EP0612881A1 - Papermakers fabric with flat machine direction yarns - Google Patents
Papermakers fabric with flat machine direction yarns Download PDFInfo
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- EP0612881A1 EP0612881A1 EP94103974A EP94103974A EP0612881A1 EP 0612881 A1 EP0612881 A1 EP 0612881A1 EP 94103974 A EP94103974 A EP 94103974A EP 94103974 A EP94103974 A EP 94103974A EP 0612881 A1 EP0612881 A1 EP 0612881A1
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- yarns
- fabric
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- yarn
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F7/00—Other details of machines for making continuous webs of paper
- D21F7/08—Felts
- D21F7/083—Multi-layer felts
-
- 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
- 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
- D21F1/0054—Seams thereof
Abstract
Description
- The present invention relates to papermakers fabrics and in particular to fabrics comprised of flat monofilament yarns.
- Papermaking machines generally are comprised of three sections: forming, pressing, and drying. Papermakers fabrics are employed to transport a continuous paper sheet through the papermaking equipment as the paper is being manufactured. The requirements and desirable characteristics of papermakers fabrics vary in accordance with the particular section of the machine where the respective fabrics are utilized.
- With the development of synthetic yarns, shaped monofilament yarns have been employed in the construction of papermakers fabrics. For example, U.S. Patent No. 4,290,209 discloses a fabric woven of flat monofilament warp yarns; U.S. Patent No. 4,755,420 discloses a non-woven construction where the papermakers fabric is comprised of spirals made from flat monofilament yarns.
- Numerous weaves are known in the art which are employed to achieve different results. For example, U.S. Patent No. 4,438,788 discloses a dryer fabric having three layers of cross machine direction yarns interwoven with a system of flat monofilament machine direction yarns such that floats are created on both the top and bottom surfaces of the fabric. The floats tend to provide a smooth surface for the fabric.
- Permeability is an important criteria in the design of papermakers fabrics. In particular, with respect to fabrics made for running at high speeds on modern drying equipment, it is desirable to provide dryer fabrics with relatively low permeability.
- U.S. Patent No. 4,290,209 discloses the use of flat monofilament warp yarns woven contiguous with each other to provide a fabric with reduced permeability. However, even where flat warp yarns are woven contiguous with each other, additional means, such as stuffer yarns, are required to reduce the permeability of the fabric. As pointed out in that patent, it is desirable to avoid the use of fluffy, bulky stuffer yarns to reduce permeability which make the fabric susceptible to picking up foreign substances or retaining water.
- U.S. Patent No. 4,290,209 and U.S. Patent No. 4,755,420 note practical limitations in the aspect ratio (cross-sectional width to height ratio) of machine direction warp yarns defining the structural weave of a fabric. The highest practical aspect ratio disclosed in those patents is 3:1, and the aspect ratio is preferably, less than 2:1.
- U.S. Patent No. 4,621,663, assigned to the assignee of the present invention, discloses one attempt to utilize high aspect ratio yarns (on the order of 5:1 and above) to define the surface of a papermakers dryer fabric. As disclosed in that patent, a woven base fabric is provided to support the high aspect ratio surface yarns. The woven base fabric is comprised of conventional round yarns and provides structural support and stability to the fabric disclosed in that patent.
- U.S. Patent No. 4,815,499 discloses the use of flat yarns in the context of a forming fabric. That patent discloses a composite fabric comprised of an upper fabric and a lower fabric tied together by binder yarns. The aspect ratio employed for the flat machine direction yarns in both the upper and lower fabrics are well under 3:1.
- In use, papermakers fabrics are configured as endless belts. Weaving techniques are available to initially weave fabrics endless. However, there are practical limitations on the overall size of endless woven fabrics as well as inherent installation difficulties. Moreover, not all papermaking equipment is designed to accept the installation of an endless fabric.
- Flat woven fabrics are often supplied having opposing ends which are seamed together during installation of the fabric on papermaking equipment. Usually one end of the fabric is threaded through the serpentine path defined by the papermaking equipment and is then joined to its opposing end to form a continuous belt.
- A variety of seaming techniques are well known in the art. One conventional method of seaming is to form the machine direction yarns on each end of the fabric into a series of loops. The loops of the respective fabric ends are then intermeshed during fabric installation to define a channel through which a pintle is inserted to lock the ends together.
- For example, U.S. Patent Nos. 4,026,331; 4,438,789; 4,469,142; 4,846,231; 4,824,525 and 4,883,096 disclose a variety of pin seams wherein the machine direction yarns are utilized to form the end loops. In each of those patents, however, the machine direction yarn projects from the end of the fabric and weaves back into the fabric adjacent to itself. Accordingly, the loops inherently have a twist or torque factor and are not entirely orthogonal to the plane of the fabric. U.S. Patent 4,883,096 specifically addresses this problem.
- It would be desirable to provide a papermakers fabric with machine direction seaming loops which do not have torque and/or twist.
