U.S. patent application number 15/977239 was filed with the patent office on 2018-12-06 for high stability stacked warp yarn dryer fabric with long warp floats.
This patent application is currently assigned to AstenJohnson, Inc.. The applicant listed for this patent is AstenJohnson, Inc.. Invention is credited to Marc P. Despault.
Application Number | 20180347114 15/977239 |
Document ID | / |
Family ID | 64454932 |
Filed Date | 2018-12-06 |
United States Patent
Application |
20180347114 |
Kind Code |
A1 |
Despault; Marc P. |
December 6, 2018 |
HIGH STABILITY STACKED WARP YARN DRYER FABRIC WITH LONG WARP
FLOATS
Abstract
An industrial textile is provided, preferably suitable for use
as a dryer fabric in a papermaking machine. The industrial textile
has first and second surfaces and is defined by first and second
systems of warp yarns interwoven with a system of weft yarns in a
repeating pattern. In the repeating pattern, each of the warp yarns
in the first system of warp yarns is interwoven with the system of
weft yarns with a float on the first surface over at least 5 of the
weft yarns, under 1 of the weft yarns, over 1 of the weft yarns,
and under 1 of the weft yarns. Additionally, each of the warp yarns
in the second system of warp yarns is interwoven with the system of
weft yarns with a float on the second surface under at least 5 of
the weft yarns, over 1 of the weft yarns, under 1 of the weft
yarns, and over 1 of the weft yarns in the repeating pattern. Each
of the warp yarns of the first system of warp yarns is stacked over
a corresponding one of the warp yarns of the second system of warp
yarns to form stacked pairs of the warp yarns.
Inventors: |
Despault; Marc P.;
(Dunrobin, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
AstenJohnson, Inc. |
Charleston |
SC |
US |
|
|
Assignee: |
AstenJohnson, Inc.
Charleston
SC
|
Family ID: |
64454932 |
Appl. No.: |
15/977239 |
Filed: |
May 11, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62512327 |
May 30, 2017 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D03D 2700/02 20130101;
D10B 2331/301 20130101; D21F 7/083 20130101; D21F 1/0045 20130101;
D03D 3/04 20130101; D21F 7/12 20130101; D10B 2505/00 20130101; D10B
2331/04 20130101; D03D 1/0094 20130101; D03D 9/00 20130101; D03D
13/004 20130101; D03D 2700/0162 20130101; D21F 1/0036 20130101 |
International
Class: |
D21F 7/12 20060101
D21F007/12; D03D 13/00 20060101 D03D013/00; D03D 9/00 20060101
D03D009/00; D03D 3/04 20060101 D03D003/04; D03D 1/00 20060101
D03D001/00; D21F 1/00 20060101 D21F001/00; D21F 7/08 20060101
D21F007/08 |
Claims
1. An industrial textile having first and second surfaces, the
textile comprising: first and second systems of warp yarns
interwoven with a system of weft yarns in a repeating pattern in
which: each of the warp yarns in the first system of warp yarns is
interwoven with the system of weft yarns on the first surface over
at least 5 of the weft yarns, under 1 of the weft yarns, over 1 of
the weft yarns, and under 1 of the weft yarns in the repeating
pattern forming a float on the first surface over the at least 5 of
the weft yarns, each of the warp yarns in the second system of warp
yarns is interwoven with the system of weft yarns on the second
surface under at least 5 of the weft yarns, over 1 of the weft
yarns, under 1 of the weft yarns and over 1 of the weft yarns in
the repeating pattern forming a float on the second surface under
the at least 5 of the weft yarns, and each of the warp yarns of the
first system of warp yarns is stacked over a corresponding one of
the warp yarns of the second system of warp yarns to form stacked
pairs of the warp yarns.
2. The industrial textile of claim 1, wherein the float on the
first surface is over 7 weft yarns, and the float on the second
surface is under 7 weft yarns.
3. The industrial textile of claim 1, wherein the system of weft
yarns includes alternating larger diameter filler wefts and smaller
diameter critical picks.
4. The industrial textile of claim 3, wherein the warp yarns of the
first system of warp yarns only weave under the critical picks, and
the warp yarns of the second system of warp yarns only weave over
the critical picks.
5. The industrial textile of claim 1, wherein the repeating pattern
of the warp yarns of the first system of warp yarns of under 1 of
the weft yarns, over 1 of the weft yarns, and under 1 of the weft
yarns forms a locking weave for maintaining a position of the warp
warns of the first system of warp yarns, and the repeating pattern
of the warp yarns of the second system of warp yarns of over 1 of
the weft yarns, under 1 of the weft yarns, and over 1 of the weft
yarns forms a locking weave for maintaining a position of the warp
warns of the second system of warp yarns.
6. The industrial textile of claim 1, wherein the stacked pairs of
the warp yarns are spaced apart to form an open mesh pattern.
7. The industrial textile of claim 6, wherein the stacked pairs of
the warp yarns are spaced apart by at least 40% of a
cross-direction dimension of one of the warp yarns.
