CA1168911A - Needle punched papermaking felt and method of manufacturing the same - Google Patents

Needle punched papermaking felt and method of manufacturing the same

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Publication number
CA1168911A
CA1168911A CA000396627A CA396627A CA1168911A CA 1168911 A CA1168911 A CA 1168911A CA 000396627 A CA000396627 A CA 000396627A CA 396627 A CA396627 A CA 396627A CA 1168911 A CA1168911 A CA 1168911A
Authority
CA
Canada
Prior art keywords
foundation
fabrics
batts
fabric
yarns
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000396627A
Other languages
French (fr)
Inventor
Naoyuki Oikawa
Wako Sato
Osamu Tanaka
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ichikawa Woolen Textile Co Ltd
Original Assignee
Ichikawa Woolen Textile Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ichikawa Woolen Textile Co Ltd filed Critical Ichikawa Woolen Textile Co Ltd
Application granted granted Critical
Publication of CA1168911A publication Critical patent/CA1168911A/en
Expired legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024Woven fabric
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21FPAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F7/00Other details of machines for making continuous webs of paper
    • D21F7/08Felts
    • D21F7/083Multi-layer felts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • B32B2262/0253Polyolefin fibres
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S162/00Paper making and fiber liberation
    • Y10S162/90Papermaking press felts
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/23907Pile or nap type surface or component
    • Y10T428/23943Flock surface
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/23907Pile or nap type surface or component
    • Y10T428/2395Nap type surface
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/23907Pile or nap type surface or component
    • Y10T428/23979Particular backing structure or composition
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree

Abstract

ABSTRACT OF THE DISCLOSURE

A needle punched papermaking felt, comprising a plurality of layers of foundation fabrics formed in an endless form by joining the opposite edges of long woven form and/or relatively easily woven foundation fabrics woven in an endless form, each of the foundation fabrics consisting of synthetic filament yarns, synthetic fiber spun yarns, synthetic fiber/
natural fiber blended spun yarns or two or more kinds of those yarns, batts consisting of synthetic fibers and/or natural fibers and being laid over one or both sides of the foundation fabric, and felted by needle punching process to cause the component fibers to be entangled with each other. Also dis-closed is a method of manufacturing the needle punched paper-making felt.