- The present invention provides a papermakers fabric having a system of flat monofilament machine direction yarns (hereinafter MD yarns) which are stacked to control the permeability of the fabric. The present weave also provides for usage of high aspect ratio yarns as structural weave components. The system of MD yarns comprises upper and lower yarns which are vertically stacked. Preferably, the upper MD yarns define floats on the upper surface of the fabric and each upper MD yarn is paired in a vertically stacked orientation with a lower MD yarn. The lower MD yarns may weave in an inverted image of the upper MD yarns to provide floats on the bottom fabric surface or may weave with a different repeat to provide a different surface on the bottom of the fabric.
- At least the upper MD yarns are flat monofilament yarns woven contiguous with each other to reduce the permeability of the fabric and to lock in the machine direction alignment of the stacking pairs of MD yarns. In the preferred embodiment, the same type and size yarns are used throughout the machine direction yarn system and both the top and the bottom MD yarns weave contiguously with adjacent top and bottom MD yarns, respectively. The stacked, contiguous woven machine direction system provides stability and permits the MD yarns to have a relatively high aspect ratio, cross-sectional width to height, of greater than 3:1.; the aspect ratio preferably ranging from about 2:1 to 6:1. machine direction yarns further define a series of orthogonal seaming loops on the opposing fabric ends. End segments of the lower MD yarns are removed and the upper MD yarn ends are looped back upon themselves and rewoven into the fabric end in the space vacated by the trimmed lower MD yarn end segments. The lower MD yarns may weave in an inverted image of the upper MD yarns such that the crimp of the upper MD yarns conforms with the lower MD yarn weave pattern space into which the upper MD yarn ends are backwoven. This improves the strength of the seam.
- Non-loop forming upper MD yarns are also preferably backwoven into the space vacated by trimming the respective lower MD yarns. Preferably, at least the upper MD yarns are woven contiguous with each other to lock in the machine direction alignment of the stacking pairs of MD yarns and the orthogonal orientation of the end loops. In the preferred embodiment, the same type of material and the same geometric shape and size yarns are used throughout the machine direction yarn system and both the top and the bottom MD yarns weave contiguously with adjacent top and bottom MD yarns, respectively.
- It is an object of the invention to provide a papermakers fabrics having permeability controlled with woven flat machine direction yarns.
- It is a further object of the invention to provide a low permeability fabric constructed of all monofilament yarns without the use of bulky stuffer yarns and without sacrificing strength or stability.
- Other objects and advantages will become apparent from the following description of presently preferred embodiments.
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- Figure 1 is a schematic diagram of a papermakers fabric made in accordance with the teachings of the present invention;
- Figure 2 is a cross-sectional view of the fabric depicted in Figure 1 along line 2-2;
- Figure 3a is a cross-sectional view of the fabric depicted in Figure 1 along line 3-3;
- Figure 3b is a cross-sectional view of a prior art weave construction;
- Figure 4a illustrates the yarn orientation in the fabric depicted in Figure 1 after the fabric is finished showing only two representative stacked MD yarns;
- Figures 4b, 4c, and 4d are a series of illustrations showing the formation of a seaming loop for the papermakers fabric depicted in Figure 1;
- Figure 5a is a perspective view of a prior art MD yarn seaming loop;
- Figure 5b is a perspective view of an orthogonal MD yarn seaming loop made in accordance with the present invention;
- Figure 6 is a schematic view of a second embodiment of a fabric made in accordance with the present invention;
- Figure 7 is a cross-sectional view of the fabric depicted in Figure 6 along line 7-7;
- Figure 8 is a cross-sectional view of the fabric depicted in Figure 6 along line 8-8;
- Figure 9 is a perspective view of a portion of the fabric illustrated in Figures 6-8;
- Figure 10 illustrates the yarn orientation in the finished fabric depicted in Figure 6 showing the end loop formed by one of the MD yarns;
- Figure 11 is a top view of the opposing ends of a fabric constructed in accordance with Figure 6 just prior to pin-seaming the ends together;
- Figure 12 is a-schematic view of a third alternate embodiment of a fabric made in accordance with the teachings of the present invention showing only one pair of stacked MD yarns;
- Figure 13 is a schematic view of a fourth alternate embodiment of a fabric made in accordance with the teachings of the present invention showing only one pair of stacked MD yarns;
- Figure 14 is a schematic view of a fifth alternate embodiment of a fabric made in accordance with the teachings of the present invention showing only one pair of stacked MD yarns;
- Figure 15 is a schematic view of a sixth alternate embodiment of a fabric made in accordance with the teachings of the present invention showing only one pair of stacked MD yarns;
- Figure 16 is a schematic view of a seventh alternate embodiment of a fabric made in accordance with the teachings of the present invention showing only one pair of stacked MD yarns; and
- Figure 17 is a schematic view of a eighth alternate embodiment of a fabric made in accordance with the teachings of the present invention showing only one pair of stacked MD yarns.