8. The industrial textile of claim 1, wherein the floats on the
first surface are arranged with a diagonal twill.
9. The industrial textile of claim 1, wherein the first system of
warp yarns is made from a different material than the second system
of warp yarns.
10. The industrial textile of claim 1, wherein the warp yarns of
the first and second systems of warp yarns have a rectangular
cross-section.
11. The industrial textile of claim 10, wherein the cross-section
of the warp yarns of the first and second systems of warp yarns are
the same.
12. The industrial textile of claim 10, wherein the weft yarns have
a circular cross-section.
13. The industrial textile of claim 12, wherein the system of weft
yarns includes alternating larger filler wefts having a diameter D1
and smaller critical picks having a diameter D2, the warp yarns of
the first and second systems of warp yarns with the rectangular
cross-section have a thickness t, wherein D1>D2, and
(D1-D2)/2.apprxeq.t.
14. The industrial textile of claim 1, wherein the first system of
warp yarns and second systems of warp yarns each have at least 100%
warp fill.
15. The industrial textile of claim 1, wherein the first and second
systems of warp yarns are woven with 8 sheds in 10 steps.
16. The industrial textile of claim 1, wherein the industrial
textile is a papermaking fabric.
17. The industrial textile of claim 1, wherein the industrial
textile is a dryer fabric for a papermaking fabric.
18. An industrial textile having first and second surfaces, the
textile comprising: first and second systems of warp yarns
interwoven with a system of weft yarns in a repeating pattern in
which: adjacent pairs of the warp yarns in the first system of warp
yarns are interwoven along a same path with the system of weft
yarns on the first surface over at least 5 of the weft yarns and
under 1 of the weft yarns in the repeating pattern forming adjacent
pairs of floats on the first surface over the at least 5 of the
weft yarns, adjacent pairs of the warp yarns in the second system
of warp yarns are interwoven along a same path with the system of
weft yarns on the second surface under at least 5 of the weft yarns
and over 1 of the weft yarns in the repeating pattern forming
adjacent pairs of floats on the second surface under the at least 5
of the weft yarns, and the adjacent pairs of warp yarns of the
first system of warp yarns are stacked over corresponding ones of
the adjacent pairs of warp yarns of the second system of warp yarns
to form stacked, adjacent pairs of the warp yarns.
19. The industrial textile of claim 18, wherein the system of weft
yarns includes alternating larger diameter filler wefts and smaller
diameter critical picks.
20. The industrial textile of claim 19, wherein the warp yarns of
the first system of warp yarns only weave under the critical picks,
and the warp yarns of the second system of warp yarns only weave
over the critical picks.
Description
BACKGROUND
[0001] The invention relates to industrial textiles, and more
particularly to papermaking fabrics.
[0002] Numerous weaves are known in the art which are employed to
achieve different results for different applications.
[0003] WO 2011/022831, which is assigned to the assignee of the
present invention, discloses a dryer fabric for a papermaking
machine having stacked warp yarns with about 193% warp fill woven
with filler wefts and critical picks.
[0004] U.S. Pat. No. 9,365,958 is directed to a stretchable fabric
for clothing that is a single layer woven with long floats and is
unrelated to papermaking fabrics or industrial conveying fabrics
used in papermaking or filtration operations. There is therefore no
need or concern with increasing the life of an industrial fabric,
and in particular, a papermaking fabric by providing a machine side
surface dominated by long machine direction (MD) floats for
increased wear resistance.
SUMMARY
[0005] The invention concerns an industrial textile, preferably
suitable for use as a dryer fabric in a papermaking machine. The
industrial textile has first and second surfaces and is defined by
first and second systems of warp yarns interwoven with a system of
weft yarns in a repeating pattern. In the repeating pattern, each
of the warp yarns in the first system of warp yarns is interwoven
with the system of weft yarns on the first surface over at least 5
of the weft yarns, under 1 of the weft yarns, over 1 of the weft
yarns, and under 1 of the weft yarns forming a float on the first
surface over the at least 5 of the weft yarns. Additionally, each
of the warp yarns in the second system of warp yarns is interwoven
with the system of weft yarns on the second surface under at least
5 of the weft yarns, over 1 of the weft yarns, under 1 of the weft
yarns, and over 1 of the weft yarns in the repeating pattern
forming a float on the second surface under the at least 5 of the
weft yarns. Each of the warp yarns of the first system of warp
yarns is stacked over a corresponding one of the warp yarns of the
second system of warp yarns to form stacked pairs of the warp
yarns.
[0006] In one embodiment, the float on the first surface is over 7
weft yarns, and the float on the second surface is under 7 weft
yarns.
[0007] Preferably, the system of weft yarns includes alternating
larger diameter filler wefts and smaller diameter critical
picks.
[0008] In one preferred arrangement, the warp yarns of the first
system of warp yarns only weave under the critical picks, and the
warp yarns of the second system of warp yarns only weave over the
critical picks.
