U.S. patent application number 17/159579 was filed with the patent office on 2021-05-20 for industrial two-layer fabric.
The applicant listed for this patent is NIPPON FILCON CO., LTD.. Invention is credited to Shinya Murakami, Ikuo Ueda, Hideyuki Yanai.
Application Number | 20210148015 17/159579 |
Document ID | / |
Family ID | 1000005382236 |
Filed Date | 2021-05-20 |
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United States Patent
Application |
20210148015 |
Kind Code |
A1 |
Ueda; Ikuo ; et al. |
May 20, 2021 |
INDUSTRIAL TWO-LAYER FABRIC
Abstract
Provided is an industrial two-layer fabric satisfying basic
characteristics of a fabric. The industrial two-layer fabric
pertaining to the present invention has at least a first structure
and a second structure in the weave repeat thereof, the first
structure being formed by a combination of two upper-surface-side
warps and a single lower-surface-side warp, the second structure
being formed by a single upper-surface-side warp and a single
lower-surface-side warp, the first structure and the second
structure being disposed adjacent to each other, the
upper-surface-side warps in the first structure being formed by a
warp binding yarn having the function of binding an
upper-surface-side fabric and a lower-surface-side fabric, the
combination of two upper-surface-side warps forming the first
structure being disposed adjacent to each other and constituting a
partial rib weave at the surface of the upper-surface-side
fabric.
Inventors: |
Ueda; Ikuo; (Shizuoka,
JP) ; Murakami; Shinya; (Shizuoka, JP) ;
Yanai; Hideyuki; (Shizuoka, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIPPON FILCON CO., LTD. |
Tokyo |
|
JP |
|
|
Family ID: |
1000005382236 |
Appl. No.: |
17/159579 |
Filed: |
January 27, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/JP2019/027881 |
Jul 16, 2019 |
|
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17159579 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D21F 1/0036 20130101;
D03D 15/46 20210101; D03D 11/00 20130101 |
International
Class: |
D03D 11/00 20060101
D03D011/00; D03D 15/46 20060101 D03D015/46 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 31, 2018 |
JP |
2018-143611 |
Claims
1. An industrial two-layer fabric comprising an upper-surface-side
fabric formed from upper-surface-side warps and upper-surface-side
wefts, lower-surface-side warps, and lower-surface-side wefts,
wherein the industrial two-layer fabric has at least a first
structure and a second structure in a weave repeat thereof, the
first structure being formed by a combination of two
upper-surface-side warps and a single lower-surface-side warp, the
second structure being formed by a single upper-surface-side warp
and a single lower-surface-side warp, the first structure and the
second structure being disposed adjacent to each other, the
upper-surface-side warps in the first structure being formed by a
warp binding yarn having the function of binding an
upper-surface-side fabric and a lower-surface-side fabric, the
combination of two upper-surface-side warps forming the first
structure being disposed adjacent to each other and constituting a
partial rib weave at the surface of the upper-surface-side fabric,
the diameter of the lower-surface-side warp being larger than the
diameter of the upper-surface-side warp forming the first
structure, and the upper-surface-side warp in the second structure
being formed by a flat warp.
2. The industrial two-layer fabric according to claim 1, wherein
the diameter of the lower-surface-side warp forming the first
structure is 130% to 300% of the diameter of the upper-surface-side
warp forming the first structure.
3. The industrial two-layer fabric according to claim 1, wherein
the aspect ratio of the flat warp is 1.1 to 2.0 in the second
structure.
4. The industrial two-layer fabric according to claim 2, wherein
the aspect ratio of the flat warp is 1.1 to 2.0 in the second
structure.
5. The industrial two-layer fabric according to claim 1, wherein
the first structure and the second structure are formed being
arranged alternately.
6. The industrial two-layer fabric according to claim 2, wherein
the first structure and the second structure are formed being
arranged alternately.
7. The industrial two-layer fabric according to claim 3, wherein
the first structure and the second structure are formed being
arranged alternately.
8. The industrial two-layer fabric according to claim 4, wherein
the first structure and the second structure are formed being
arranged alternately.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of
priority from the prior Japanese Patent Application No.
2018-143611, filed on Jul. 31, 2018 and International Patent
Application No. PCT/JP2019/027881, filed on Jul. 16, 2019, the
entire content of each of which is incorporated herein by
reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates to a new industrial two-layer
fabric that has a thin net thickness, is excellent in rigidity,
wear resistance, dewaterability, and mark suppression, and can be
used in a high-speed paper machine. In particular, the present
invention relates to an industrial two-layer fabric that has a flat
yarn structure due to the formation of an upper-surface-side fabric
by a combination of a warp rib weave structure of two
upper-surface-side warps and a flat warp and that further achieves
slow dewatering and low water retention effects due to a warp
binding arrangement.