- Referring to Figures 1, 2, and 3a, there is shown a
papermakers dryer fabric 10 comprising upper, middle and lower layers of cross machine direction (hereinafter CMD)yarns upper MD yarns CMD yarns 11, 12 andlower MD yarns CMD yarns - The
upper MD yarns fabric 10 by weaving over two upper layer CMD yarns 11 dropping into the fabric to weave in an interior knuckle under one middlelayer CMD yarn 12 and under one CMD yarn 11 and thereafter rising to the surface of the fabric to continue the repeat of the yarn. The floats over upper layer CMD yarns 11 ofupper MD yarns yarns 11, 12 are maintained in the weave. - As will be recognized by those skilled in the art, the disclosed weave pattern with respect to Figures 1, 2, and 3a, results in the top surface of the fabric having a twill pattern. Although the two-float twill pattern represented in Figures 1, 2, and 3a is a preferred embodiment, it will be recognized by those of ordinary skill in the art that the length of the float, the number of MD yarns in the repeat, and the ordering of the MD yarns may be selected as desired so that other patterns, twill or non-twill, are produced.
- As best seen in Figures 2 and 3a,
lower MD yarns upper MD yarns lower MD yarn layer CMD yarns 13, rises into the fabric over oneCMD yarn 13 and forms a knuckle around one middlelayer CMD yarn 12 whereafter the yarn returns to the lower fabric surface to continue its repeat floating under the next two lowerlayer CMD yarns 13. - With respect to each pair of stacked yarns, the interior knuckle, formed around the middle layer CMD
yarns 12 by one MD yarn, is hidden by the float of the other MD yarn. For example, in Figures 1 and 3a,lower MD yarn 15 is depicted weaving a knuckle overCMD yarn 12 whileMD yarn 14 is weaving its float over CMD yarns 11, thereby hiding the interior knuckle oflower MD yarn 15. Likewise, with respect to Figures 1 and 3a,upper MD yarn 18 is depicted weaving a knuckle underyarn CMD yarn 12 while it is hidden bylower MD yarn 19 as it floats underCMD yarns 13. - The
upper MD yarns - The crowding of
MD yarns MD yarns respective MD yarns MD yarns MD yarns - Since the
lower MD yarns upper MD yarns MD yarns - As set forth in the U.S. Patent No. 4,290,209, it has been recognized that machine direction flat yarns will weave in closer contact around cross machine direction yarns than round yarns. However, a 3:1 aspect ratio was viewed as a practical limit for such woven yarns in order to preserve overall fabric stability. The present stacked MD yarn system preserves the stability and machine direction strength of the fabric and enables the usage of yarns with increased aspect ratio, in a preferred range of 2:1 to 6:1, to more effectively control permeability.
- The high aspect ratio of the MD yarns translates into reduced permeability. High aspect ratio yarns are wider and thinner than conventional flat yarns which have aspect ratios less than 3:1 and the same cross-sectional area. Equal cross-sectional area means that comparable yarns have substantially the same linear strength. The greater width of the high aspect ratio yarns translates into fewer interstices over the width of the fabric than with conventional yarns so that fewer openings exist in the fabric through which fluids may flow. The relative thinness of the high aspect ratio yarns enables the flat MD yarns to more efficiently cradle, i.e. brace, the cross machine direction yarns to reduce the size of the interstices between machine direction and cross machine direction yarns.
- For example, as illustrated in Figure 3b, a fabric woven with a single layer system of a flat machine direction warp having a cross-sectional width of 1.5 units and a cross-sectional height of 1 unit, i.e. an aspect ratio of 1.5:1, is shown. Such fabric could be replaced by a fabric having the present dual stacked MD yarn system with MD yarns which are twice the width, i.e. 3 units, and half the height, i.e. 0.5 units. Such MD yarns thusly having a fourfold greater aspect ratio of 6:1, as illustrated in Figure 3a.
- The thinner, wider MD yarns more efficiently control permeability while the machine direction strength of the fabric remains essentially unaltered since the cross-sectional area of the MD yarns over the width of the fabric remains the same. For the above example, illustrated by Figures 3a and 3b, the conventional single MD yarn system fabric has six conventional contiguous flat yarns over 9 units of the fabric width having a cross-sectional area of 9 square units, i.e. 6*(1u.*1.5u.). The thinner, wider high aspect ratio yarns, woven as contiguous stacked MD yarns, define a fabric which has three stacked pairs of MD yarns over 9 units of fabric width. Thus such fabric also has a cross-sectional area of 9 square units, i.e.
- In one example, a fabric was woven in accordance with Figures 1, 2 and 3, wherein the
CMD yarns - The fabric was heat set in a conventional heat setting apparatus under conditions of temperature, tension and time within known ranges for polyester monofilament yarns. For example, conventional polyester fabrics are heat set within parameters of 340°F-380°F temperature, 6-15 PLI (pounds per linear inch) tension, and 3-4 minutes time. However, due to their stable structure, the fabrics of the present invention are more tolerant to variations in heat setting parameters.
