Classifications

• • 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
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
  • D02G3/36—Cored or coated yarns or threads
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
  • D02G3/447—Yarns or threads for specific use in general industrial applications, e.g. as filters or reinforcement
• • 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
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
  • Y10T442/3146—Strand material is composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
  • Y10T442/3154—Sheath-core multicomponent strand material
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/40—Knit fabric [i.e., knit strand or strip material]
  • Y10T442/444—Strand is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/608—Including strand or fiber material which is of specific structural definition
  • Y10T442/627—Strand or fiber material is specified as non-linear [e.g., crimped, coiled, etc.]
  • Y10T442/629—Composite strand or fiber material
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/608—Including strand or fiber material which is of specific structural definition
  • Y10T442/627—Strand or fiber material is specified as non-linear [e.g., crimped, coiled, etc.]
  • Y10T442/634—A nonwoven fabric having a layer comprising non-linear synthetic polymeric strand or fiber material and a separate and distinct layer comprising strand or fiber material which is not specified as non-linear
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
  • Y10T442/638—Side-by-side multicomponent strand or fiber material
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
  • Y10T442/641—Sheath-core multicomponent strand or fiber material
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/659—Including an additional nonwoven fabric
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/659—Including an additional nonwoven fabric
  • Y10T442/668—Separate nonwoven fabric layers comprise chemically different strand or fiber material