2. Description of the Related Art
[0003] Traditionally, fabrics made of warp and weft have been
widely used as industrial fabrics. For example, the fabrics include
fabrics for paper manufacturing, conveying belts, filter cloths,
etc., and are each required to have fabric characteristics suitable
for their application and usage environment. Of these fabrics, the
demand for fabrics for papermaking used in a papermaking process
of, e.g., dewatering materials using the mesh of the fabrics is
particularly strict. For example, there is a demand for fabrics
that show excellent surface smoothness that prevents wire marks of
the fabrics from easily transferred to paper, that have
dewaterability for sufficiently and uniformly dewatering excess
water contained in the materials and rigidity and wear resistance
that allow the fabrics to be suitably used even in a harsh
environment, and that can maintain conditions necessary for
producing better paper for a long period of time. In addition,
fiber supporting properties, improvement in yield in paper
manufacturing, dimensional stability, running stability, etc., are
required. Furthermore, since the speed of papermaking machines has
increased in recent years, the demand for fabrics for papermaking
has become even stricter.
[0004] Taking, as an example, fabrics for papermaking for which the
demand is the strictest among industrial fabrics, mark suppression
by particularly excellent dewaterability and surface smoothness is
required with the recent increase in the speed of paper machines.
Although dewaterability characteristics that are required differ
depending on paper machines and sheeted products, dewaterability
for uniform dewatering is an essential condition for any sheeted
product. Further, in recent years, the use of used paper has
increased, and a large amount of fine fibers are mixed, resulting
in insufficient dewatering. Thus, sufficient and uniform dewatering
is more important, and it is becoming more difficult to satisfy the
required characteristics for fabrics for papermaking. Further,
there is also a demand for low water retention that reduces the
amount of water retained by industrial fabrics in their spaces
during dewatering (hereinafter referred to as "the amount of water
retained"). For example, by reducing the net thickness, the amount
of water retained can be reduced. Therefore, the diameter of the
warp is simply reduced to reduce the net thickness. However, in
such a case, the mesh becomes coarse, the rigidity due to the mesh
strength decreases, and an excessive mesh space is generated. As a
result, the material does not stay on the fabric and falls off,
causing a decrease in yield. Further, a layer of fibers
(hereinafter referred to as "initial mat") is formed on the fabric
by dewatering when the material is discharged onto the fabric
(hereinafter referred to as "initial dewatering"). When the
dewatering speed of the fabric is high, for example, the mesh of
the fabric becomes clogged with the fibers, resulting in the
formation of a strong initial mat. A strong initial mat clogs the
mesh of the fabric before the dewatering of the material is
completed. Thus, the subsequent dewatering becomes incomplete and
causes poor dewatering, which is, e.g., the cause for the worsening
of the texture of the paper. Therefore, the dewatering performance
is unstable. The dewatering speed of the fabric is determined by
the influence of the surface of the fabric, the space inside
thereof, etc. In particular, an industrial fabric having a
triple-woven structure in which the upper-surface-side fabric and
the lower-surface-side fabric are bonded with a binding yarn has a
high dewatering speed. Therefore, the dewatering speed is
restrained by setting the weft density to be high in order to
suppress the initial dewatering. However, when a strong initial mat
is formed, a more significant decrease in dewaterability
occurs.
[0005] Meanwhile, fabrics having good dewaterability include
industrial two-layer fabrics or the like in which dewatering holes
are formed penetrating from the upper surface side to the lower
surface side. In particular, as fabrics for the purpose of
satisfying the surface property, fiber supportability, and
dewaterability required for industrial two-layer fabrics,
industrial two-layer fabrics are known that use warp binding yarns
that are woven with upper-surface-side wefts and lower-surface-side
wefts forming upper-surface-side warp structures and
lower-surface-side warp structures. Patent Document 1 shows a
two-layer fabric using warp binding yarns. Such a conventional
technology represents a two-layer fabric in which a part of the
warps functions as binding yarns that allow an upper-surface-side
layer and a lower-surface-side layer to be interwoven, and the
paired warp binding yarns complement the upper-surface-side warp
structure and the lower-surface-side warp structure so as to form
the respective surface structures, allowing the fabric to be
excellent in surface properties and binding strength. However, it
is necessary to break knuckles at a part of the structures so as to
achieve binding, and it is thus essential to complement the
knuckles at such a part using another warp. It is known that since
intersections appear continuously between adjacent warps,
dewatering resistance occurs that is likely to cause marks on the
paper at this time.
[0006] Further, for the purpose of uniform dewatering, an
industrial two-layer fabric in which a set consisting of an
upper-surface-side warp and a warp binding yarn is arranged is
shown in cited document 2. In this fabric, a uniform structure is
formed on the surface by combining upper-surface-side knuckles and
the upper-surface-side warp structure of the warp binding yarn that
weaves the upper and lower surfaces together. In this fabric, the
two warps work together to form the structure of a single warp on
the surface, and there is thus no collapsing of the structure.
However, the structure of one or both of the warps must be
collapsed, forming intersections when going back and forth between
the upper and lower surface sides, and the warps, being a
combination of two warps, are arranged as a single warp. However,
since the two warps are not overlapped on the line of a single warp
and are lined up side by side, the warp binding yarn may block the
mesh near the weaving of the upper-surface-side weft, and the
dewaterability characteristics of the wire may be partially changed
giving marks to the paper. Further, in such an industrial two-layer
fabric, dewaterability is good since dewatering holes that
completely penetrate from the upper-surface-side layer to the
lower-surface-side layer are arranged on the entire surface.
However, due to strong vacuum or the like, the sheet material on
the wire may stick into the fabric, and the fibers, filler, etc.,
may come off, causing dewatering marks to be created noticeably.
Further, in conventional industrial two-layer fabrics, an on-stack
structure may be adopted in order to improve the dewaterability.
