WO2008073301A2 - Dessin de tissage de couche côté machine pour fabrication de tissus composites - Google Patents

Dessin de tissage de couche côté machine pour fabrication de tissus composites Download PDF

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Publication number
WO2008073301A2
WO2008073301A2 PCT/US2007/025083 US2007025083W WO2008073301A2 WO 2008073301 A2 WO2008073301 A2 WO 2008073301A2 US 2007025083 W US2007025083 W US 2007025083W WO 2008073301 A2 WO2008073301 A2 WO 2008073301A2
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WO
WIPO (PCT)
Prior art keywords
fabric
warp
yarns
weft
weft yarns
Prior art date
Application number
PCT/US2007/025083
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English (en)
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WO2008073301A3 (fr
Inventor
Rex Barrett
Original Assignee
Astenjohnson, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Astenjohnson, Inc. filed Critical Astenjohnson, Inc.
Publication of WO2008073301A2 publication Critical patent/WO2008073301A2/fr
Publication of WO2008073301A3 publication Critical patent/WO2008073301A3/fr

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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
    • D21F1/0036—Multi-layer screen-cloths
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
    • D03D13/004—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft with weave pattern being non-standard or providing special effects

Definitions

  • the present invention is directed to woven, composite forming fabrics for use in papermaking machines. It is particularly concerned with such fabrics wherein the machine side fabric weave helps to reduce edge curl. [0004] BACKGROUND
  • 5,826,627 (Seabrook et al.), WO 06/034576 (Danby et al) or US 7,108,020 (Stone) are comprised of two sets of weft yarns interwoven with at least one system of warp yarns.
  • One of the sets of weft yarns is located on the paper side surface (PS) of the fabric to provide support for the papermaking fibers in the sheet forming process; these weft yarns tend to be small and closely woven, typically in a plain weave or 3-shed pattern so as to maximize the number of available support points for the papermaking fibers.
  • PS weave The function of the PS weave is to optimize paper sheet formation by providing a very finely woven papermaking surface which will support the fibers suspended in the stock as it drains through the fabric.
  • the warp and weft yarns in the PS are generally of relatively small diameter, in the range of from about 0.10mm to about 0.25mm depending on the papermaking application for which the fabric is intended.
  • "better" quality sheets which offer improved printing characteristics and uniformity, are formed on fabrics having a larger number of support points; such fabrics have a very high yarn density on the PS and are woven using relatively small yarns.
  • the warp and weft yarns in the PS are thus interwoven a great number of times to provide the desired sheet support characteristics.
  • each weft yarn will pass over and under each of the warp yarns 100 times in each inch of fabric width.
  • Typical warp yarn counts in these fabrics will usually range from about 60 to 100 yarns per inch interwoven with from about 50 to 150 weft yarns per inch, although higher and lower numbers of yarns are known and used.
  • these finely woven PS weave designs are not sufficiently rugged or stable to withstand the stresses to which they will be exposed on modern high speed pape ⁇ naking machines and could not be used for this purpose on their own without additional reinforcement.
  • a second set of weft yarns is located on the machine side surface (MS) of the fabric and is interwoven with the warp yarns according to a pattern which is intended to provide a measure of wear resistance and stability to the overall fabric.
  • the function of the cooperating MS weave is to provide a rugged, stable platform upon which the PS weave is mounted to maximize fabric wear life and stability.
  • the MS weft yarns are usually larger than those used in the PS, often by an order of magnitude of about 2, and are typically interwoven according to a weave design that maximizes the wear volume presented to the fabric bearing surfaces of the papermaking machine. This is usually accomplished by interweaving the MS warp and second set of weft yarns so that relatively long weft floats are formed.
  • These yarns will generally not be interwoven with the same frequency as those in the PS because the MS weave in a composite forming fabric is a comparatively coarser structure.
  • These MS layer weave designs are typically 4-, 5-, 6- or more shed patterns which cause the MS weft yarns to bow outwardly between the points at which they are interlaced by the warp yarns.
  • Typical yarn counts used in the MS weave of a composite forming fabric will be in the range of from about 100 x 66 yarns/in (warp x weft) (39 x 26 yarns/cm) to about 50 x 25 yarns/in (20 x 10 yarns/cm).