[0009] Preferably, the repeating pattern of the warp yarns of the
first system of warp yarns of under 1 of the weft yarns, over 1 of
the weft yarns and under 1 of the weft yarns forms a locking weave
for maintaining a position of the warp yarns of the first system of
warp yarns, and the repeating pattern of the warp yarns of the
second system of warp yarns of over 1 of the weft yarns, under 1 of
the weft yarns, and over 1 of the weft yarns forms a locking weave
for maintaining a position of the warp warns of the second system
of warp yarns. In prefered arrangements for certain filter fabrics,
this allows the stacked pairs of the warp yarns to be spaced apart
to form an open mesh pattern while still maintaining a high
stability for the industrial textile. On one preferred arrangement,
the stacked pairs of the warp yarns are spaced apart by at least
40% of a cross-direction dimension of one of the warp yarns.
[0010] In one preferred arrangement, the floats on the first
surface are arranged with a diagonal twill.
[0011] In one embodiment, the first system of warp yarns is made
from a different material than the second system of warp yarns.
[0012] In several of the preferred arrangements, the warp yarns of
the first and second systems of warp yarns have a rectangular
cross-section. Preferably, the cross-section of the warp yarns of
the first and second systems of warp yarns are the same.
Preferably, the weft yarns have a circular cross-section. However,
this can be varied. The warp and/or weft yarns may be grooved
and/or profiled in the manner described by U.S. Pat. No. 6,773,786
to assist in rendering the fabric contamination resistant.
[0013] For a preferred application, the first system of warp yarns
and second system of warp yarns each have at least about 96% warp
fill. This is particulary useful for dryer fabrics for papermaking
machines.
[0014] In one arrangement where the floats in the first and second
systems of warp yarns are over 5 of the weft yarns on a top surface
and under 5 weft yarns on a bottom surface, the industrial textile
is woven with an 8 shed, 10 step pattern. Depending on the length
of the warp floats, the number of steps needed to weave the
industrial textile may need to be increased.
[0015] As noted above, the present industrial textile has preferred
applications as a papermaking fabric. The industrial textile is
preferably flat woven, and the ends are seamed to form an endless
belt that can then be used in papermaking applications on a
papermaking machine. One preferred application is a dryer fabric
for a papermaking fabric.
[0016] The resulting constructions are a rugged and wear resistant
industrial textile that resists warp nesting and canting and is
highly stable (meaning it is resistive to out of plane distortion
due in part to its diagonal stability). The fabric is adaptable to
a wide range of applications by appropriate selection of warp and
weft yarn types, sizes and shapes. For example, air permeability of
the fabric is easily adjusted according to need; the fabric can be
rendered temperature or contamination resistant by appropriate
selection of the warp yarn materials and sizes. In addition the
fabric provides for high seam strength due to the stacked warp
construction which preferably utilizes approximately 100% of the
warp yarns to form the seam, and which also provides the fabric
with approximately 200% warp fill. The term "warp fill" refers to
the amount of warp yarns in a given space relative to total space
considered. Warp fill can be over 100% when there are more warp
strands jammed into the available space than the space can
dimensionally accommodate in a single plane. A fabric with
approximately 200% warp fill or more may have two layers of warp
yarns each woven at at least approximately 100% warp fill. In this
context, those skilled in the art would understand that 190% to
210% would be considered approximately 200% warp fill. The fabric
can be highly stable, and resists creasing and distortion when the
warp yarns in each layer are woven at 100% warp fill, or more, and
are thus immediately adjacent to and braced against one another.
This in combination with the locking weave of the warp yarns
provides enhanced stability in combination with increased longevity
due to the long warp floats. The weave pattern of the novel fabrics
provide long floats of the warp yarns on both exterior surfaces
that enhance the ability of these fabrics to resist abrasive
wear.
[0017] The fabric design can be adapted for many different
applications by proper warp and weft selection which will allow the
fabric to obtain a wide range of air permeabilities. Although
fabric caliper (thickness) can be made low to allow for use in high
speed applications, the stability of the textile is maintained due
to the warp yarn bracing and locking weave provided with the weft
yarns. The two independent warp systems provide a further benefit
in that the materials used in each can be optimized to resist the
environmental effects to which each fabric surface is exposed. For
example, the monofilament warp yarns used to form a first fabric
surface can be comprised of PPS (polyphenylene sulfide) or PCTA
(polycylcohexane dimethanol terephthalic acid) polymers which are
more resistant to thermal and hydrolytic degradation than PET
(polyethylene terephthalate) yarns (and more expensive). Warp yarns
formed from PET polymer could be utilized on the paper side of the
textile (in papermaking applications) where heat and hydrolysis
resistance are less critical properties.