However, in such a structure, when warps are formed with different
diameters at the top and bottom, the surface space becomes
excessively large. Since the spaces between the warps on the upper
surface side become large while the spaces between the warps on the
lower surface side become small, the control of the dewatering
speed is not sufficient. [0007] Patent Document 1: Japanese Patent
Application Publication No. 2004-36052 [0008] Patent Document 2:
Japanese Patent Application Publication No. 2004-68168
SUMMARY OF THE INVENTION
[0009] A purpose of the present invention is to provide an
industrial two-layer fabric satisfying basic characteristics of a
fabric such as rigidity, wear resistance, dewaterability, mark
suppression, and low water retention for reducing the amount of
water retained. The present invention also provides a new
industrial two-layer fabric that is compatible with a high-speed
paper machine. That is, the correlation between dewaterability and
water retention is an important factor for increasing the speed of
industrial two-layer fabrics, and further, high yield is required
by suppressing the loss of the materials. Therefore, a purpose of
the present invention is to provide an industrial two-layer fabric
that improves dewaterability and realizes low water retention by
improving the opening on the upper and lower surface sides and
internal space so as to, e.g., increase the dewatering amount while
suppressing the initial dewatering. Further, since the difference
in space density can be arbitrarily set by making the warp space
ratio of the upper-surface-side fabric and the warp space ratio of
the lower-surface-side fabric to be about the same and allowing the
diameter of the upper-surface-side weft and the diameter of the
lower-surface-side weft to be different, a purpose of the present
invention is to provide an industrial two-layer fabric whose
dewaterability and water retention can be adjusted by changing the
ratio between the upper-surface-side weft and the
lower-surface-side weft.
[0010] An industrial two-layer fabric according to the present
invention is characterized in that the upper-surface-side warps are
arranged in a combination of two and that at least one warp of the
combination of two warps has a first structure as a warp having a
binding function and a second structure in which a flat yarn is
used for an upper-surface-side warp, thereby realizing high
dewaterability and low water retention while having rigidity. That
is, the following features are employed in the present invention in
order to solve the above problems.
[0011] The following features are employed in the present invention
in order to solve the above problems of the prior art. (1) An
industrial two-layer fabric including an upper-surface-side fabric
formed from upper-surface-side warps and upper-surface-side wefts,
lower-surface-side warps, and lower-surface-side wefts, wherein the
industrial two-layer fabric has at least a first structure and a
second structure in a weave repeat thereof, the first structure
being formed by a combination of two upper-surface-side warps and a
single lower-surface-side warp, the second structure being formed
by a single upper-surface-side warp and a single lower-surface-side
warp, the first structure and the second structure being disposed
adjacent to each other, the upper-surface-side warps in the first
structure being formed by a warp binding yarn having the function
of binding an upper-surface-side fabric and a lower-surface-side
fabric, the combination of two upper-surface-side warps forming the
first structure being disposed adjacent to each other and
constituting a partial rib weave at the surface of the
upper-surface-side fabric, the diameter of the lower-surface-side
warp being larger than the diameter of the upper-surface-side warp
forming the first structure, and the upper-surface-side warp in the
second structure being formed by a flat warp.
[0012] The rib weave means that two upper-surface-side warps are
disposed adjacent to each other, and both warps pass above and
below the upper-surface-side weft to form knuckles on the surface
of the fabric. In the present invention, the two upper-surface-side
warps are binding yarns, and since the warps complement each other
and exert a binding function, there are some parts that are not
rib-woven. By forming the rib weave with the two upper-surface-side
warps, it is possible to obtain a pseudo effect to make it appear
as if flat yarns were used. More specifically, the knuckle shape
can be flattened, and surface smoothness and fiber supportability
can be improved. Further, by arranging the flat yarns described
later to be adjacent to each other, the effect of a warp ground
yarn binding type two-layer fabric can be exhibited. Further, the
flat yarns in the present invention mean yarns having a shape in
which the cross-sectional shape is not circular and the upper and
lower surfaces are substantially flat. The flat yarns according to
the present invention include not only those whose cross-sectional
shape is rectangular but also those whose cross-sectional shape is
elliptical; however, those having a width that is larger than the
vertical diameter are used. The preferred aspect ratio is 1.1 to
2.0. By using such flat yarns, the net thickness in the industrial
two-layer fabric can be suppressed.
[0013] Further, the diameter of the yarns constituting a fabric is
conventionally reduced to suppress the net thickness. However, in
the case of an industrial two-layer fabric having different
diameters at the top and bottom, the warp space on the upper
surface side is larger than that on the lower surface side.
Therefore, it is difficult to suppress dewatering and reduce net
thickness at the same time. In the present invention, since the net
thickness is reduced by the combination of two thin warps and flat
warps, the dewatering speed can be controlled. Further, the present
invention has arrangement in which a weave structure is formed by
two warps and is bound. Therefore, for a binding yarn, at least one
of the two warps has both a weave structure arrangement and a
binding structure arrangement, and the other warp of the pair
forming the upper surface at that portion can achieve the effect of
minimizing the collapse of the weave structure at the binding
part.