  • Composite forming fabrics in use today will generally be woven at 2:1 or 3:2 weft count ratios (PS:MS) so the number of PS weft will be from 1.5 to 2.0 times the number in the MS.
  • the warp and weft yarns are generally monofilaments formed from extruded thermoplastic polymers, with poly amides (PA) and polyethylene terephthalate (PET) being the preferred materials for such applications.
  • PA poly amides
  • PET polyethylene terephthalate
  • the PS weave and MS weave are woven simultaneously on the loom as a unified structure using either, or both, the warp and/or weft yarns of one or both weaves to tie the two woven structures together.
  • the resulting fabric known variously in the industry as a triple layer fabric, composite fabric, multilayer fabric, etc., will be referred to henceforth as a "composite" fabric.
  • a composite fabric is one woven using at least two sets of weft yarns (arranged in two layers one over the other, with the individual yarns not necessarily in vertical alignment) and at least one system of warp yarns.
  • weft yarns arranged in two layers one over the other, with the individual yarns not necessarily in vertical alignment
  • system of warp yarns For example, in the weave patterns described in WO 06/034576 (Danby et al) or US 7,108,020 (Stone), one set of warp yarns woven in pairs or triplets is used to interconnect the PS and MS weft into a unified fabric.
  • Composite fabrics of this sort are referred to as "warp tie designs" meaning that the warp yarns are used to integrate the two sets of weft yarns together into the resulting fabric.
  • the disclosed fabric contains two sets of weft yarns and two sets of warp yarns, and it is a portion of the PS weft which are used to integrate the two sets of warp and weft yarns into a unified structure.
  • Fabrics of this sort are referred to as "intrinsic weft tie designs", “weft tie designs” or “sheet support binder” (SSB) fabrics because it is the PS weft yarns, which provide support for the sheet as it is being formed and which are thus "intrinsic" to the PS, that are used to unite the two fabric structures into a unified whole.
  • the present invention is applicable to any composite fabric including both warp tie designs and weft tie designs.
  • both warp tie and weft tie design forming fabrics provide various benefits to the papermaker, they share a common problem.
  • the resulting fabrics tend to curl at their lateral or side edges.
  • the curl is frequently up and out of the plane of the PS, and may involve from about 2 inches to 2 feet (5 to 60 cm) or more of each of the lateral edges of the fabric, causing the fabric to form a pronounced "U" shape.
  • the fabric may roll up like a tube when removed from the loom.
  • US 4,281,688 to Kelly et al. attempts to solve the problem of edge curl in a single layer forming fabric by providing a plurality of dominating floats on each fabric face.
  • US 4,356,844 and US 4,453,573 both to Thompson offer similar methods of solving this problem by modifying the fabric weave design without compromising pape ⁇ naking properties.
  • US 6,123,116 to Ward et al. addresses the problem by providing a fabric having a large number of relatively small CD yarns in the MS, rather than a small number of relatively large yarns.
  • the present invention is based on the understanding that edge curl in composite forming fabrics is due, at least in part, to the differing amount of crimp that is imparted to the relatively small diameter cross- machine direction (CD) oriented weft yarns located on the PS of the fabric as compared to the amount of crimp imparted to the relatively fewer and larger diameter weft yarns located on the MS of the fabric.
  • crimp is defined as the bend in the yarns formed by the interweaving of each warp and weft yarn.
  • the number of PS interweaves is greater than the number of MS interweaves (by a magnitude of from about 1.5 to 2) due to the greater number of weft involved. It is believed that the greater amount of crimps in the PS weft yarns as compared to the MS weft yarns causes the lateral edges of a forming fabric to curl upwards. In order to balance or counteract this effect, it is believed that the MS weft yarns must be crimped to a greater degree, which is accomplished according to the present invention.
  • the present invention is directed to a machine side layer weave design for use in a composite forming fabric.
  • the MS weave design is constructed and arranged so as to counteract the edge curl effects induced in the overall fabric by the crimp imparted to the yarns in the paper side layer weave.
  • at least 50% of the warp yarns pass under two weft yarns in succession in the MD to form a double warp knuckle.
  • a double warp knuckle occurs when a warp yarn passes or is crimped under two weft yarns located adjacent to one another in the fabric weave structure.