Description

1 1689~1 This invention relates to a needle punched papermaking felt and a method of manufacturing the same.
At the present time, the papermaking industry tends to employ papermaking machines of enlarged size and increased operating speed for the purpose of improving papermaking effi-ciency requiring papermaking felts of enlarged size as compared with the conventlonal papermaking felts. In addition to the requirement for such enlarged size, needle punched felts which are resistant to yielding to the high nipping pressure applied to the felts by press rollers and have smooth and soft working surfaces, are required to maintain stabilized size and shape of the felts under high operating speed, to provide good squeezing capability and to avoid marking on papers. Accordingly, strong and relatively hard yarns are used for forming the foundation fabrics of the papermaXing felts, and in most cases, double layer fabrics or multiple layer fabrics are used, since the foundation fabrics are required of sufficient thickness, as well as the requirement of non-compressibility for the compo-nent yarns, to provide sufficient capacity of dewatering and containing a large quantity of water squeezed out from wet papers. Furthermore in order to avoid the vibration of the press rollers, the component foundation fabric woven in a long woven form must be joined at the opposite edges thereof to form an endless fabric having a flat surface over the entire area without forming a rugged seam, or the component fabric must be woven in an endless form, namely, in the hollow weave.
However, weaving a multiple layer fabric of the hollow weave with strong and relatively hard yarns, is extremely difficult and needs advanced skill, and also it is necessary to use a special and heavy loom, since it is extremely difficult to weave such a fabric of stable quality with an ordinary loom for weaving fabrics and production of many faulty fabrics is liable to result.
As shown in the accompanying drawings, the conventional papermaking felt is manufactured by weaving a foundation fabric of a multiple layer construction ~ith a special heavy loom, then laying batts of staple fibers over the foundation fabric, and finally needle punching the hybrid layers of the foundation -1- ~' I :~ 689 1 1 fabric and the batts of staple fibers to cause the component fibers to be entangled with each other. In the manufacturing process for the conventional felts as shown in the accompanying drawings, an endless foundation fabric a multiple layer con-struction is extended between a driving roller and a drivenroller with its upper side being set up horizontally and with its lower side being loosened. A batt of staple fibers con-veyed by a lattice is wound around the foundation fabric by a required number of turns while the layer of batt is subjected to the needle punching operation of a needle board. Such a conventional felt, however, inevitably raises the manufacturing cost due to various unfavorable reasons, such as the high cost of equipments due to the necessity of using costly special heavy loom, and the necessity of many hours and much expenses for training operators due to requirement of advanced and skilled weaving techniques.
The present invention was made to overcome the afore-mentioned disadvantages. According to the present invention, a plurality of either one or both kinds of foundation fabrics woven with an ordinary loom for papermaking felt, without a special heavy loom, in a long woven form and joined at the respective opposite edges to form endless fabrics and relatively easily woven foundation fabrics woven in an endless form and in a hollow weave are superimposed one over the other, batts of fibers are laid over one or both sides of the foundation fabric in layers, and then the combination of the foundation fabric and the layers of the batts is subjected to needle punching.
Thus a papermaking felt having papermaking capability the same with or superior to that of the conventional felts is provided easily as well as at a low cost, more particularly, the pre-sent invention relates to a needle punched papermaking felt comprising a plurality of layers of foundation fabric being formed in an endless form by joining the opposite edges of long woven fabric and/or relatively easily woven foundation fabrics woven in an endless form, each of said foundation fabrics consisting of synthetic filament yarns, synthetic fiber spun yarns, synthetic fiber/natural fiber blended spun yarns or two or more kinds of those yarns, batts consisting of syn-1 ~ 6891 1 thetic fibers and/or natural fibers and being laid over one or both sides of the foundation fabric, and felted by needle punch-ing process to cause the component fibers to be entangled with each other, and to a method of manufacturing a needle punched papermaking felt, comprising weaving foundation fabrics in a long woven form and joining the respective opposite edges there-of to form endless fabrics having seams, weaving relatively easily woven foundation fabrics woven in an endless form, sett-ing up either a plurality of said endless fabrics having seams or a plurality of said relatively easily woven fabrics woven in an endless form, or a plurality of both of said former foundation fabrics and said latter foundation fabrics in a superposed relationship to a needle punching machine under tension, supplying and laying batts consisting of synthetic fibers and/or natural fibers over said superposed foundation fabrics while said superposed foundation fabrics are being advanced, and needle punching the combination of said super-posed foundation fabrics and said batts so that the component fibers are caused to be entangled with each other~
In one aspect of the present invention, there is pro-vided a needle punched papermaking felt, comprising a plurality of layers of foundation fabrics formed in an endless form by joining the opposite edges of long woven form foundation fabrics or foundation fabrics woven in an endless form, each of said foundation fabrics consisting of synthetic filament yarns, synthetic fiber spun yarns, synthetic fibers-natural fiber blended spun yarns and mixtures thereof, laying over one or both sides of said foundation :Eabrics batts consisting of synthetic fibers or natural fibers or mixtures thereof, and by felting by a needle punching process to cause the component fibers to be entangled with each other wherein a thin layer of said batts consisting of synthetic fibers, natural fibers or mixtures thereof, is inter-posed between the adjacent layers of said foundation fabrics and wherein the adjacent layers of said foundation fabrics are characterized by the outermost layer having yarns of relatively high elasticity in a relatively dense construction, and the _~

innermost layer having relatively non-compressible yarns in a relatively coarse construction.
In a further aspect of the present invention, there is provided a method of manufacturing a needle punched paper-making felt, comprising the steps of placing in a needle pun-ching machine under tension, a plurality of 1) foundation fabrics in a long woven form, the respective opposite edges thereof being joined to form endless fabrics having seams, or a plurality of 2) relatively easily woven foundation fabrics in an endless form, or a plurality of both of said foundation fabrics 1) and said foundation fabrics 2), applying and laying batts consisting of synthetic fibers or natural fibers or mixtures thereof over said foun-dation fabrics while said foundation fabrics are being ad-vanced in said needle punching machine, and needle punching the combination of said superimposed foundation fabrics and said batts while under tension so that the component fi.bers are caused to be entangled with each other wherein a thin layer of said batts consisting of synthetic fibers, natural fibers or mixtures thereof, is interposed between said ad-jacent fabrics, and the method comprises needle punching a first mixed layer of the first one of said foundation fabric and a first thin layer of said batts while said batts are delivered over the surface of said first foundation fabric, interrupting the delivery of said batts, laying the second one of said foundation fabric over said first mixed layer of said first foundation fabric and said flrst thin layer of batts, delivering a second layer of batts over the surface of said second foundation fabric, needle punching said combination of said first mixed layer and said second foundation fabric and a second thin layer of said batts and repeating said procedure wherein the adjacent layers of said foundation fabrics are characterized by the outermost layer having yarns of relatively high elasticity in a relatively dense construction, and the innermost layer having relatively non-compressible yarns in a relatively coarse construction.