[0014] (2) The industrial two-layer fabric according to (1) above,
wherein the diameter of the lower-surface-side warp forming the
first structure is 130% to 300% of the diameter of the
upper-surface-side warp forming the first structure. When the
diameter of the lower-surface-side warp is less than 130% of the
diameter of the upper-surface-side warp, the difference in diameter
between the upper-surface-side warp and the lower-surface-side warp
becomes small, causing the stretching of the fabric, etc., which
cause a risk of affecting rigidity and dewaterability. On the other
hand, when the diameter of the lower-surface-side warp exceeds 300%
of the diameter of the upper-surface-side warp, the space of the
fabric itself becomes small, causing a risk that a problem may
occur from the viewpoint of the dewatering speed. (3) The
industrial two-layer fabric according to (1) or (2) above, wherein
the aspect ratio of the flat warp is 1.1 to 2.0 in the second
structure. When the aspect ratio of the flat warp is less than 1.1,
a sufficiently thin net thickness cannot be obtained. On the other
hand, when the aspect ratio of the flat warp exceeds 2.0, the flat
yarn itself becomes thin, the space of the fabric itself becomes
small, and the strength of the fabric decreases, causing a risk of
affecting the dewaterability.
[0015] (4) The industrial two-layer fabric according to any one of
(1) through (3) above, wherein the first structure and the second
structure are formed being arranged alternately. As yarns forming
the industrial two-layer fabric according to the present invention,
there are an upper-surface-side warp to be woven with an
upper-surface-side weft and a warp binding yarn to be woven with
both the upper-surface-side weft and a lower-surface-side weft, and
the yarns form a set of warp binding yarns where the
upper-surface-side warp and the warp binding yarn are arranged
vertically. Although the yarns are described to be arranged
vertically, since the upper-surface-side warp is woven only with
the upper-surface-side weft and the warp binding yarn is woven with
both the upper-surface-side weft and the lower-surface-side weft,
the yarns are not arranged in such a way the yarns completely
overlap with each other and are actually arranged in such a way the
yarns are not aligned. Further, in addition to the set of warp
binding yarns, a set of upper and lower warps formed of an
upper-surface-side warp to be woven with an upper-surface-side weft
and a lower-surface-side warp to be woven with a lower-surface-side
weft may be arranged.
[0016] By employing the configuration of the industrial two-layer
fabric according to the present invention, advantages of satisfying
the basic characteristics of a fabric, such as rigidity, wear
resistance, dewaterability, mark suppression, and low water
retention for reducing the amount of water retained can be
obtained. Further, by employing the configuration of the industrial
two-layer fabric according to the present invention, it is possible
to provide a new industrial two-layer fabric that is compatible
with a high-speed paper machine. In the present invention, by
combining a warp rib weave with a flat warp, slow dewatering and
low water retention due to a warp binding arrangement having a
fabric of a flat yarn structure can be realized, and therefore
excellent advantages of greatly improving dewaterability compared
to that of a conventional fabric and having low water retention can
be achieved. Further, by employing the structure of the industrial
two-layer fabric according to the present invention, the warp space
ratio of the upper-surface-side fabric and the warp space ratio of
the lower-surface-side fabric can be made to be about the same.
Thus, by allowing the diameter of the upper-surface-side weft and
the diameter of the lower-surface-side weft to be different, the
difference in space density can be arbitrarily set, and the effect
of allowing for the adjustment of the dewaterability and water
retention can be obtained by changing the ratio between the
upper-surface-side weft and the lower-surface-side weft.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Embodiments will now be described, by way of example only,
with reference to the accompanying drawings that are meant to be
exemplary, not limiting, and wherein like elements are numbered
alike in several figures, in which:
[0018] FIGS. 1A-1C are conceptual diagrams for explaining the
operation and effect of a fabric having the knuckle shapes and
heights of a warp and a weft that form the present invention. FIG.
1A is a conceptual diagram of a conventional warp and weft. FIGS.
1B and 1C are conceptual diagrams of the warp and the weft that
form the present invention.
[0019] FIG. 2 is a design diagram showing a weave repeat according
to the first embodiment of the present invention;
[0020] FIG. 3 is a partial side layout view showing a state of
warps as viewed from the side according to the first embodiment of
the present invention;
[0021] FIG. 4 is a design diagram showing a weave repeat according
to the second embodiment of the present invention;
[0022] FIG. 5 is a partial side layout view showing a state of
warps as viewed from the side according to the second embodiment of
the present invention;
[0023] FIG. 6 is a design diagram showing a weave repeat according
to the third embodiment of the present invention;
[0024] FIG. 7 is a partial side layout view showing a state of
warps as viewed from the side according to the third embodiment of
the present invention;
[0025] FIG. 8 is a design diagram showing a weave repeat according
to the fourth embodiment of the present invention; and
[0026] FIG. 9 is a partial side layout view showing a state of
warps as viewed from the side according to the fourth embodiment of
the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Hereinafter, embodiments of an industrial two-layer fabric
according to the present invention will be described. The
embodiments shown below are examples of the present invention and
do not limit the present invention. The industrial two-layer fabric
according to the present invention includes an upper-surface-side
fabric formed from upper-surface-side warps and upper-surface-side
wefts, lower-surface-side warps, and lower-surface-side wefts, and
the industrial two-layer fabric has at least a first structure and
a second structure in a weave repeat thereof, the first structure
being formed by a combination of two upper-surface-side warps and a
single lower-surface-side warp, the second structure being formed
by a single upper-surface-side warp and a single lower-surface-side
warp, the first structure and the second structure being disposed
adjacent to each other, the upper-surface-side warps in the first
structure being formed by a warp binding yarn having the function
of binding an upper-surface-side fabric and a lower-surface-side
fabric, the combination of two upper-surface-side warps forming the
first structure being disposed adjacent to each other and
constituting a partial rib weave at the surface of the
upper-surface-side fabric, the diameter of the lower-surface-side
warp being larger than the diameter of the upper-surface-side warp
forming the first structure, and the upper-surface-side warp in the
second structure being formed by a flat warp.