  • a single warp knuckle occurs when a warp yarn passes or is crimped under a single weft yarn, and is also used herein to refer to each knuckle formation of a double warp knuckle.
  • First and second single warp knuckles are located on the next adjacent warp yarns on each lateral side of the double warp knuckle.
  • the first single warp knuckle is produced by a warp yarn being crimped under a first of the two weft yarns of the double warp knuckle, and the second single warp knuckle is formed under a second of the two weft yarns of the double warp knuckle.
  • each MS weft yarn is interlaced by two adjacent warp yarns so as to form two adjacent MS warp knuckles.
  • two adjacent warp yarns pass together under each MS weft yarn at each MS weft interlace point. This serves to pull the weft yarn "up” into the interior of the forming fabric causing the MS weft yarn float to bow outwardly, forming an enhanced weft wear plane that is in contact with the fabric bearing surfaces of the pape ⁇ naking machine on which it is installed. This helps to increase both the wear resistance of the fabric and the "intensity" of crimp imparted to the MS weft.
  • the double and single warp knuckles occur throughout and are uniformly distributed over the MS surface of the fabric in groups which include two single knuckles and one double knuckle.
  • the distribution of the warp knuckles is reasonably uniform and does not appear to impart a pronounced twill or herringbone knuckle pattern onto the fabric surface as the warp knuckles are offset from and do not form twill lines.
  • the MS surface of the novel fabrics is not susceptible to guiding or related tracking issues such as sometimes occur in fabrics where the MS yarn knuckles have a pronounced or clearly discernible angular orientation.
  • benefits of this novel weave pattern include improved fabric guiding/tracking, good resistance to abrasive weave, and fabric stability.
  • the warp yarns pass under two consecutive MS layer weft yarns to form a double warp knuckle, and the warp yarns always pass together in pairs under each weft yarn at each MS weft interlace point to each form two single adjacent MS warp knuckles.
  • Each warp yarn adjacent to the double MS warp knuckle passes under one of the two consecutive MS layer weft yarns of the double warp knuckle on either side thereof.
  • a flat woven composite forming fabric for use in the forming section of a papermaking machine is provided with the following: i. a first set of weft yarns located on the paper receiving side (PS) of the fabric, ii. a second set of weft yarns located on the machine contacting surface side (MS) of the fabric, and iii.
  • each repeat of the MS weave at least 50% of the warp yarns pass under two adjacent weft yarns in the second set of weft yarns to form a double warp knuckle.
  • 100% of the warp yarns include double warp knuckles formed by passing under two adjacent ones of the weft yarns in the second set of weft yarns.
  • a single warp knuckle located in the next adjacent warp yarn on each lateral side of every double warp knuckle.
  • a first one of the single warp knuckles is formed under a first of the two weft yarns passed under by the warp yarn forming the double warp knuckle, while a second one of the single warp knuckles is formed under a second of the two weft yarns passed under by the warp yarn forming the double warp knuckle.
  • a repeating pattern of the MS warp knuckles is uniformly distributed over the MS surface of the fabric, offset from and not forming diagonal twill lines.
  • the flat woven composite forming fabric is woven according to a design requiring 24 sheds in the loom.
  • the flat woven composite forming fabric is woven according to a design requiring 20 sheds in the loom.
  • the flat woven composite forming fabric is woven according to a design requiring 16 sheds in the loom.
  • the MS weave is woven according to a design requiring 4, 5 or 6 sheds in the loom.
  • the MS weave is woven according to a design requiring 12 sheds in the loom.
  • the warp and weft yarn materials are selected from the group consisting of PET, PBT, PEN, nylon or a polymer blend of thermoplastic polyurethane and a polyester such as is disclosed in US
  • the warp and weft materials are extruded monofilaments.
  • the cross sectional shape of the monofilaments comprising the warp and weft yarns is one, or a combination of the following: round, oval, trapezoidal, elliptical, hollow, rectangular or square.
  • Figure 1 is a weave diagram of a first embodiment of a fabric according to the present invention.
  • Figure 2 is a simplified version of the weave diagram of Figure 1 which has been reversed to show only the MS knuckle pattern of the fabric whose full weave design appears in Figure 1.
  • Figure 3 is plan view of one repeat of the weave of the MS surface of the fabric whose design is shown in Figures 1 and 2.