[0018] Fabrics according to the invention such as are shown in the
Figures were woven using rectangular cross-section polymeric
monofilament warp yarns whose dimensions are 0.25.times.1.05 mm or
0.36.times.1.07 mm to obtain a width to height ratio of between 4:1
and 3:1, but other cross-sectional shapes and ratios may be
employed. The weft yarns used in these fabrics have a generally
circular cross-sectional shape and range in size from about 0.50 mm
to 1.0 mm; although other sizes may be employed depending upon the
specific application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The foregoing Summary and the following detailed description
will be better understood when read in conjunction with the
appended drawings, which illustrate a preferred embodiment of the
invention. In the drawings:
[0020] FIG. 1 is a weave diagram showing a first embodiment of an
industrial textile having the present construction.
[0021] FIG. 2 is a cross-sectional view showing the weave pattern
of two of the stacked warp yarns in the fabric construction shown
in FIG. 1.
[0022] FIG. 3 is a top view of a second embodiment of an industrial
textile of the present construction.
[0023] FIG. 4 is a cross-sectional view showing the weave paths of
two pairs of stacked warp yarns shown in FIG. 3.
[0024] FIG. 5 is a top view of an industrial textile according to a
third embodiment of the present construction.
[0025] FIG. 6 is a cross-sectional view showing the weave path of
two pairs of the stacked warp yarns shown in FIG. 5.
[0026] FIG. 7 is a weave diagram showing a fourth embodiment of an
industrial textile having the present construction.
[0027] FIG. 8 is a cross-sectional view showing the weave pattern
of two of the stacked warp yarns in the fabric construction shown
in FIG. 7.
[0028] FIG. 9 is a weave diagram of a fifth embodiment of an
industrial textile having a high stability construction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Certain terminology is used in the following description for
convenience only and is not limiting. The fabric according to the
invention is an industrial textile, which can have many industrial
applications, such as conveyor belts, filtration fabrics, specialty
fabrics for non-woven applications, etc. The words "paper side"
(PS) and "machine side" (MS) designate surfaces of the fabric with
reference to their use in one preferred application in a
papermaking machine; however, these terms merely represent first
and second or upper and lower surfaces of the planar fabric. "Yarn"
is used to generically identify a monofilament or multifilament
fiber. "Warp" and "weft" are used to designate yarns or
monofilaments based on their position in the loom that extend in
perpendicular directions in the fabric and either could be a
machine direction (MD) or cross-machine direction (CMD) yarn in the
fabric once it is installed on a papermaking machine, depending on
whether the fabric is flat woven or continuously woven. In the
preferred arrangement, the fabric is flat woven and seamed at the
warp ends in order to form a continuous belt, so that the warp
yarns are MD yarns and the weft yarns are CMD yarns.
[0030] One preferred application of the fabrics according to the
invention is on a papermaking machine, and the fabric could have
application as a base for a press fabric, or a dryer fabric for use
in the corresponding press and dryer sections of a papermaking
machine. These are generally all referred to as a "papermaking
fabric" regardless of the position of use in a papermaking machine.
Other applications include filtration fabrics, as well as other
non-woven applications.
[0031] Referring to FIGS. 1 and 2, an industrial textile 20 in
accordance with a first preferred embodiment of the present
construction is illustrated using a weave diagram (FIG. 1) and a
cross-section taken along the MD. The industrial textile 20
includes a first surface 24 and a second surface 26. In one
preferred construction as a papermaking fabric, the first surface
24 corresponds to the PS and the second surface 26 corresponds to
the MS.
[0032] The industrial textile 20 is woven with first and second
systems of warp yarns 21, 22, which are interwoven with a system of
weft yarns 30 in a repeating pattern. The warp yarns are identified
as warp yarns 1-16, with the first group of warp yarns including
the even numbered warp yarns, i.e., 2, 4, 6, 8, 10, 12, 14, 16, and
the second system of warp yarns including the odd numbered warp
yarns, i.e. 1, 3, 5, 7, 9, 11, 13, 15. The weft yarns 31-40 are
interwoven with the warp yarns 1-16, of which preferably there are
alternating larger diameter filler wefts 31, 33, 35, 37, 39, and a
smaller diameter critical picks 32, 34, 36, 38, 40. Each of the
warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in the first system of warp
yarns 21 is interwoven with the system of weft yarns 30 with a
float on the first surface 24 over at least five of the weft yarns
31-40. In the first embodiment of the industrial textile 20, the
floats of each of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in the
first system of warp yarns 21 are over 7 of the weft yarns 31-40.
This is shown in connection with the warp yarn 2 in FIG. 2 and
would be true for each of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16
in the first system of warp yarns 21. In order to form a locking
weave each of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the
first system of warp yarns 21 then extends under one of the weft
yarns 32, 34, 36, 38, 40, over one of the weft yarns 31, 33, 35,
37, 39, and under another one of the weft yarns 32, 34, 36, 38, 40
in the repeating pattern. Preferably the warp yarns 2, 4, 6, 8, 10,
12, 14, 16 of the first system of warp yarns 21 only weave under
the critical picks 32, 34, 36, 38, 40. Preferably, the first and
second systems of warp yarns 21, 22 are woven with 8 sheds in 10
steps.