~3a ~

~ 1 6~3'3 1 1 The invention is illustrated by way of example in the accompanying drawings wherein:-Figure 1 is a segmentary sectional view of a conven-tional needle punched papermaking felt, Figure 2 is a schematic side elevation of a needle punching machine for manufacturing the needle punched felt of Figure 1, Figure 3 is a fragmentary sectional view of a needle punched papermaking felt according to the present invention; and Figure 4 is a schematic side elevation of a needle punching machine for manufacturing the needle punched felt of Figure 3.
As shown in Figure 3, a needle punched papermaking felt of the present invention comprises an outside foundation fabric 7 and an inside foundation fabric 8 superposed one over the other, each foundation fabric being a fabric woven in a lo~g woven form and formed in an endless form by joining the opposite edges thereof or a relatively easily woven foundation fabric woven in -3b-~ J 6~9 1 1 an endless form in a hollow weave, and batts 2 laid over one or both sides of the foundation fabric. The combina-tion of the foundation fabrics and the batts are subjected to needle punching process to form a felt by making the component fibers of the warps and wefts consisting the foundation fabric and the component fibers of the batts to be entangled firmly with each other. The felt thus produced is subjected to finishing processes, such as chemical treatment and singeing, according to the purpose.
Regarding the woven construction of the foundation substrate fabric, the fabric woven in a long woven form and formed in an endless form by ~oining the opposite edges may, ~o a certain degree, be of a complex woven construction, whereas the fabrics woven in an endless lS form preferably be of a relatively simple woven construc-tion, since the number of yarns in a unit area is doubled in a hollow weave as compared with that of a long woven form. It is preferable that all of the foundation fabrics are single layer fabric in order to facilitate the pre-paration of those foundation fabrics and also to display contentedly all of the paper making capability, such as dewatering ability, furthermore, the foundation fabrics may comprise a combination of multiple layer fabrics and single layer fabrics, or all of multiple layer fabrics.
In the case of applying of a multiple layer fabric, it is preferable to-weave the fabric in a long woven form, and a long woven fabric is formed in an endless form by joining the opposite edges thereof according to a conven-tional method, that is, according a method in which some wefts are removed from each edge part of the fabric and the warps of the one side edge are replaced alternately the corresponding warps of the other side edge. In join-ing the edges, it is essential to make the seam level and identical in construction with the other part. The respective woven construction, compornent yarns, yarn densities, length ratio and width ratio of the foundation fabric are selectively determined so that the felt can meets the requirements of the papermaking conditions,such as the dewatering ability, pickup performance, dimensional stability, marking preventing capability, resistance to tension and wear resistance, and also so that the super-posed foundation fabrics are heaped up perfectly to each other without stretching and slackening even if the contraction or elongation of the foundation fabrics are caused by the needle punching process.
Generally, it is preferable to form the outside foundation fabric 7 with yarns of superior elasticity in a dense construction to provide a surface capable of preventing the marking, whereas it is preferable to form the inside foundation fabric 8 with non-compressible yarns _ 5 _ 1l ~ 6~