  • Figure 4 is a perspective view of the MS surface of the fabric whose design is shown in Figures 1 and 2.
  • Figure 5 is a photograph of the MS surface of a fabric woven according to the weave design shown in Figure 1.
  • Figure 6 is a photograph of the PS surface of a fabric woven according to the weave design shown in Figure 1.
  • Figure 7 is a simplified weave diagram of the MS surface of a fabric which is a further embodiment of the present invention and is woven according to a 10-shed design.
  • Figure 8 is a simplified weave diagram of the MS surface of a fabric that is an alternate embodiment of the 10-shed weave design shown in
  • Figure 9 is a simplified weave diagram of the MS surface of a fabric which is a further embodiment of the present invention and is woven according to a weave design requiring 8-sheds.
  • a "double warp knuckle” is the adjacent knuckle formations caused by a warp yarn passing (or being crimped) under two adjacent weft yarns in the fabric weave structure.
  • a “single warp knuckle” is the knuckle formation caused by a warp yarn passing or being crimped under a single weft yarn, or also refers to each of the adjacent knuckle formations of a double warp knuckle.
  • “Yarns” refers to monofilaments, multi-filaments, twisted or cabled fibers, stacked or assembled two-part fibers or fiber assemblies, or any other type of elongated filament-like structure used for weaving industrial papermaking fabrics.
  • Interlace refers to the bending or crimping of a yarn from one of the wrap or weft systems around another yarn from the other of the warp or weft systems as they pass beneath or around one another.
  • a weave diagram of a first embodiment of a fabric 200 according to the present invention is shown in Figure 1.
  • the warp yarns 212 are numbered horizontally across the top of the pattern as 1-24, and the weft yarns 214 are numbered in sequence vertically down the left side of the pattern as 101-142.
  • the overall weave pattern requires 42 weft yarns 214 for a repeat (18 "primary” weft yarns 214A interwoven on the PS layer 202 only, 12 "intrinsic” weft yarns 214B interwoven as 6 pairs to form the part of the PS layer 202 and "tie” into the MS layer 204 to bind the two fabric layers 202, 204 together in a similar manner to Seabrook et al.
  • FIG. 2 A simplified version of the weave diagram showing the warp yarns 212 and only the MS weft yarns 214C used in the formation of the MS layer 204 of the fabric and a clearer picture of the warp knuckle pattern, is provided in Figure 2.
  • Figure 2 the locations where the warp yarns 212 pass under (i.e., are on the MS surface of the fabric) the MS weft yarns 214C to form the single and double warp knuckle arrangement of this invention are clearly shown.
  • the knuckles 220A, 220B, 220C and 220D formed by warp yarns 214 numbered 17, 18 and 19 as they pass under weft yarns 214C numbered 129 and 132 are exemplary.
  • the warp yarn number 17 passes under one weft yarn 129 to form a single warp knuckle 220A
  • the immediately adjacent warp yarn 18 passes under weft yarns 129 and 132 respectively to form a double warp knuckle consisting of knuckles 220B and 220C
  • the next adjacent warp yarn 19 forms a single warp knuckle 220D as it passes under the weft yarn 132.
  • Figures 3 and 4 are line drawings of the MS surface 204 of the novel fabric 200 which is made in accordance with the weave pattern provided in Figures 1 and 2.
  • Figure 3 is a planar view of the MS surface 203 of the fabric
  • Figure 4 is a bottom perspective representation of the MS layer 204 of the same fabric as is shown in Figure 3.
  • the single warp knuckles 220A, 220D and the double warp knuckles formed by the knuckles 220B and 220C over (with respect to the MS surface) adjacent MS weft yarns 214 are shown in different shading in Figure 3.
  • Figures 5 and 6 are photographs of the MS and PS of an actual fabric 200 woven according to the weave design shown in Figure 1.
  • the warp knuckles 220A, 220B, 220C and 220D are indicated in Figure 5.
  • the weft yarns 214 are oriented horizontally across the page while the warp yarns 212 run vertically up and down the page.
  • the PS surface 202 shown in Figure 6 is a plain weave and is a construction similar to that illustrated in Seabrook et al. in which every 4 th weft yarn is an intrinsic weft yarn pair 214B, and each pair member alternately passes down to the MS and interlaces there with one of the warp yarns 212 to bind the PS and MS layers together into a unified structure.
  • Figure 7 is a weave diagram for the MS layer of a first alternate embodiment of a fabric 200' according to the invention.
  • the MS weave diagram of Figure 7 is similar to Figure 2 in that only the MS weft yarns 214C (numbered 301 - 320) are shown interweaving with the warp yarns 212' (numbered 1-10) illustrated in a 10-shed pattern in order to form the warp knuckles 220'.