[0028] The yarn used in the present invention may be selected
depending on the intended use. For example, in addition to
monofilaments, multifilaments, spun yarn, processed yarn generally
referred to as textured yarn, bulky yarn, stretch yarn, etc., on
which crimping, bulk processing, or the like has been performed, or
yarn into which these yarns are combined by, e.g., twisting can be
used. Further, regarding the cross-sectional shape of yarn other
than a flat warp, not only those of a circular shape but also a
star-shaped, rectangular, or polygonal yarn or an elliptical yarn,
a hollow yarn, or the like can be used. Also, the material of the
yarn can be freely selected, and polyester, polyamide,
polyphenylene sulfide, polyvinylidene fluoride, polypro, aramid,
polyetheretherketone, polyethylene naphthalate,
polytetrafluoroethylene, cotton, wool, metal, etc., can be used.
Needless to say, a yarn may be used that is obtained by blending or
including various substances in a copolymer or in these materials
depending on the purpose. In general, for an industrial fabric, a
polyester monofilament is preferably used that allows the
upper-surface-side warps, the lower-surface-side warps, the lower
warp binding yarns, and the upper-surface-side wefts to have
rigidity and is excellent in dimensional stability. Further, for
the lower-surface-side wefts, which are required to have rigidity
and wear resistance, polyester monofilaments and polyamide
monofilaments can be mixed-woven by, e.g., alternately arranging
the polyester monofilaments and the polyamide monofilaments.
[0029] Further, in the present invention, the combination of two
warps in the first structure is rib woven in cooperation by
arranging the warps in parallel. FIGS. 1A-1C are conceptual
diagrams for explaining the knuckle shape and height of a warp that
forms the present invention. FIG. 1A is a conceptual diagram
showing a conventional interwoven portion of a warp and a weft.
Also, FIG. 1A is a conceptual diagram that shows a knuckle shape
and a height using a warp and a weft having diameters in a fabric.
Further, FIG. 1B is a diagram in which a combination of two
upper-surface-side warps 1t and 2t in the first structure is
arranged under an upper-surface-side weft 1'u. Also, FIG. 1C is a
diagram in which a flat warp 3h in the second structure is arranged
under the upper-surface-side weft 1'u. The warps used for the first
structure in the present invention is characterized in that the
upper-surface-side warp has a smaller diameter than the
lower-surface-side warp. Therefore, as shown in FIGS. 1A-1C, the
vertical lengths L2 and L3 of respective knuckle shapes formed by
the upper-surface-side warps 1t and 2t and by the flat warp 3h are
found to be smaller than the vertical length L1 of a knuckle shape
formed by a yarn of a conventional diameter. Therefore, since the
industrial two-layer fabric according to the present invention can
form a flat knuckle shape on the upper surface structure side as
compared with conventional industrial two-layer fabrics, a fabric
having a reduced net thickness can be obtained. Further, since the
knuckle shape of a weft woven into the combination of two warps or
the flat warp becomes flattened, surface smoothness and fiber
supportability can be improved. Further, since the mesh can be
adjusted to be small without increasing the thickness,
unprecedented dewatering characteristics can be provided. The
present invention has a structure in which a weave structure is
formed by two warps and is bound. Therefore, for a binding yarn,
one of the two warps in a set has both a structure arrangement and
a binding structure arrangement, and the other yarn forming the
upper surface side allows the collapse of the weave structure at
the binding part to be minimized.
[0030] Further, in the industrial two-layer fabric according to the
present invention, the respective diameters of the
upper-surface-side warps can be all set to be the same. Also, the
respective diameters of the lower-surface-side warps may be all set
to be the same. Further, the diameter of the lower-surface-side
warps may be set to be 130 to 300% of the diameter of the
upper-surface-side warps. With this configuration, in a rib weave
formed by two relatively thin warps, the upper-surface-side fabric
and the lower-surface-side fabric can be bound by one of the yarns.
Therefore, regarding the diameter of the binding yarn going up and
down inside the fabric, the binding yarn can be formed from a yarn
that is thinner than a warp binding yarn in an industrial two-layer
fabric using a conventional warp binding yarn. Therefore, the
occurrence of partial dewatering unevenness can be minimized.
Further, the diameter of the yarns forming a fabric is
conventionally controlled to suppress the net thickness. However,
in the case of an industrial two-layer fabric having different
diameters at the top and bottom, the warp space on the upper
surface side is larger than that on the lower surface side.
Therefore, it is difficult to suppress dewatering and reduce net
thickness at the same time. In the present invention, the
dewatering speed can be adjusted while maintaining the net
thickness by combining two thin warps and a flat warp.