[0033] Each of the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 in the
second system of warp yarns 22 is interwoven with the system of
weft yarns 30 with a float on the second surface 26 under at least
five of the weft yarns 31-40. In the first embodiment 20,
preferably the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 in the second
system of warp yarns 22 are interwoven with the system of weft
yarns 30 with a float on the second surface under 7 of the weft
yarns 31-40. In order to form the locking weave, the warp yarns 1,
3, 5, 7, 9, 11, 13, 15 in the second system of warp yarns 22 then
weave over one of the weft yarns 32, 34, 36, 38, 40 under one of
the weft yarns 31, 33, 35, 37, 39, and over one of the weft yarns,
32, 34, 36, 38, 40 in the repeating pattern. As shown, each of the
warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first system of warp
yarns 21 is stacked over a corresponding one of the warp yarns 1,
3, 5, 7, 9, 11, 13, 15 of the second system of warp yarns 22 to
form stacked pairs of warp yarns. As illustrated in FIG. 2, warp
yarn 2 is stacked over warp yarn 1. With respect to the weave
diagram shown in FIG. 1, the even numbered warp yarns 2, 4, 6, 8,
10, 12, 14, 16 in the first system of warp yarns 21 are stacked
over the corresponding ones of the odd numbered warp yarns 1, 3, 5,
7, 9, 11, 13, 15 in the second system of warp yarns 22. The warp
yarns 1, 3, 5, 7, 9, 11, 13, 15 of the second system of warp yarns
22 only weave under the critical picks 32, 34, 36, 38, 40 which
have the smaller diameter D2 than the filler wefts 31, 33, 35, 37
which have a larger diameter D1. The repeating pattern of the warp
yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first system of warp yarns
21 of under one of the weft yarns, over one of the weft yarns and
under one of the weft yarns forms a locking weave for maintaining a
position of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first
system of warp yarns 21 in position within the industrial textile.
The repeating pattern of the warp yarns 1, 3, 5, 7, 9, 11, 13, 15
of the second system of warp yarns 22 of over one of the weft
yarns, under one of the weft yarns, and over one of the weft yarns,
also forms a locking weave for maintaining a position of the warp
yarns 1, 3, 5, 7, 9, 11, 13, 15 of the second system of warp yarns
22 in position.
[0034] In a preferred arrangement of the industrial textile 20,
100% warp fill is provided for each of the first and second systems
of warp yarns 21, 22, which, in combination with the locking
weaves, provide an extremely stable fabric 20.
[0035] In a preferred arrangement, the warp yarns 1-16 preferably
have a rectangular cross-sectional shape which contributes to the
stability of the fabric 20 and its smoothness. The warp yarns 1-16
are preferably monofilaments formed of a polymeric material. In one
embodiment, the dimensions are 0.25.times.1.05 mm or
0.36.times.1.07 mm to obtain a width to height ratio of between 4:1
and 3:1. Those skilled in the art will recognize that other
cross-sectional shapes and ratios may also be used, such as oval or
flattened shapes with rounded sides and aspect ratios of 2:1 to
6:1. The weft yarns 31-40 preferably have a circular
cross-sectional shape that in some preferred arrangements may range
in size from 0.6 mm, 0.7 mm, 0.8 mm, or 0.9 mm. Other sizes may
also be used depending on the intended application for the fabric.
In one preferred arrangement, the fabric 20 is woven at 22 picks
per inch (weft yarns per inch) (8.7 yarns/cm).
[0036] The use of first and second systems of warp yarns, 21, 22
also allow different materials to be used for the first and second
system of warp yarns 21, 22 in order to provide optimal materials
on the first and second surfaces 24, 26, of the industrial textile
20 for the preferred application.
[0037] For example, the monofilament warp yarns 2, 4, 6, 8, 10, 12,
14, 16 of the first system of warp yarns 21 used to form the first
surface 24 can be comprised of PPS (polyphenylene sulfide) or PCTA
(polycylcohexane dimethanol terephthalic acid) polymers which are
more resistant to thermal and hydrolytic degradation than PET
(polyethylene terephthalate) yarns (and more expensive). The warp
yarns 1, 3, 5, 7, 9, 11, 13, 15 of the second system of warp yarns
can be formed from PET polymer since the PS of the textile (at
least in papermaking applications) is where heat and hydrolysis
resistance are less critical yarn properties. Those skilled in the
art will understand from the present disclosure that these
materials are merely exemplary, and that other materials could be
used depending on the particular application. These warp yarns 1-16
may be grooved, profiled, coated, or otherwise treated for
contamination resistance.
[0038] Additionally, due to the long warp floats, a higher contact
area can be achieved that reduces fabric wear rates in comparison
to similar fabrics having more defined knuckles due to the weave.
The long warp floats also provide for benefits in contamination
resistance in comparison to similar weft proud fabrics.