  • the weave pattern of Figure 7 is a structure in which every second warp yarn 212' (here numbered 1, 3, 5, 7, and 9) does not form any double warp knuckles - only the even numbered warp yarns 212' weave under two adjacent MS weft yarns 214C to form the double warp knuckles. Therefore 50% of the warp yarns form double warp knuckles. However, as in the pattern shown in Figures 1 and 2, two adjacent warp yarns 212' pass under each MS weft yarn 214C. Other weave patterns would also be possible with at least 50% of the warp yarns having double warp knuckles.
  • Figure 8 is a weave diagram for the MS layer of a second alternate embodiment of a fabric 200" according to the invention.
  • the MS layer in this embodiment is woven according to a 10-shed pattern to form warp knuckles 220"; however, it is more similar to Figures 1 and 2 in that every warp yarn 212" (numbered 1-10) includes double warp knuckles formed under adjacent ones of the MS weft yarns 214C" (here numbered 401- 420).
  • a single warp knuckle is located in the next adjacent warp yarns 212" on each side of the double warp knuckle.
  • Figure 9 is a weave diagram for the MS layer of a third alternate embodiment of a fabric 200"' according to the invention.
  • the MS layer is woven in an 8-shed pattern to form warp knuckles 220"'. It has all of the features of the designs shown in Figures 1, 2 and 8 in that every warp yarn 212"' (here numbered 1-10) passes under two adjacent ones of the weft yarns 214C"' (here numbered 501-532) in the repeat to form a double warp knuckle.
  • a single warp knuckle is located in the adjacent warp yarn 212"' on each side of the double warp knuckle, with one of the single warp knuckles being located on each of the weft yarns 214C" used to form the double warp knuckle such that each MS weft yarn 214C" is passed under by two warp yarns 212"' at each MS weft interlace point.
  • a first one of the single warp knuckles 220, 220', 220", 220"' is formed under a first of the two MS weft yarns 214C, 214C, 214C", 214C"' passed under by the warp yarn 212, 212', 212", 212"' forming the double warp knuckle, while a second one of the single warp knuckles 220, 220', 220", 220"' is formed under a second of the two MS weft yarns 214C, 214C, 214C", 214C"' passed under by the warp yarn 212, 212', 212", 212"' forming the double warp knuckle.
  • Sample 1 was woven using a MS layer weave design which was in accordance with the teachings of the present invention and in which the warp yarns pass together in adjacent pairs under all of the machine side layer weft yarns to form two adjacent single warp knuckles at each MS weft interlace point.
  • Sample 2 was a prior art fabric construction including a machine side layer weave in accordance with the teachings of Barrett, US 5,544,678 and in which the warp yarns are not arranged to pass together in adjacent pairs under all of the MS weft yarns. Both fabrics were intrinsic weft tie type composite forming fabrics similar to those described by Seabrook et al US 5,826,627.
  • the wet and dry curl test values were obtained in the following way. Samples from both the inventive and the prior art fabrics were obtained and their MD length and CD width measured. The samples are laid onto a flat surface and the height of their curl relative to that flat surface was measured. The curl test value obtained is a ratio that utilizes the measured height of the sample fabric curl above the flat surface relative to a chord length of that particular curl. Higher curl test values indicate larger amounts of fabric curl. Positive curl test values indicate fabric curl towards the paper side surface, while negative curl test values indicate fabric curl towards the machine side surface. In the dry curl test, the fabric sample is fully dry; in the wet curl test, the fabric sample is soaked in room temperature water for 24 hours prior to this measurement. Curl test values around zero indicate that the fabric sample is essentially flat with no curl at its edge. Curl test values near 2.0 are considered unacceptable and the fabric will require further treatment in order to reduce its edge curl.
  • the preferred fabric is flat woven, it could be continuously woven, and the systems of yarns would be first and second systems of cross- direction yarns interwoven with at least one system of machine direction yarns according to the invention as described above.
  • the preferred embodiment of the fabric is for use as a forming fabric on a pape ⁇ naking machine, additional embodiments could prove useful in other sections of a papermaking machine. Further modifications and extensions of the present invention may be developed and all such modifications are deemed to be within the scope of the present invention as defined by the appended claims.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Woven Fabrics (AREA)
  • Paper (AREA)