- The fabric exhibited a warp modulus of 6000 PSI (pounds per square inch) measured by the ASTM D-1682-64 standard of the American Society for Testing and Materials. The fabric stretched less that 0.2% in length during heat setting. This result renders the manufacture of fabrics in accordance with the teachings of the present invention very reliable in achieving desired dimensional characteristic as compared to conventional fabrics.
- The resultant heat set fabric had 12.5 CMD yarns per inch per layer with 106% MD warp fill with respect to both upper and lower MD yarns resulting in 212% actual warp fill for the fabric. The finished fabric has a permeability of 83CFM as measured by the ASTM D-737-75 standard.
- As illustrated in Figure 4a, when the
fabric 10 is woven the three layers ofCMD yarns - It will be recognized by those of ordinary skill in the art that if either
top MD yarns bottom MD yarns upper yarns lower layer yarns - Such variations can be used to achieve a selected degree of permeability. Alternatively, such variations could be employed to make a forming fabric. In such a case, the lower MD yarns would be woven 100% warp fill to define the machine side of the fabric and the upper MD yarns would be woven at a substantially lower percentage of fill to provide a more open paper forming surface.
- The stacked pair MD weave permits the formation of orthogonal seaming loops within MD yarns. With reference to Figures 4a-d, after the fabric has been woven and heat set (Figure 4a), CMD yarns are removed leaving the crimped
MD yarns lower yarn 15, of the stacked pair is trimmed back a selected distance leaving the other exposedMD yarn 14 of the MD yarn pair and vacated space between the CMD yarns, as illustrated in Figure 4c.Upper MD yarn 14 is then backwoven into the space vacated in the weave pattern bylower MD yarn 15 such that a loop L is formed on the end of the fabric, as illustrated in Figure 4d. Preferably, between 0.5 - 5.0 inches ofupper layer yarn 14 is backwoven into the fabric to provide sufficient strength for the end loop and assure retention of the free end ofMD yarn 14 within the weave of the fabric. The inverted image weave permits the crimp of theupper MD yarn 14 to match the space vacated by thelower MD yarn 15 which further enhances the strength of the end loop. - As shown in phantom in Figure 4d,
adjacent yarn pair upper yarn 16 is looped back and backwoven in the fabric, it is pulled against the CMD yarns. In the preferred embodiment, wherein the upper MD yarns are woven 100% fill, the crowding of the yarns secure the orthogonal orientation of the seaming loops. - To achieve a uniform seam for a fabric woven in accordance with the weave pattern depicted in Figure 1, each
upper MD yarn 14 forms a loop and the otherupper MD yarns - Preferably,
loop forming yarns 14 would all be backwoven approximately the same distance within the fabric to provide sufficient strength to prevent the loops from being pulled apart during normal usage. Non-loop formingyarns upper MD yarns 14 would be backwoven approximately 3 inches,MD yarns 16 would be backwoven approximately 2 inches, andMD yarns 18 would be backwoven approximately 1 inch. Respectivelower layer yarns yarn pair yarns - Figures 5a and 5b, respectively, illustrate a
conventional seaming loop 50 in comparison with an orthogonal seaming loop L of the present invention. In conventional loop forming techniques, theMD yarn 51 is backwoven into the fabric adjacent to itself thereby inherently imparting twist and/or torque to theloop structure 50. In the present invention, the MD yarn is looped directly beneath itself and does not have any lateral offset which would impart such twist or torque to the seaming loop. - Referring to Figures 6, 7 and 8, there is shown a second preferred embodiment of a
fabric 20 made in accordance with the teachings of the present invention.Papermakers fabric 20 is comprised of a single layer ofCMD yarns upper MD yarns fabric 20 by weaving over three CMD yarns, under the next oneCMD yarn 21a to form a knuckle, and thereafter returning to float over the next three CMD yarns in a continuation of the repeat. -
Lower MD yarns upper MD yarns lower MD yarn CMD yarn 21a forming a knuckle and thereafter continues in the repeat to float under the next three CMD yarns. - As can be seen with respect to Figures 6 and 8, the knuckles formed by the
lower MD yarns upper MD yarns upper MD yarns lower MD yarns - The caliper of the fabric proximate the knuckle area shown in Figure 8, has a tendency to be somewhat greater than the caliper of the fabric at
non-knuckle CMD yarns 21b, shown in Figure 7. However, theCMD yarns 21a around which the knuckles are formed become crimped which reduces the caliper of the fabric in that area as illustrated in Figure 8. Additionally, slightly larger diameter CMD yarns are preferably used forCMD yarns 21b, shown in Figure 7, which are not woven around as knuckles by the MD yarns to eliminate any difference in fabric caliber. Preferably the diameter of thelarger CMD yarn 21b equals the diameter d of thesmaller CMD yarns 21a plus the thickness t of the MD yarns. - In one example, a fabric was woven in accordance with Figures 6-9, wherein the
CMD yarns - In another example, fabric was woven in accordance with Figures 6, 7 and 8, wherein the
CMD yarns -
- d =
- diameter of the CMD yarn
- Θ =
- the degree of arc over which there is contact between the MD and CMD yarns
- w =
- width of the MD yarn
- π =
- the constant pi.
