in which the warp wires measure .00775 inch in diameter and the shute wires measure .008 inch in diameter. In comparing the last two examples the volume of metal in the first warp is about 45% greater in the shute direction than round warp and the flat warp Fourdrinier cloth is much stiffer in the lateral direction. Other typical examples of flat warp constructions may comprise 63 warp wires and 57 shute Wires per inch with the warp wires measuring .00725 x .009 inch in cross-section and the shute wires .009 inch in diameter, and 68 warp wires and 65 shute wires per inch with the warp wires measuring .00675 x .0075 inch in cross-section and the shute wires .0085 inch in diameter. As above described round warp wires of the present invention lie in a range of .016 to .004 inch in diameter or in a range of .0002011 to .00001257 square inch in cross-sectional area. The flat warp wires of Fourdrinier cloth of the present invention also lie in the foregoing range of cross-sectional areas of .0002011 to .00001257 square inch.
In the present invention, shute or weft wires at end portions of the Fourdrinier cloth adjacent the seaming shute may be of any suitable material characterized by having a melting point of 1,850 F. or greater, a maximum modulus elasticity of 21 X 10 a tensile of a minimum of 30,000 p.s.i., a yield point between 15,00030,000 p.s.i., percent of elongation a minimum of 2% and shear strength of a minimum of 24,000 p.s.i, One such material responding to the aforementioned characteristics are copper-nickel alloys consisting essentially of 10% nickel and balance copper. As noted, such material embodied as shutes in the Fourdrinier wire cloth is similar in most physical characteristics to brass. Thus, the shutes adjacent the seaming shute may be of the aforementioned materials or indeed all the shutes may be of such material if economically competitive with known shute materials. However, as noted, only a few of the shutes subject to the seaming operation adjacent the seam shute may be composed of the aforementioned material. In addition to the aforementioned specific copper-nickel alloy for the shute material of the present invention, it will be understood that such shute material need not be of uniform chemical composition throughout its cross-section, it being possible to employ, for example, a 20% nickel and copper core material, or of many other alloys, and plate 15% to 30% copper by weight thereon to the end of providing such composite material with the physical characteristics above noted. As before noted a nickel-silver alloy of 65% copper, 18% nickel and 17% Zinc has utility as weft wires throughout the whole cloth. Upon weaving of the Fourdrinier cloth in the manner above described, the adjacent ends of the Fourdrinier wire cloth are disposed to lay with the ends of the warp wire at opposite sides of the shute seam. The shute seam as above mentioned may be composed of any of the aforementioned brazing materials over a nickel or other suitable core and characterized by a melting point in the range of 1,500 F. to 2,100 F. As seen in FIGURE 2, the brazing material diffuses through the copper coating of the warp wires and bonds with the stainless core providing a strong seam. Even though the melting temperature of the brazing material may exceed the melting temperature of certain of the shutes of the present invention, the copper coating of the stainless steel warps dissipates the heat of the seaming operation protecting not only the shutes adjacent the seam from damage but also the stainless steel cores of the warp. Indeed the seaming temperature of the brazing material which is in excess of the temperature of conventional seaming solders effects a strong bond between abutting ends of the stainless steel cover of the warp wires. The copper coatings of the warps also importantly serve to keep the outer surfaces of the stainless steel cores clean so as to form a good brazed seam between adjacent opposed ends of the warps.
While there has been shown and described preferred embodiments of the invention, it will be understood that various modifications and rearrangements may be made therein without departing from the spirit and scope of the invention.
The invention claimed is:
1. In a Fourdrinier wire cloth comprising warp wires having a relatively hard core made of a material having a modulus of elasticity of at least 25 10 p.s.i., and an outer metal coating on said hard core made of a material having a modulus of elasticity which does not exceed 20 10 p.s.i., said outer coating comprising approximately 10-50 percent by weight of said warp wires, and a plurality of shutes extending transversely of said warp wires, the combination therewith of a seam seaming opposed ends of said warp wires to form said cloth into an endless loop comprising brazing material characterized by a melting temperature in excess of 1,500 F. diffused through the coatings of and bonded to the cores of said warp wires.
2. In the Fourdrinier wire cloth of claim 1 in which said warp wires are of a cross-sectional area in the approximate range of 0.00001257 to 0.0002011 square inch.
3. In the Fourdrinier wire cloth of claim 1 in which said warp wires are of a cross-sectional area in the approximate range of 0.00001257 to 0.0002011 square inch, and in which said shutes are of a diameter in the approximate range of 0.006 to 0165 inch.
4. In the Fourdrinier wire cloth of claim 1 in which said shutes adjacent said seam are characterized by a melting point in excess of 1,850 P. a maximum modulus of elasticity of 21 10 p.s.i., a tensile of a minimum of 30,000 p.s.i., a yield point between 15,000 to 30,000 p.s.i., percent of elongation a minimum of 2%, and shear strength of a minimum of 24,000 p.s.i.
5. In the Fourdrinier wire cloth of claim 1 in which the cores of said warp wires are of stainless steel, and said outer coatings of said warp wires are of copper.
6. In the Fourdrinier wire cloth of claim 1 in which said shutes adjacent said seam comprise a core consisting essentially of 20% nickel and 80% copper and having a copper coating in the range of 15% to 30% by weight thereon.
7. In the Fourdrinier wire cloth of claim 1 in which said shutes adjacent said seam are composed of an alloy consisting essentially of 10% nickel and the balance copper.
8. In the Fourdrinier wire cloth of claim 1 in which said shutes are composed of an alloy consisting essentially of 65% copper, 18% nickel and 17% zinc.
said shutes adjacent said seam are characterized by a melting point in excess of 1,850 F.
References Cited UNITED STATES PATENTS Abendroth 24510 Hayden 24510 Gerhauser 245-40 Stanton 245-10 9. In the Fourdrinier wire cloth of claim 1 in which 10 RICHARD J. HERBST, Primaly Examiner.
US536545A 1965-08-19 1966-03-04 Woven wire cloth for fourdrinier machines Expired - Lifetime US3392942A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3494579A (en) * 1967-02-02 1970-02-10 Johnson Wire Works Ltd Seam for wire fabric

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2357492A (en) * 1943-06-05 1944-09-05 Otto A Abendroth Fourdrinier wire
US2851233A (en) * 1955-09-07 1958-09-09 Hayden Wesley Seam for joining ends of stainless steel wire cloth
US2893664A (en) * 1955-03-16 1959-07-07 Appleton Wire Works Corp Seam for wire fabric and method of making same
US3329378A (en) * 1966-03-04 1967-07-04 Cheney Bigelow Wire Works Inc Woven wire cloth for fourdrinier machines

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2357492A (en) * 1943-06-05 1944-09-05 Otto A Abendroth Fourdrinier wire
US2893664A (en) * 1955-03-16 1959-07-07 Appleton Wire Works Corp Seam for wire fabric and method of making same
US2851233A (en) * 1955-09-07 1958-09-09 Hayden Wesley Seam for joining ends of stainless steel wire cloth
US3329378A (en) * 1966-03-04 1967-07-04 Cheney Bigelow Wire Works Inc Woven wire cloth for fourdrinier machines

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3494579A (en) * 1967-02-02 1970-02-10 Johnson Wire Works Ltd Seam for wire fabric

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