Definitions

• the present direction is directed to yarns of high modulus materials, such as polymer materials, covered within a second material.
• the yarns can be used to construct fabrics used in clothings for paper making machines and other industrial fabrics .
• Paper machine clothing is the term for industrial fabrics used on paper machines in the forming, pressing and drying sections. They are generally fabricated with either polyester or polyamide multifilaments and/or onofilaments woven on conventional, large textile looms. These fabrics have generally been fabricated by conventional weaving techniques.
• PMC paper machine clothing
• the surface topography of PMC fabrics contributes to the quality of the paper product. Efforts have been made to create a smoother contact surface with the paper sheet. However, surface smoothness of PMC woven fabrics is limited by the topography resulting from the weave pattern and the filament physical properties. In a woven fabric (or knitted fabric), smoothness is inherently limited by the knuckles formed at the cross-over points of intersecting yarns.
• High modulus materials are potential materials for use in applications requiring high mechanical properties and light weight. On a property-weight basis, high modulus polymers have a distinct advantage over metals and ceramics. High modulus polymers are highly anisotropic, and high modulus is achieved only in the direction of molecular chain orientation. In fact, properties normal to the molecular axis exhibit considerably lower values than the properties exhibited in the longitudinal direction. As a result, low shear and compressive properties are exhibited in the direction normal to the molecular axis.
• the present invention is directed towards yarns of covered high modulus filament materials and fabrics which are formed therefrom.
• the present invention is intended to provide a composite filamentary material which exhibits the advantages of high modulus materials while providing a means for compensating the diminished properties exhibited by such fibers in the direction normal to molecular chain orientation.
• the present invention is a composite filament structure wherein a high modulus filament material is covered with bicomponent filaments.
• the composite filament structure has a first interior layer of high modulus filament material and a second exterior layer of bicomponent fibers, the second exterior layer of bicomponent fibers being covered around the first interior layer of high modulus material along its entire length. The entire surface area of the high modulus material should be covered.
• the bicomponent fibers of the present invention may be either a sheath-core arrangement or a side-by- side arrangement, with sheath-core being preferred. It is further preferred that the sheath component have a melting point lower than the core component .
• Suitable bicomponent fibers include sheath-core combinations of co-polyester/poly (ethylene t erepht hal at e ) , polyamide /po ly (ethylene terephthalate) , polyamide/polyamide , polyethylene/poiy (ethylene terephthalate) , polypropylene/poly (ethylene terephthalate) , p o 1 y e t hy 1 e n e / po 1 y a i de , p o 1 y r opy 1 e n e / p o 1 y am i de , thermoplastic polyure thane /polyamide and thermoplastic polyurethane/poly (ethylene terephthalate.
• Modulus refers to the tensile modulus as defined by the slope of the initial linear portion of the load extension response (stress-strain curve) of a specimen deformed at room temperature.
• High modulus material includes high modulus polymers that exhibit tensile modulus greater than about 25% of theory.
• a high modulus polymer is one possessing a tensile modulus greater than about 25 GPA. Encyclopedia of Polymer Science 2d ed. vol 7, pp. 699-722. It should be noted that highly oriented polymer structures are anisotropic, and as modulus is increased by raising the degree of molecular chain orientation, modulus decreases commensurately in other directions .
• Suitable high modulus polymers include, but are not limited to aramids such as poly (p- phenyleneterephthalamide) , available from Dupont under the tradename Kevlar ® , other aramids such as Kermel ® (available from Rhone-Poulenc) Arenka ® , available from Akzo, Nomex (available from DuPont) , polyethylene naphthalate (PEN) , poly (p-phenylene benzobisthiazole) , polyesters, glass, aromatic polyamide resins Arenka ® , an aramid available from Akzo, thermotropic copolyesters such as Vectra ® (Celanese) and Xydar ® (Dart) , high modulus polyethylene fibers such as Spectra 900 (Allied) .
• aramids such as poly (p- phenyleneterephthalamide) , available from Dupont under the tradename Kevlar ® , other aramids such
• the high modulus interior could be covered, such as braiding and wrapping.
• a braid of bicomponent fibers around the high modulus interior provides a structure with good stability. Wrapping the high modulus fibers with the bicomponent fiber material is another suitable method. Fibers could be covered with either a single covering machine or a double covering machine. In either case, the core fibers are spirally covered at a selected pitch.
• the melting point of the sheath component is lower than the melting point of the core component, and lower than the melting point of the high modulus interior. Improved structural integrity is imparted by heating the fabric, which has been formed from the yarns, which intersect each other in the fabric, to a temperature in excess of the melting point of the sheath but lower than the melting point of the core and high modulus interior, followed by subsequent cooling.
• This process hereinafter referred to heat fusion, causes the sheath components of the bicomponent fibers to enter a softened state, and accordingly, the yarns fuse together at contact points when cooled to temperatures below the melting point of the sheath material. For the most part, such contact points are the points where the yarns intersect each other.
• the present invention provides a means for producing single layered fabrics able to withstand the demanding conditions which paper machine clothings are subjected to.
• fabrics must be constructed of at least two layers to insure that the fabrics have the necessary dimensional stability and strength in order to withstand the demanding running conditions.
• the present invention could also be used as the top laminate structure of a multilayer structure, and it is believed that its use as such a layer would offer advantages over conventional materials due to reduced knuckle size on the surface of the fabric and reduced caliper of the fabric.
• Reduced knuckle size would create a smoother fabric surface, a feature desired by paper makers. It is also possible that a thinner fabric can be made using the high modulus composite yarns of the present invention since the excellent tensile properties possessed by high modulus materials means that less material could be used to attain the degree of strength possessed by conventional fabrics.
• the present invention may also be used as the base layer of a multilayer structure. The improved dimensional stability of this layer makes it well suited for this usage. Using a fabric according to the invention as a base layer would impart certain advantages to the overall fabric construction. Because the composite yarns of the present invention exhibit a relatively high degree of strength along the axis of the yarn, the use of this fabric layer as the base layer would provide the stability and strength required of the overall fabric structure.
• the yarns of the present invention are the sole constituents of at least one layer of a clothing.
• at least one layer is constructed of the yarns of the present invention, and preferably constitute the surface layer in contact with the paper sheet. Whether the fabric is a single layer or multiple layer, the bicomponent fibers are to be arranged in an orderly non-random manner.
• fibers of a clothing run in a first direction; the first direction fibers do not intersect with other fibers running in the first direction; and that fibers of the clothing run in a second direction; the second direction fibers do not intersect with other fibers running in the second direction; that fibers running in the first direction intersect with fibers running in the second direction, and vice versa.
• fibers arranged in the machine direction will not intersect with each other and such fibers will intersect only with fibers running in the cross machine direction.
• the clothings of the present invention be constructed of fibers running in the machine or cross machine direction, but such clothings could be constructed of fibers which run in directions that are at angles to the machine and cross machine direction of a paper making machine .
• Figure 1 is a composite braided fabric of the present invention.
• Figure 2 is another composite braided fabric of the present invention.
• Figure 3 is a cross section of a yarn of the present invention.
• Figure 1 is a fabric comprised of yarns of the present invention.
• the fabric is a plain weave construction, with yarns in the warp and shute direction being comprised of yarns of the present invention. It can be observed from Fig. 1 that the yarns are interconnected with other yarns at the points at which the yarns intersect. This is attributable to heat fusion of the yarns, wherein the sheaths of the bicomponent materials fuse to each other after heating the fabric to a temperature above the melting point of the sheath material, yet lower than the melting point of the core material.
• Both the warp and shute yarns of the fabric shown in Figure 1 are of the same structure.
• the high modulus interior of the yarns are about 134 filaments of Kevlar ® 49.
• Eight bicomponent yarns have been braided around the Kevlar ® interior.
• Each yarn is constituted of sixteen (16) bicomponent filaments.
• the filaments are Bellcouple ® from Kanebo, 250 denier, 16 filament count having a low melt copolyester sheath material and a poly (ethylene terephthalate) core, with the melting point of the copolyester sheath being lower than the melting point of the PET core.
• the eight bicomponent yarns are braided around the Kevlar ® interior.
• Braiding forms a relatively stable structure
• the covered high modulus yarns can be used to form fabrics as shown in Figure 1.
• Such fabrics are formed according to methods readily appreciated to one skilled in the art. After the fabric has been formed, it is placed under tension, heated to a temperature greater than the melting point of the sheath, yet lower than the melting point of the core, and then cooled to a temperature lower than the melting point of the sheath.
• the present invention provides a means for producing single layered fabrics able to withstand the demanding conditions which paper machine clothings are subjected to.
• fabrics must be constructed of at least two layers to insure that the fabrics have the necessary dimensional stability and strength in order to withstand the demanding running conditions.
• the paper machine clothings of the present invention are characterized by high modulus, low stretch materials, the stiffness and dimensional stability of the fabric is provided by the layer of high modulus materials and accordingly, one layer fabrics are possible.
• the present invention could also be used as the top laminate structure of a multilayer structure, and it is believed that its use as such a layer would offer advantages over conventional materials due to increased planarity on the surface. Increased planarity is the result of reduced knuckle size at points where yarns intersect. Upon heat fusion of the fabric, the low-melt component of the bicomponent fiber collapses and flows, reducing the knuckle size of the crossover points.
• the present invention may also be used as the base layer of a multilayer structure.
• the improved dimensional stability of this layer makes it well- suited for this usage.
• other materials such as those of fine diameters, can be used in other layers, since stability and strength is imparted by the layer constructed of the high modulus material.
• the use of fine diameter materials in paper-sheet contacting layers would improve surface smoothness, a desirable feature of paper machine clothings.
• Figure 2 shows a fabric wherein the yarns described in relation to Figure 1 above are used in the warp direction.
• the shute direction yarns are comprised of 9 ply material. That is, they are a ply of nine yarns of bicomponent material as described in Figure 1.
• the plied yarns are twisted loosely together.
• the yarns have a distinctly flattened appearance. That is, after heat fusion, the yarns take on a ribbon like appearance.
• Figure 3 shows a cross section of a composite yarn according to the present invention.
• the Kevlar ® interior is visible as a distinct region.
• the bicomponent exterior is not discrete.
• Heat fusion of a fabric comprised of bicomponent fibers are characterized in part by fused, intersecting yarns.
• conventional monofilaments have interstices at points where yarns intersect. Fusion at the intersections of bicomponent fibers diminishes, and possibly eliminates, such interstices. Interstices are pinch points at which debris can be entrapped and collect over time. Accordingly, the heat fused intersecting yarns produced with bicomponent fibers provides a structure that should remain relatively cleaner than a clothing comprised of conventional monofilaments .
• Another advantage that paper machine clothings of the present invention are believed to possess over conventional clothings comprised of monofilaments is that such clothings exhibit relatively planar, knuckle free surfaces at cross over points.