[0039] Preferably, industrial textile 20 is formed into a
continuous loop for use as a papermaking fabric, and more
particularly as a papermaking dryer fabric, for use on a
papermaking machine. In order to form the loop, a seam is created
at the ends of the warp yarns 1-16. Preferably, the seam uses 100%
of the warp yarns to form the seam. Seams can be formed in a known
manner by unweaving and back-weaving warp yarns from the first
system of warp yarns 21 back into the fabric along the paths of the
corresponding stacked ones of the warp yarns from the second system
of warp yarns 22 that have been cut back from the end of the fabric
to form seam loops at each end of the planar fabric, with the seam
loops then being interdigitated and joined by a pintle to form an
endless fabric loop. Other types of seaming, such as QuickLink
seam, which was developed by AstenJohnson, the assignee of the
present invention, can also be utilized. In a preferred arrangement
for papermaking, the warp fill is preferably about 200% warp fill,
with each layer having warp yarns woven at about 100% warp fill.
This contributes to the stability of the industrial textile 20 and
helps to resist creasing and distortion due to the fact that the
warp yarns 1-16 in each layer are woven at about 100% warp fill,
and thus are immediately adjacent to and braced against one
another. This in connection with the locking weave provides
enhanced fabric stability for the industrial textile 20.
[0040] Referring to FIGS. 3 and 4, a second embodiment of an
industrial textile 120 is shown. The industrial textile 120 is
similar to the industrial textile 20 and includes first and second
systems of warp yarns 121, 122 that are interwoven with a system of
weft yarns 130. The arrangement is similar to the industrial
textile 20 with the exception that the floats in the first warp
system 121 are over five of the weft yarns 131-138 and the floats
in the second system of warp yarns 122 are under 5 of the weft
yarns 131-138. The warp yarns 102, 104 of the first system of warp
yarns 121 are woven in stacked pairs over the warp yarns 101, 103
of the second system of warp yarns 122 as shown. The warp yarn 102
weaves over weft yarns 131-135, under weft yarn 136 over weft yarn
137 and under weft 138. As in the first embodiment, the weft yarns
132, 134, 136, 138 are critical pics having a smaller diameter than
the filler wefts 131, 133, 135, 137. The warp yarn 101 of the
second system of warp yarns 122, which is stacked under the warp
yarn 102, weaves under weft yarn 131, over weft yarn 132, under
weft yarn 133, over weft yarn 134, and then under weft yarns
135-138. The next stacked pair of warp yarns 104, 103 are woven
with the warp yarn 104 extending over weft yarn 131, under weft
yarn 132, over weft yarn 133, under weft yarn 134, and over weft
yarns 135-138. The warp yarn 103 which is stacked under the warp
yarn 104 weaves under weft yarns 131-135 over weft yarn 136, under
weft yarn 137, and over weft yarn 138. This stacked arrangement of
warp yarns 101-104 extends across the fabric width in an
alternating arrangement as shown in FIG. 3. As in the industrial
textile 20, the warp yarns 102, 104 of the first system of warp
yarns 121 only weave under the critical pics 132, 134, 136, 138 and
the warp yarns 101, 103 of the second system of warp yarns 122 only
weave over the critical pics 132, 134, 136, 138. As in the first
embodiment of the industrial textile 20, each of the warp yarns
102, 104 in the first system of warp yarns 121 forms a locking
weave after each float by weaving under one of the weft yarns 132,
134, 136, 138 over one of the weft yarns 131, 133, 135, 137 and
under one of the weft yarns 132, 134, 136, 138. Similarly, the warp
yarns 101, 103 of the second system of warp yarns 122 form a
locking weave after each of the floats by weaving over one of the
weft yarns 132, 134, 136, 138, under one of the weft yarns 131,
133, 135, 137, and over one of the weft yarns 132, 134, 136, 138.
This provides enhanced stability for the fabric 120 which is also
preferably woven with 100% warp fill in each of the first system of
warp yarns 121 and the second system of warp yarns 122. The warp
yarns 101-104 and the weft yarns 131-138 are similar to the warp
yarns 1-16 and weft yarns 31-40 as described above in connection
with the first embodiment of the industrial textile 20. As shown in
FIG. 3, this arrangement provides a diagonal twill on the first
surface 124 of the industrial textile 120. A diagonal twill would
also be provided on the second surface 126.
[0041] Referring now to FIGS. 5 and 6, a third embodiment of the
industrial textile 120' is shown. The third embodiment of the
industrial textile 120' is woven with the same repeating weave
pattern as the second embodiment of the industrial textile 120 and
similar elements have been marked with the same reference numbers
as in the second embodiment with a prime. For example, the warp
yarns 101'-104' correspond to the warp yarns 101-104 in the second
embodiment 120, and the weft yarns 131'-138' correspond with the
weft yarns 131-138 of the second embodiment 120. The primary
difference is that based on the locking weave provided for the warp
yarns 101'-104', the warp yarns 101'-104' in each of the layers are
woven with less than 80% warp fill in order to provide an open
mesh. In a preferred embodiment, the first system of warp yarns
121' is woven with approximately 50% warp fill and the second
system of warp yarns 122' is also woven with approximately 50% warp
fill so that an open mesh dryer fabric as shown in FIG. 5 can be
produced. The stacked pairs of warp yarns 102', 101', and 104',
103', are maintained in position by their locking weave as
discussed above in connection with the industrial textile 120. This
allows for further applications of the industrial textiles
according to the invention.