[0031] Further, in the present invention, the respective diameters
of the two upper-surface-side warps forming the first structure may
be smaller than the diameter of the single upper-surface-side warp
forming the second structure. By reducing the respective diameters
of the two upper-surface-side warp forming the first structure, the
force applied to the weft when forming a knuckle can be made to be
about the same as that in the case of a single upper-surface-side
warp, and the surface smoothness, fiber supportability, etc., can
thus be improved. Further, since the diameter can be adjusted by
selecting the diameter in accordance with the wire, the diameter
and the wire can be appropriately selected. Also, in the present
invention, an on-stack arrangement may be employed. By using the
on-stack arrangement, high dewaterability can be obtained, and an
excessive difference in opening between the upper surface side and
the lower surface side can be suppressed by appropriately closing a
vertical opening with two yarns since the surface structure is a
rib weave. Therefore, the dewatering speed can be controlled.
[0032] Next, embodiments pertaining to the industrial two-layer
fabric of the present invention will be described with reference to
the drawings. FIGS. 2 to 9 are design diagrams and partial side
layout views showing examples pertaining to the industrial
two-layer fabric of the present invention. A design drawing shows
the smallest repeating unit of a fabric structure, and this weave
repeat is connected vertically and horizontally to form the
structure of the entire fabric. In the design drawings, warps are
indicated by Arabic numerals, for example, 1, 2, 3 . . . . Wefts
are indicated by Arabic numerals with dashes, for example, 1', 2',
3' . . . . A binding yarn is an upper-surface-side warp that
constitutes the first structure. Further, a cross mark indicates
that one upper-surface-side warp that constitutes the first
structure is located above an upper-surface-side weft, a triangle
mark indicates that an upper-surface-side warp is located under a
lower-surface-side weft, and a circle mark indicates that a
lower-surface-side warp is located under a lower-surface-side weft.
An upper-surface-side warp and a lower-surface-side warp, and an
upper-surface-side weft and a lower-surface-side weft with the same
number are arranged vertically. In the design drawings, yarns are
arranged so as to be exactly overlapped vertically, or a
lower-surface-side warp is arranged at the midpoint between two
upper-surface-side warps. This is for the convenience of the
drawings, and the yarns may be arranged with a slight deviation in
the actual fabric.
First Embodiment
[0033] FIG. 2 is a design diagram of the first embodiment
pertaining to the industrial two-layer fabric of the present
invention. FIG. 3 is a partial side layout view of the first
embodiment pertaining to the industrial two-layer fabric of the
present invention. The first structure according to the first
embodiment is composed of a combination of two upper-surface-side
warps and a single lower-surface-side warp. The upper-surface-side
warps in the first structure are formed by warp binding yarns
having a function of binding the upper-surface-side fabric and the
lower-surface-side fabric. Further, the combination of two
upper-surface-side warps forming the first structure are disposed
adjacent to each other and forms a partial rib weave on the surface
of the upper-surface-side fabric. Also, the second structure is
composed of a single upper-surface-side warp and a single
lower-surface-side warp. The upper-surface-side warp in the second
structure is formed by a flat warp. Further, as shown in FIG. 2,
the first structures 1, 3, and 5 and the second structures 2, 4,
and 6 are formed being adjacent to one another and arranged
alternately. Further, the diameter of the lower-surface-side warp
is formed to be larger than the diameter of the upper-surface-side
warp forming the first structure.
[0034] More specifically, as shown in FIGS. 2 and 3, a structure is
formed where one upper-surface-side warp 1 in the first structure
passes under a lower-surface-side weft 1' and passes above
upper-surface-side wefts 5', 7', 9', 11', 13', 15', 17', 19', and
21'. Then, a structure is formed where the other upper-surface-side
warp 1 in the first structure passes above upper-surface-side wefts
1', 3', 5', 7', and 9', passes under a lower-surface-side weft 13',
and further pass above upper-surface-side wefts 17', 19', 21', and
23'. The lower-surface-side warp 1 passes under the
lower-surface-side wefts 1' and 13'. Therefore, as is clear from
FIG. 3, the combination of two upper-surface-side warps 1 in the
first structure forms a partial rib weave at the upper-surface-side
wefts 5', 7', 9', 17', 19', and 21' on the surface of the
upper-surface-side fabric. Next, an upper-surface-side warp 2
serving as a flat warp in the second structure passes above
upper-surface-side wefts 2', 4', 6', 8', 10', 12', 14', 16', 18',
20', 22', and 24' so as to form a plain weave. A lower-surface-side
warp 2 in the second structure passes under lower-surface-side
wefts 3' and 15'.
[0035] The first structure in the industrial two-layer fabric
according to the first embodiment can form a pseudo-flat yarn by
forming a rib weave by arranging two thin upper-surface-side warps
in parallel on a part of the surface of the upper-surface-side
fabric. Furthermore, by arranging the flat warp in the second
structure adjacent to the first structure, suitable rigidity and
elongation resistance can be ensured while suppressing the
thickness, and a fabric excellent in wear resistance, suitable
dewaterability, low water retention, and surface smoothness can be
provided, in the same way as in a fabric in which only flat yarns
are used to form a surface structure. Further, by employing the
fabric structure according to the first embodiment, it is possible
to reduce the mesh size while suppressing the thickness of the
fabric. Therefore, the dewaterability and the water retention
property can be adjusted by selecting the diameter of the yarn.