Abstract

L'invention concerne un dessin de tissage de couche côté machine pour utilisation avec les tissus composites en particulier les tissus pour la fabrication de papier aux dessins de tissage différents sur chaque surface plane. Le tissu composite se compose de deux ensembles de fils de trame entrelacés avec au moins un système de fils de chaîne. Un premier ensemble de fils de trame est entrelacé avec ledit ou lesdits systèmes de fils de chaîne pour constituer la couche côté papier, tandis que le second ensemble de fils de trame est entrelacé avec ledit ou lesdits systèmes de fils de chaîne pour constituer la couche côté machine. Dans chaque répétition du dessin de tissage de couche côté machine, au moins 50% des fils de chaîne passent sous deux fils de trame adjacents sur le côté machine du tissu pour constituer une double articulation à chaîne, et chaque double articulation à chaîne est liée sur l'un ou l'autre côté par une simple articulation à chaîne formée sur chacune des première et seconde trames sous lesquelles passe la double articulation à chaîne. De plus, dans chaque répétition du tissage, sous chaque fil de trame passent deux fils de chaîne adjacents pour constituer deux simples articulations à chaîne adjacentes. Dans un mode de réalisation, tous les fils de chaîne forment des doubles articulations à chaîne; dans un autre mode de réalisation, 50% des fils de chaîne forment des doubles articulations à chaîne. Les articulations sont uniformément réparties de part et d'autre de la surface côté machine pour minimiser toute propension au guidage. Le dessin de tissage de couche côté machine de l'invention convient à une utilisation dans tout tissu composite et est efficace pour minimiser ou éliminer toute frisure de bord de tissu, problème commun dans les tissus de ce type.
PCT/US2007/025083 2006-12-08 2007-12-06 Dessin de tissage de couche côté machine pour fabrication de tissus composites WO2008073301A2 (fr)

Applications Claiming Priority (2)

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US86914406P 2006-12-08 2006-12-08
US60/869,144 2006-12-08

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WO2008073301A3 WO2008073301A3 (fr) 2008-07-31

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