- The degrees of arc over which MD yarns 22-25 are in contact with
CMD yarns 21a is dependent upon the spacing of the CMD yarns within the weave. For the above example, employing alternating 0.6mm and 0.8mm diameter CMD yarns with 0. 2mm thick MD yarns, the degree of contact arc can be maintained in a preferred range of between 60° to 180° by varying the pick count of the CMD yarns from 14 picks per inch to a maximum of 28.22 picks per inch. - In the preferred embodiment where the pick count is 20 picks per inch, the degree of contact arc Θ is approximately 101°. This results in a bracing contact area of approximately 0.79mm² at each knuckle in the fabric.
- Applicant's use of high ratio aspect yarns, i.e. yarns having a width: thickness ratio of at least 3:1, provides for increased bracing contact of the flat MD yarns with the
CMD yarns 21a. This is comparatively exemplified by modifying the equation for contact bracing area, CBA, to be defined in terms of the thickness of the MD yarns. - Since the MD yarn width w equals the thickness t of the MD yarn multiplied by the aspect ratio, w > 3t for yarns having an aspect ratio greater than 3:1. Accordingly, fabrics made in accordance with the teachings of the present invention utilizing high aspect ratio MD yarns exhibit enhanced bracing of the CMD yarns by the MD yarns such that:
- As best seen in Figure 10, seaming loops are formed by
upper MD yarns 22. The respectivelower MD yarns 23 are trimmed a selected distance from the fabric end and theupper MD yarns 22 are backwoven into the space vacated by the trimmedlower MD yarns 23. -
Upper MD yarns 24 are similarly backwoven into the space vacated by trimming backlower MD yarns 25. However, as best seen in Figure 10,upper MD yarns 24 are backwoven against the madness CMDyarn 21b. - As illustrated in Figure 11, a series of seaming loops is formed on each of the opposing fabric ends 27, 28. When the fabric is installed on papermaking equipment, the respective end loops formed by
MD yarns 22 are intermeshed and apintle 30 is inserted therethrough to lock the intermeshed series of loops together. - Since the seaming loops L are formed by
backweaving MD yarns 22 directly beneath themselves, no lateral twist or torque is imparted on the loop and the loops are orthogonal with the plane of the fabric. This facilitates the intermeshing of the loop series of the opposing fabric ends 27, 28. The orthogonal loops are particularly advantageous where, as shown in Figure 10, theMD yarns loop MD yarns 22. Lateral torque or twist on the seaming loops make the seaming process more difficult particularly where the loop-receiving gaps between the loops of one fabric end are essentially the same width as the loops on the opposing fabric end and vice versa. - With reference to the fabric depicted in Figures 6-11, the loop forming
MD yarns 22 are preferably backwoven approximately 2 inches while the non-loop formingMD yarns 24 are preferably backwoven 1 inch. - With reference to Figure 12, a third embodiment of a
papermakers fabric 30 is shown.Fabric 30 comprises a single layer ofCMD yarns 31 interwoven with stacked pairs of flat monofilament yarns in a selected repeat pattern. For clarity, only one pair of stacked MD yarns is shown comprisingupper MD yarn 32 andlower MD yarn 33. The upper MD yarns weave in a float over twoCMD yarns 31, form a single knuckle under thenext CMD yarn 31 and thereafter repeat. Similarly the lower MD yarns weave in an inverted image of the upper MD yarns weaving under twoCMD yarns 31, forming a knuckle over thenext CMD yarn 31 and then returning to the bottom surface of the fabric in the repeat. Since the repeat of both the upper and lower MD yarns is with respect to threeCMD yarns 31, a total of three different stacked pairs of yarns comprise the weave pattern of the MD yarn system. - A fabric was woven in accordance with Figure 12 wherein the
CMD yarns 31 were polyester monofilament yarns 0.7mm in diameter interwoven with MD yarns which were flat polyester monofilament yarns having a width of 1.12mm and a height of 0.2mm. Accordingly, the aspect ratio of the flat MD yarns was 5.6:1. The fabric was woven 48 warp ends per inch under a loom tension of 60 PLI and 18 CMD pick yarns per inch. The fabric was heat set using conventional methods. The fabric exhibited amodulus of 6000 PSI. The fabric stretched less than 0.2% in length during heat setting. The resultant fabric had 18 CMD yarns per inch with 106% MD warp fill with respect to both upper and lower MD yarns resulting in 212% actual warp fill for the fabric. The finished fabric having a caliper of 0.046 inches and an air permeability of 66CFM. - With reference to Figure 13, a fourth embodiment of a
papermakers fabric 40 is shown.Fabric 40 comprises upper, middle and lower layers ofCMD yarns upper MD yarn 44 and lower MD yarn 45. The upper MD yarns weave in a float over two upper layer CMDyarns 41, under thenext yarn 41 and amiddle layer yarn 42 to form a single knuckle, under thenext CMD yarn 41 and thereafter rise to the top surface to continue to repeat. Similarly, the lower MD yarns weave in an inverted image of the upper MD yarns weaving under two lowerlayer CMD yarns 43 over thenext CMD yarn 43 and amiddle CMD yarn 42 forming a knuckle, over thenext CMD yarn 43 then returning to the bottom surface of the fabric to repeat. Since the repeat of both the upper and lower MD yarns is with respect to four upper andlower CMD yarns - A fabric was woven in accordance with Figure 13, wherein the upper and lower