Furthermore, since the knuckle shape of the weft can be flattened
by two rib weave structures, the surface smoothness and the fiber
supportability can be improved.
Second Embodiment
[0036] FIG. 4 is a design diagram of the first embodiment
pertaining to the industrial two-layer fabric of the present
invention. FIG. 5 is a partial side layout view of the second
embodiment pertaining to the industrial two-layer fabric of the
present invention. The first structure according to the second
embodiment is composed of a combination of two upper-surface-side
warps and a single lower-surface-side warp. The upper-surface-side
warps in the first structure are formed by warp binding yarns
having a function of binding the upper-surface-side fabric and the
lower-surface-side fabric. Further, the combination of two
upper-surface-side warps forming the first structure are disposed
adjacent to each other and forms a partial rib weave on the surface
of the upper-surface-side fabric. Also, the second structure is
composed of a single upper-surface-side warp and a single
lower-surface-side warp. The upper-surface-side warp in the second
structure is formed by a flat warp. Further, as shown in FIG. 4,
the first structures 1, 3, and 5 and the second structures 2, 4,
and 6 are formed being adjacent to one another and arranged
alternately. Further, the diameter of the lower-surface-side warp
is formed to be larger than the diameter of the upper-surface-side
warp forming the first structure.
[0037] More specifically, as shown in FIGS. 4 and 5, a structure is
formed where one upper-surface-side warp 1 in the first structure
passes above upper-surface-side wefts 1', 3', 5', and 7', passes
under a lower-surface-side weft 10', and further pass above
upper-surface-side wefts 13', 15', and 17'. Further, a structure is
formed where the other upper-surface-side warp 1 in the first
structure passes under a lower-surface-side weft 1' and passes
above upper-surface-side wefts 3', 5', 7', 9', 11', 13', 15', and
17'. The lower-surface-side warp 1 passes under the
lower-surface-side wefts 1' and 10'. Therefore, as is clear from
FIG. 5, the combination of two upper-surface-side warps 1 in the
first structure forms a partial rib weave at the upper-surface-side
wefts 3', 5', 7', 13', 15', and 17' on the surface of the
upper-surface-side fabric. Next, an upper-surface-side warp 2
serving as a flat warp in the second structure passes above
upper-surface-side wefts 2', 4', 6', 8', 10', 12', 14', 16', and
18' so as to form a plain weave. A lower-surface-side warp 2 in the
second structure passes under lower-surface-side wefts 2' and
11'.
[0038] The first structure in the industrial two-layer fabric
according to the second embodiment can form a pseudo-flat yarn by
forming a rib weave by arranging two thin upper-surface-side warps
in parallel on a part of the surface of the upper-surface-side
fabric. Furthermore, by arranging the flat warp in the second
structure adjacent to the first structure, suitable rigidity and
elongation resistance can be ensured while suppressing the
thickness, and a fabric excellent in wear resistance, suitable
dewaterability, and surface smoothness can be provided, in the same
way as in a fabric in which only flat yarns are used to form a
surface structure. Further, by employing the fabric structure
according to the second embodiment, it is possible to reduce the
mesh size while suppressing the thickness of the fabric. Therefore,
the dewatering characteristics can be adjusted by selecting the
diameter of the yarn. Furthermore, since the knuckle shape of the
weft can be flattened by two rib weave structures, the surface
smoothness and the fiber supportability can be improved.
Third Embodiment
[0039] FIG. 6 is a design diagram of the third embodiment
pertaining to the industrial two-layer fabric of the present
invention. FIG. 7 is a partial side layout view of the third
embodiment pertaining to the industrial two-layer fabric of the
present invention. The first structure according to the third
embodiment is composed of a combination of two upper-surface-side
warps and a single lower-surface-side warp. The upper-surface-side
warps in the first structure are formed by warp binding yarns
having a function of binding the upper-surface-side fabric and the
lower-surface-side fabric. Further, the combination of two
upper-surface-side warps forming the first structure are disposed
adjacent to each other and forms a partial rib weave on the surface
of the upper-surface-side fabric. Also, the second structure is
composed of a single upper-surface-side warp and a single
lower-surface-side warp. The upper-surface-side warp in the second
structure is formed by a flat warp. Further, as shown in FIG. 6,
the first structures 1, 3, and 5 and the second structures 2, 4,
and 6 are formed being disposed adjacent to one another. Further,
the diameter of the lower-surface-side warp is formed to be larger
than the diameter of the upper-surface-side warp forming the first
structure.
[0040] More specifically, as shown in FIGS. 6 and 7, a structure is
formed where one upper-surface-side warp 1 in the first structure
passes above upper-surface-side wefts 1', 3', 5', and 7', passes
under a lower-surface-side weft 10', and further pass above
upper-surface-side wefts 13', 15', and 17'. The lower-surface-side
warp 1 passes under the lower-surface-side wefts 1' and 10'. A
structure is formed where the other upper-surface-side warp 1 in
the first structure passes under a lower-surface-side weft 1' and
passes above upper-surface-side wefts 5', 7', 9', 11', 13', and
15'. Therefore, as is clear from FIG. 7, the combination of two
upper-surface-side warps 1 in the first structure forms a partial
rib weave at the upper-surface-side wefts 5', 7', 13', and 15' on
the surface of the upper-surface-side fabric. Next, an
upper-surface-side warp 2 serving as a flat warp in the second
structure passes above upper-surface-side wefts 2', 4', 6', 8',
10', 12', 14', 16', and 18' so as to form a plain weave. A
lower-surface-side warp 2 in the second structure passes under
lower-surface-side wefts 2' and 11'.