[0042] Preferably the industrial textiles 120, 120' are formed into
endless belts by seaming at the warp ends as discussed above in
connection with the first embodiment of the industrial textile 20.
A preferred application for the industrial textile 120 is as a
papermaking fabric, and in particular, a dryer fabric for a
papermaking machine.
[0043] A preferred application for the industrial textile 120' is
for use as a dryer fabric. However, those skilled in the art will
recognize that there are other applications.
[0044] Referring to FIGS. 7 and 8, a fourth embodiment of an
industrial textile 220 is shown. The industrial textile 220 is
similar to the industrial textile 20 and includes first and second
systems of warp yarns 221, 222 that are interwoven with a system of
weft yarns 230. The arrangement is similar to the industrial
textile 20 with the exception that the floats in the first warp
system 221 are over seven of the weft yarns 231-242 and the floats
in the second system of warp yarns 222 are under 7 of the weft
yarns 231-242. The warp yarns 202, 204, 206, 208, 210, 212, 214,
216 of the first system of warp yarns 221 are woven in stacked
pairs over the warp yarns 201, 203, 205, 207, 209, 211, 213, 215 of
the second system of warp yarns 222 as shown. The warp yarn 202
weaves over weft yarns 231-237, under weft yarn 238 over weft yarn
239 and under weft 240. In a similar manner to the first
embodiment, the weft yarns 232, 234, 236, 238, 240, 242 are
critical pics having a smaller diameter than the filler wefts 231,
233, 235, 237, 239. 241. The warp yarn 201 of the second system of
warp yarns 222, which is stacked under the warp yarn 202, weaves
under weft yarn 231, over weft yarn 232, under weft yarn 233, over
weft yarn 234, and then under weft yarns 235-242. The next stacked
pair of warp yarns 204, 203 are woven with the warp yarn 204
extending over weft yarn 231, under weft yarn 232, over weft yarn
233, under weft yarn 234, and over weft yarns 235-242. The warp
yarn 203 which is stacked under the warp yarn 204 weaves under weft
yarns 231-237 over weft yarn 238, under weft yarn 239, and over
weft yarn 240, under weft yarn 241, and over weft yarn 242. The
weave diagram in FIG. 7 shows the paths of the remaining stacked
pairs of warp yarns in a clearly defined manner, and in this
embodiment, the warp pattern repeats with warp yarns 205-208 having
the same weave pattern as warp yarns 201-204. The stacked
arrangement of warp yarns 201-216 extends across the fabric width.
As in the industrial textile 20, the warp yarns 202, 204, 206, 208,
210, 214, 216 of the first system of warp yarns 221 only weave
under the critical pics 232, 234, 236, 238, 240, 242 and the warp
yarns 201, 203, 205, 207, 209, 211, 213, 215 of the second system
of warp yarns 222 only weave over the critical pics 232, 234, 236,
238, 240, 242. As in the first embodiment of the industrial textile
220, each of the warp yarns 202, 204, 206, 208, 210, 212, 214, 216
in the first system of warp yarns 221 forms a locking weave after
each float by weaving under one of the weft yarns 232, 234, 236,
238, 240, 242 over one of the weft yarns 231, 233, 235, 237, 239,
241 and under one of the weft yarns 232, 234, 236, 238, 240, 242.
Similarly, the warp yarns 201, 203, 205, 207, 209, 211, 213, 215 of
the second system of warp yarns 222 form a locking weave after each
of the floats by weaving over one of the weft yarns 232, 234, 236,
238, 240, 242 under one of the weft yarns 231, 233, 235, 237, 239,
241 and over one of the weft yarns 232, 234, 236, 238, 240, 242.
This provides enhanced stability for the fabric 220 which is also
preferably woven with 100% warp fill in each of the first system of
warp yarns 221 and the second system of warp yarns 222. The warp
yarns 201-216 and the weft yarns 231-242 are similar to and can
have the same constructions as the warp yarns 1-16 and weft yarns
31-40 as described above in connection with the first embodiment of
the industrial textile 20. As shown in FIG. 7, this arrangement
provides a diagonal twill on the first surface 224 of the
industrial textile 220. A diagonal twill would also be provided on
the second surface 226.