layer CMD yarns yarns 42 were polyester monofilament yarns 0.5mm in diameter interwoven with MD yarns 22-25 which were flat polyester monofilament yarns having a width of 0.60mm and a height of 0.38mm. Accordingly, the aspect ratio of the flat MD yarns was 1.58:1. The fabric was woven with 96 warp ends per inch under a loom tension of 40 PLI and 15 CMD pick yarns per inch per layer. The fabric was heat set using conventional methods. The resultant fabric had 15 CMD yarns per inch per layer with 113% MD warp fill with respect to both upper and lower MD yarns resulting in 226% actual warp fill for the fabric. The finished fabric had a caliper of .075 inches and an air permeability of 60CFM. - Figures 14, 15 and 16 illustrate the fifth, sixth and seventh embodiments of the present invention. Figure 14 illustrates the weave of a relatively long float on both sides of the fabric; Figure 15 illustrates how a stacked pair MD yarn weave can define floats of different lengths on opposite sides of the fabric; and Figure 16 illustrates how a stacked pair MD yarn weave can be used to construct fabrics having MD knuckles on one side of the fabric.
- Relatively long floats predominating the surfaces of a dryer fabric are beneficial for both the paper-carrying side as well as the machine side of the fabric. On the paper-carrying side, long floats provide greater contact area with the paper sheet for increased heat transfer. On the machine side, long floats provide increased wear surface and contact area to reduce bounce and flutter. The stacked pair MD yarn weave is versatile in allowing different surfaces to be defined on the top and bottom sides of the fabric. Accordingly, fabrics made in accordance with the teachings of the present invention may be used for other industrial purposes such as in the drying of sludge.
- With respect to Figure 14, a
fabric 50 is illustrated comprising three layers ofyarns upper layer yarn 54 andlower layer yarn 55, define relatively long floats on both the top and bottom surfaces of the fabric.Upper yarn 54 weaves over five upper layer CMDyarns 51, drops into the fabric to form a knuckle under one middlelayer CMD yarn 52, weaves under the nextupper layer yarn 51 and thereafter repeats.Lower MD yarn 55 weaves in an inverted image under five lowerlayer CMD yarns 53, rising into the fabric over thenext CMD 53 to weave a knuckle over one middlelayer CMD yarn 52 thereafter dropping to the bottom surface of the fabric to continue its repeat. In such a construction, six pairs of stacked MD yarns are utilized in the repeat of the fabric and are sequentially woven in a selected sequence to produce a desired pattern on the surfaces of the fabric which will be predominated by the MD yarn floats. - The embodiment shown in Figure 15 depicts a
fabric 60 in which the MD yarns weave with a five-float repeat on the top fabric surface and a two-float repeat on the bottom fabric surface. For example,upper MD yarn 64 interweaves with upper andmiddle CMD yarns upper MD yarn 54 weaves withrespective CMD yarns fabric 50 in Figure 14. However,lower MD yarn 65, which forms a stacked pair withupper MD yarn 64, weaves in a two-float bottom repeat with respect lower andmiddle CMD yarns lower MD yarn 65 floats under two lowerlayer CMD yarns 63, rises above thenext CMD yarn 63 to form a knuckle over one middlelayer CMD yarn 62 and thereafter drops to the bottom surface of thefabric 60 to continue to repeat. As with the other embodiments discussed above, the interior knuckles formed by the lower MD yarns are hidden by the upper MD yarn of the respective stacked pair and vice-versa. - The construction shown in Figure 15 permits different surfaces to be defined on the top and bottom of the fabric while utilizing the benefits of the stacked MD yarn pairing.
- The embodiment shown in Figure 16 discloses another example of a
fabric 70 having five-float MD yarns predominating the upper surface of the fabric, but with MD knuckles on the lower surface of the fabric. This type of construction may be advantageously used to construct a forming fabric where the upper fabric surface, having relatively long floats, would be used as the machine side of the fabric and the knuckled lower surface of the fabric would be used as the paper forming side. -
Fabric 70 includes three layers ofCMD yarns MD yarns 74, 75 is depicted for clarity. Upper MD yarn 74 weaves in a five-float pattern with respect to upper and middle layer CMDyarns upper MD yarn 54 with respect tofabric 50 shown in Figure 14.Lower MD yarn 75 weaves three interior knuckles and three lower surface knuckles with respect to middle and lowerlayer CMD yarns yarns 71 and the repeat of the lower MD yarns is defined with respect to only two lowerlayer CMD yarns 73. Accordingly, there are six different pairs of stacked MD yarns which constitute the MD yarn system which, as noted above, can be arranged such that a desired pattern is formed on the upper surface of the fabric. - Generally for stacked pair weaves, the repeat of the upper MD yarns will be equally divisible by, or an equal multiple of, the repeat of the lower MD yarns in defining the stacking pair relationship. For example, with respect to Figure 12 the repeat of the upper MD yarns is six upper layer CMD yarns which is equally divisible by the repeat of the lower MD yarns which is three lower layer CMD yarns.