[0041] The first structure in the industrial two-layer fabric
according to the third embodiment can form a pseudo-flat yarn by
forming a rib weave by arranging two thin upper-surface-side warps
in parallel on a part of the surface of the upper-surface-side
fabric. Furthermore, by arranging the flat warp in the second
structure adjacent to the first structure, suitable rigidity and
elongation resistance can be ensured while suppressing the
thickness, and a fabric excellent in wear resistance, suitable
dewaterability, and surface smoothness can be provided, in the same
way as in a fabric in which only flat yarns are used to form a
surface structure. Further, by employing the fabric structure
according to the third embodiment, it is possible to reduce the
mesh size while suppressing the thickness of the fabric. Therefore,
the dewatering characteristics can be adjusted by selecting the
diameter of the yarn. Furthermore, since the knuckle shape of the
weft can be flattened by two rib weave structures, the surface
smoothness and the fiber supportability can be improved.
Fourth Embodiment
[0042] FIG. 8 is a design diagram of the fourth embodiment
pertaining to the industrial two-layer fabric of the present
invention. FIG. 9 is a partial side layout view of the fourth
embodiment pertaining to the industrial two-layer fabric of the
present invention. The first structure according to the fourth
embodiment is composed of a combination of two upper-surface-side
warps and a single lower-surface-side warp. The upper-surface-side
warps in the first structure are formed by warp binding yarns
having a function of binding the upper-surface-side fabric and the
lower-surface-side fabric. Further, the combination of two
upper-surface-side warps forming the first structure are disposed
adjacent to each other and forms a partial rib weave on the surface
of the upper-surface-side fabric. Also, the second structure is
composed of a single upper-surface-side warp and a single
lower-surface-side warp. The upper-surface-side warp in the second
structure is formed by a flat warp. Further, as shown in FIG. 8,
the first structure 1 and the second structures 2 and 8 are formed
being disposed adjacent to each other, and the first structure 5
and the second structures 4 and 6 are formed being disposed
adjacent to each other. Further, the diameter of the
lower-surface-side warp is formed to be larger than the diameter of
the upper-surface-side warp forming the first structure.
[0043] More specifically, as shown in FIGS. 8 and 9, a structure is
formed where one upper-surface-side warp 1 in the first structure
passes above upper-surface-side wefts 1', 3', 5', 7', 9', and 11',
passes under a lower-surface-side weft 13', and further pass above
upper-surface-side wefts 15', and 17'. The lower-surface-side warp
1 passes under the lower-surface-side wefts 1', 7', and 13'. A
structure is formed where the other upper-surface-side warp 1 in
the first structure passes under a lower-surface-side weft 1' and
passes above upper-surface-side wefts 3', 5', 7', 9', 11', 13',
15', and 17'. Therefore, as is clear from FIG. 9, the combination
of two upper-surface-side warps 1 in the first structure forms a
partial rib weave at the upper-surface-side wefts 3', 5', 7', 9',
11', 15', and 17' on the surface of the upper-surface-side fabric.
Next, an upper-surface-side warp 2 serving as a flat warp in the
second structure passes above upper-surface-side wefts 2', 4', 6',
8', 10', 12', 14', 16', and 18' so as to form a plain weave. A
lower-surface-side warp 2 in the second structure passes under
lower-surface-side wefts 2', 8', and 14'. Next, an
upper-surface-side warp 3 serving as a flat warp in the second
structure passes above upper-surface-side wefts 1', 3', 5', 7', 9',
11', 13', 15', and 17' so as to form a plain weave. A
lower-surface-side warp 3 in the second structure passes under
lower-surface-side wefts 4', 10', and 16'. Next, an
upper-surface-side warp 4 serving as a flat warp in the second
structure passes above upper-surface-side wefts 2', 4', 6', 8',
10', 12', 14', 16', and 18' so as to form a plain weave. A
lower-surface-side warp 4 in the second structure passes under
lower-surface-side wefts 5', 11', and 17'.
[0044] The first structure in an industrial two-layer fabric
according to the fourth embodiment can form a pseudo-flat yarn by
forming a rib weave by arranging two thin upper-surface-side warps
in parallel on a part of the surface of the upper-surface-side
fabric. Furthermore, by arranging the flat warp in the second
structure adjacent to the first structure, suitable rigidity and
elongation resistance can be ensured while suppressing the
thickness, and a fabric excellent in wear resistance, suitable
dewaterability, and surface smoothness can be provided, in the same
way as in a fabric in which only flat yarns are used to form a
surface structure. Further, by employing the fabric structure
according to the fourth embodiment, it is possible to reduce the
mesh size while suppressing the thickness of the fabric. Therefore,
the dewatering characteristics can be adjusted by selecting the
diameter of the yarn. Furthermore, since the knuckle shape of the
weft can be flattened by two rib weave structures, the surface
smoothness and the fiber supportability can be improved.
* * * * *