[0045] FIG. 9 shows a further alternative embodiment of a high
stability industrial textile 320 is shown. The industrial textile
320 includes first and second systems of warp yarns 321, 322 that
are interwoven with a system of weft yarns 330. Here, the floats in
the first warp system 321 are over at least 5, and preferably over
seven of the weft yarns 331-338 and the floats in the second system
of warp yarns 322 are under at least 5 and preferably under 7 of
the weft yarns 331-338. The warp yarns 301-316 are woven in
adjacent pairs that are stacked. Adjacent warp yarns 303, 304 are
arranged on the first surface 324 and are woven along the same path
over at least 5 of the weft yarns 331-338, and are stacked over
adjacent warp yarns 301, 302 which are arranged on the second
surface 326 and are woven along the same path under at least 5 of
the weft yarns 331-338. Adjacent first surface warp yarns 307, 308
are also woven along the same path and are stacked over adjacent
second surface warp yarns 305, 306 which are woven along the same
path. Similarly, adjacent first surface warp yarns 311, 312 are
also woven along the same path over at least 5 of the weft yarns
331-338 and are stacked over adjacent second surface warp yarns
309, 310 that are woven along the same path under at least 5 of the
weft yarns, and adjacent first surface warp yarns 315, 316 are also
woven along the same path over at least 5 of the weft yarns 331-338
and are stacked over adjacent second surface warp yarns 313, 314
that are woven along the same path under at least 5 of the weft
yarns. The weave diagram in FIG. 9 shows the repeat, and in this
example, the warp yarn floats are over/under 7 of the weft yarns
331-338. Based on the paired arrangement of the warp yarns 301-316
in the first surface 324 and the second surface 326, a distinct
double float arrangement is provided with a distinct diagonal
twill. As shown, the warp yarns 303, 304 of the first system of
warp yarns 321 weave over weft yarns 331-337, and under weft yarn
338. The warp yarns 301, 302 of the second system of warp yarns
322, which are stacked under the warp yarns 303, 304, weave under
weft yarns 331-333, over weft yarn 334, and under weft yarns
335-338. The next adjacent pair of warp yarns 307, 308 are woven as
an adjacent pair over weft yarns 231-233, under weft yarn 234, and
over weft yarns 235-238. The adjacent warp yarns 205, 206 which are
stacked under the warp yarns 207, 208 weave under weft yarns
231-237, and over weft yarn 238. The arrangement of adjacent warp
yarns 311, 312 of the first system of warp yarns 321 over adjacent
warp yarns 309, 310 of the second system of warp yarns 322, as well
as the arrangement of adjacent warp yarns 315, 316 of the first
system of warp yarns 321 over adjacent warp yarns 313, 314 of the
second system of warp yarns 322 are similar. The interweaving of
the warp yarns of the first and second systems of warp yarns 321,
322 is only with critical pics 332,334, 336, 338, and not with the
filler wefts 331, 333, 335, 337. Preferably the warp fill is about
200% warp fill, with each layer having warp yarns woven at about
100% warp fill. This contributes to the stability of the industrial
textile 320 and helps to resist creasing and distortion due to the
fact that the warp yarns 301-316 in each layer are woven at about
100% warp fill, and thus are immediately adjacent to and braced
against one another.
[0046] In order to provide for smooth first and second surfaces 24,
26, of the fabric 20, as well as the first and second surfaces 124,
126; 124', 126'; 224, 226; 324, 326 of the industrial textiles 120,
120', 220, 320 preferably, the filler wefts 31, 33, 35, 37, 39;
131, 133, 135, 137; 131', 133', 135', 137'; 231, 233, 235, 237,
239, 241; 331, 333, 335, 337 have a diameter D1 and the smaller
critical pics 32, 34, 36, 38, 40; 132, 134, 136, 138; 132', 134',
136', 138'; 232, 234, 236, 238, 240, 242; 332, 334, 446, 338 have a
diameter D2 which is smaller than D1, and the warp yarns 1-16,
101-104, 101'-104', 210-216, 301-316 have a rectangular
cross-section with a thickness t. Preferably, (D1-D2)/2.apprxeq.2t.
This provides for generally smooth first and second surfaces in the
industrial textiles 20, 120, 120', 220, 320. In one exemplary
embodiment D1=0.90 mm, D2=0.60 mm and t=1.55 mm. Those skilled in
the art will recognize that other dimensions could be used
depending on the particular application.
[0047] Having thus described the present invention in detail, it is
to be appreciated and will be apparent to those skilled in the art
that many physical changes, only a few of which are exemplified in
the detailed description of the invention, could be made without
altering the inventive concepts and principles embodied therein. It
is also to be appreciated that numerous embodiments incorporating
only part of the preferred embodiment are possible which do not
alter, with respect to those parts, the inventive concepts and
principles embodied therein. The present embodiment and optional
configurations are therefore to be considered in all respects as
exemplary and/or illustrative and not restrictive, the scope of the
invention being indicated by the appended claims rather than by the
foregoing description, and all alternate embodiments and changes to
this embodiment which come within the meaning and range of
equivalency of said claims are therefore to be embraced
therein.
* * * * *