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Textile Engineering (AREA)
• Woven Fabrics (AREA)
• Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
• Multicomponent Fibers (AREA)
• Paper (AREA)

Priority Applications (9)

Applications Claiming Priority (2)

Publications (1)

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Family Applications (1)

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Cited By (7)

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Citations (4)

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• 1997
  • 1997-09-12 DE DE69732234T patent/DE69732234T2/de not_active Expired - Lifetime
  • 1997-09-12 JP JP51484498A patent/JP3477210B2/ja not_active Expired - Lifetime
  • 1997-09-12 EP EP97943351A patent/EP0906460B1/en not_active Expired - Lifetime
  • 1997-09-12 AU AU44842/97A patent/AU716177B2/en not_active Ceased
  • 1997-09-12 ES ES97943351T patent/ES2231892T3/es not_active Expired - Lifetime
  • 1997-09-12 KR KR1019980703651A patent/KR100305120B1/ko not_active IP Right Cessation
  • 1997-09-12 BR BR9706771A patent/BR9706771A/pt not_active IP Right Cessation
  • 1997-09-12 CN CN97191589A patent/CN1096510C/zh not_active Expired - Fee Related
  • 1997-09-12 NZ NZ330367A patent/NZ330367A/xx unknown
  • 1997-09-12 WO PCT/US1997/016505 patent/WO1998012371A1/en active IP Right Grant
  • 1997-09-12 AT AT97943351T patent/ATE286997T1/de active
  • 1997-09-12 CA CA002237964A patent/CA2237964C/en not_active Expired - Fee Related
• 1998
  • 1998-05-18 MX MX9803908A patent/MX9803908A/es not_active IP Right Cessation

Patent Citations (4)

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