- With respect to the eighth alternate embodiment shown in Figure 17, a
fabric 80 is illustrated having a single layer ofCMD yarns 81 and a representative stacked pair ofMD yarns Upper MD yarn 82 weaves with two floats overCMD yarns 81 with a repeat occurring with respect to threeCMD yarns 81.Lower MD yarn 83 weaves with five floats underCMD yarns 81 with a repeat of six CMDyarns 81. Thus, infabric 80, the repeat of the upper MD yarns, which is three, is an equal multiple of the repeat of lower MD yarns, which is six. - A variety of other weave patterns employing the paired stacked weave construction of the instant invention may be constructed within the scope of the present invention. For example, in some applications it may be desirable to have MD yarn surface floats over six or more CMD yarns. Such fabrics are readily constructed in accordance with the teachings of the present invention.
Claims (11)
- An industrial fabric, for example a papermakers fabric, comprising a single layer of CMD yarns interwoven with a system of MD yarns characterised in that alternate CMD yarns are crimped to a significantly greater degree than the respective adjacent CMD yarns in said single CMD layer.
- A fabric according to claim 1 wherein said CMD yarns include yarns of at least two different diameters and are interwoven in a selected repeat pattern such that the CMD yarns having the relatively smaller diameter are crimped significantly more than the CMD yarns having the relatively larger diameter.
- A fabric according to claims 1 or 2 wherein said:
MD yarns are flat monofilament yarns having paired upper and lower yarns stacked in vertical alignment; and
the actual warp fill of at least said upper MD yarns is in the range of 80% - 125%. - A fabric according to claims 1 or 2 wherein CMD yarns alternate between a first relatively larger diameter and a second relatively smaller diameter in said single CMD layer.
- A fabric according to claim 4 wherein said MD yarns are flat monofilament yarns having a thickness t and said first diameter is approximately equal to said second diameter plus t.
- A fabric according to claim 4 wherein said first diameter is about 0.8mm, said second diameter is about 0.6mm, and said MD yarns are flat monofilament yarns having a thickness of about 0.2mm.
- A fabric according to claims 1 or 2 wherein said CMD yarns are flat monofilament yarns having an
aspect ratio greater than 3:1. - A fabric according to claims 1 or 2 wherein said MD yarns repeat with respect to four of said CMD yarns with a float of three such that the first and third CMD yarns within the float are not the alternate CMD yarns which have the significantly greater degree of crimp.
- A fabric according to claim 8 wherein the float of some of said MD yarns is over three CMD yarns and the float of other of said MD yarns is under three CMD yarns within the fabric repeat.
- A fabric according to claim 9 wherein said MD yarns are flat monofilament yarns.
- A fabric according to claim 10 wherein each of the MD yarns which have floats under the CMD yarns are disposed beneath at least one MD yarn which has its float weaving over the CMD yarns.
Applications Claiming Priority (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US534164 | 1990-06-06 | ||
US07/534,164 US5103874A (en) | 1990-06-06 | 1990-06-06 | Papermakers fabric with stacked machine direction yarns |
US07/567,974 US5092373A (en) | 1990-06-06 | 1990-08-15 | Papermakers fabric with orthogonal machine direction yarn seaming loops |
US567974 | 1990-08-15 | ||
US07/654,008 US5117865A (en) | 1990-06-06 | 1991-02-14 | Papermakers fabric with flat high aspect ratio yarns |
US654008 | 1991-02-14 | ||
EP91907325A EP0532510B1 (en) | 1990-06-06 | 1991-03-15 | Papermakers fabric with flat machine direction yarns |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP91907325.4 Division | 1991-03-15 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0612881A1 true EP0612881A1 (en) | 1994-08-31 |
EP0612881B1 EP0612881B1 (en) | 1997-06-11 |
Family
ID=27415139
Family Applications (4)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP91907325A Expired - Lifetime EP0532510B1 (en) | 1990-06-06 | 1991-03-15 | Papermakers fabric with flat machine direction yarns |
EP92122165A Expired - Lifetime EP0553501B1 (en) | 1990-06-06 | 1991-03-15 | Papermakers fabric with flat machine direction yarns |
EP94103975A Expired - Lifetime EP0612882B1 (en) | 1990-06-06 | 1991-03-15 | Papermakers fabric with flat machine direction yarns |
EP94103974A Expired - Lifetime EP0612881B1 (en) | 1990-06-06 | 1991-03-15 | Papermakers fabric with flat machine direction yarns |
Family Applications Before (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP91907325A Expired - Lifetime EP0532510B1 (en) | 1990-06-06 | 1991-03-15 | Papermakers fabric with flat machine direction yarns |
EP92122165A Expired - Lifetime EP0553501B1 (en) | 1990-06-06 | 1991-03-15 | Papermakers fabric with flat machine direction yarns |
EP94103975A Expired - Lifetime EP0612882B1 (en) | 1990-06-06 | 1991-03-15 | Papermakers fabric with flat machine direction yarns |
Country Status (12)
Country | Link |
---|---|
EP (4) | EP0532510B1 (en) |
JP (4) | JP3655301B2 (en) |
AT (4) | ATE172764T1 (en) |
AU (1) | AU673615B2 (en) |
CA (1) | CA2084054C (en) |
DE (6) | DE553501T1 (en) |
DK (4) | DK0612881T3 (en) |
ES (4) | ES2063504T3 (en) |
FI (2) | FI96881B (en) |
NO (3) | NO305216B1 (en) |
NZ (1) | NZ237553A (en) |
WO (1) | WO1991019044A1 (en) |
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WO1999006631A1 (en) * | 1997-07-31 | 1999-02-11 | Asten, Inc. | Double layer fabric having a high stability weave |
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ATE131555T1 (en) * | 1991-10-11 | 1995-12-15 | Asten Inc | PAPER MAKER FABRIC WITH A CONNECTING SEAM MADE OF OWN THREAD AND METHOD FOR THE PRODUCTION THEREOF |
DE4302031C1 (en) * | 1993-01-26 | 1993-12-16 | Heimbach Gmbh Thomas Josef | Fourdrinier for paper mfg. machine for large contact surface area - comprises oven plastics filaments with gp. in sub-gps. shrunk for longitudinal filaments side by side, for flexibility |
ATE161298T1 (en) * | 1993-03-19 | 1998-01-15 | Jwi Ltd | HIGH LOOP DENSE SEAM |
GB9417720D0 (en) * | 1994-09-03 | 1994-10-19 | Scapa Group Plc | Papermakers fabric |
US5503196A (en) | 1994-12-07 | 1996-04-02 | Albany International Corp. | Papermakers fabric having a system of machine-direction yarns residing interior of the fabric surfaces |
US6079454A (en) * | 1997-11-24 | 2000-06-27 | Astenjohnson, Inc. | Loop/tie-back woven loop seam press base |
FR2789702B1 (en) * | 1999-02-16 | 2001-03-30 | Cofpa | SYMMETRICAL WEAVE JUNCTION FOR ASYMMETRIC WEAVE WEBBAND |
DE19923088C1 (en) * | 1999-05-20 | 2000-10-12 | Heimbach Gmbh Thomas Josef | Woven blanket for drying section of papermaking machine has paired longitudinal filaments pulled out into long and short loops at end sides for smooth surface on paper side when locked together by inserted wire |
JP2002013088A (en) * | 2000-06-27 | 2002-01-18 | Ichikawa Woolen Textile Co Ltd | Felt for papermaking |
JP4261341B2 (en) | 2001-07-05 | 2009-04-30 | アステンジョンソン・インコーポレーテッド | Industrial fabric including yarn assembly |
US20030208886A1 (en) * | 2002-05-09 | 2003-11-13 | Jean-Louis Monnerie | Fabric comprising shaped conductive monofilament used in the production of non-woven fabrics |
US6902652B2 (en) * | 2003-05-09 | 2005-06-07 | Albany International Corp. | Multi-layer papermaker's fabrics with packing yarns |
DE102005056618A1 (en) * | 2005-11-25 | 2007-05-31 | Voith Patent Gmbh | tissue structure |
JP4263201B2 (en) * | 2006-06-30 | 2009-05-13 | シキボウ株式会社 | Dryer canvas for papermaking |
US7617846B2 (en) * | 2006-07-25 | 2009-11-17 | Albany International Corp. | Industrial fabric, and method of making thereof |
US8025969B2 (en) | 2008-10-21 | 2011-09-27 | Voith Paper Holding Gmbh & Co. Kg | PET yarns with improved loop tensile properties |
CN104631189A (en) * | 2015-01-28 | 2015-05-20 | 安徽华宇网业有限公司 | Three-warp-yarn ribbon-like filament drying net |
DE102015101449A1 (en) * | 2015-02-02 | 2016-08-04 | AstenJohnson PGmbH | Industrial fabric, process for producing a nonwoven fabric and use of an industrial fabric |
CN104818642B (en) | 2015-05-22 | 2016-08-17 | 安平县鑫鹏网带有限公司 | A kind of technical fabric |
CN108291363A (en) * | 2015-09-30 | 2018-07-17 | 艾斯登强生股份有限公司 | High stability is stacked through dryer fabric |
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- 1991-03-15 DK DK94103975T patent/DK0612882T3/en active
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