in a relatively coarse construction to provide the inside foundation fabric with a capability of maintaining space under a high compressive force and good dewatering ability.
Synthetic fiber spun yarns, synthetic fiber/natural fiber blended spun yarns, synthetic multifilament yarns or synthetic monofilament yarns are used as the component yarns of fabrics. Single synthetic monofilament yarns or twisted synthetic monofilament yarns are preferable particularly for the needle punched felts used under high speed and high nipping pressure. These yarns are used individually or in combination of different types.
Synthetic fibers of polyamide system, polyester system, polyacrylonitrile system, polyolefin system and poly-propylene system are used. Wool is used in most cases as the natural fiber component, however, cotton and flax may also be used as the material for the natural fiber.
Epoxy resin, phenol resin, melamine resin, formaldehyde resin, polyamide resin, polyvinyle resin and polyurethane resin are used for the resin treatment of the felts.
Batts are formed in one to ten layers and are needled with foundation fabrics while the layer of batts are being laid over the surface of foundation fabric or further are needled several required times after the lay-ing of batts has been completed to cause the component fibers to be firmly entangled with each other. A thin ~ ~ fi8~ 1 1 layer of the batt can be interposed between the adjacent component fabrics. Such provision of a thin layer of the batt contributes to enhancing the binding between the component foundation fabrics as well as increasing the elaciticity of the felt.
Needle punched papermaking felts according to the present invention are manufactured by using a needle punching machine as illustrated in Figure 4. A plurality of foundation fabrics woven in endless forms or woven in long woven forms and joined at the respective opposite edges to form endless fabrics taking into consideration the woven construction, compornent yarns, yarn density, length ratio and width ratio as described hereinbefore, are laid one over the other and extended over the rollers of the needle punching machine.~ The layers of the founda-tion fabrics are tightened with a stretching roller 9 so that the outside foundation fabric 7 and the inside foundation fabric 8 are tightened and made to adhere to each other, without any slackening, and then turned slowly by a driving roller 3 and a driven roller 4 along the guide rollers 10. A batt of fibers is supplied con-tinuously over the surface of the foundation fabric 7 from feed latice 5 in required number of layers while the foundation fabrics 7 and 8 and the layer of the batt are subjected to needling operation of a needle board 6.

1 1 6~

After a required number of layers of batt has been formed over the surface of foundation fabric 7, the batt supply is interrupted. The foundation fabrics and the layers of the batt are subjected to further needling when required.
Thus the component fibers are caused to be entangled firmly with each other. When the felt is required to be provided with a batt on the opposite side of the foundation fabric, it is only necessary to turn inside out and to repeat the same batt supplying and needling procedure. When the felt is required to be provided with thin layers of batts between the adjacent foundation fabrics, the following process is put into the above mentioned process, that is first a single foundation fabric is subjected to the batt supplying and needling process, then the batt supply is interrupted after a thin layer of batt has been supplied over the surface of the foundation fabric then the first hybrid layer of said first foundation fabric and said first thin layer of batts is loosened, and a second foundation fabric is laid over the first thin layer of batt formed over, the surface of the first foundation fabric, then the founda-tion fabrics are tightened, and then the second thin layer of batt supplying and needling procedure is repeat-ed. After the needling process, the felt is subjected to the conventional finishing processes, such as chemical ~ 1 6R ~ 1 1 treatment and singeing, according to the purpose.
It is obvious from what has been described herein-before, that, since the foundation fabric of the needle punched papermaking felt of the present invention is formed by laying a plurality of foundation fabrics one over the other, various foundation fabrics of different woven constructions, component yarns and yarn densities can be selectively combined to provide the foundation fabric with papermaking properties according to the purpose.
Accordingly, the papermaking properties, such as dewater-ing ability, dimensional stability, marking preventing property and wear resistance, are the same with or superior to those of the conventional papermaking felts.
Furthermore, according to the present invention the cost lS of equipment is remarkably reduced, only a reduced floor space for installing the machines is necessary, and the training time is saved as the operators of ordinary skill can meet the operating requirements, since the foundation fabrics of the present invention can be woven with an ordinary loom for weaving them without using a special heavy loom which is necessary for the conventional methods and only the provision of a stretching roller for the needle punching machine is necessary. When some special heavy loom have already been installed, the weaving effi-ciency will be improved when those special heavy loom are g 1 ~ 6~

used for weaving relatively difficult woven foundation fabrics in case of a long woven form or relatively easily woven foundation fabrics in case of an endless woven form. Still further, even if increased installation of loom is necessary for the purpose of increasing the pro-duction, it is only necessary to install ordinary loom for papermaking felt. Thus the present invention is capable of remarkably reducing the manufacturing cost.
Various embodiments will now be described.
Embodiment 1:
An outside foundation fabric was woven in a long woven form with an ordinary loom using polyamide staple fiber/wool blended spun yarns of 5's in a construction of a warp density: 58 ends/5 cm, weft density: t52 picks/
5 cm, length ratio: 102~ and 1/3 broken twill weave.
An inside foundation fabric was woven in much the same means to the outside one by using 1800 denier polyamide monofilament yarns in a construction of a warp density:
48 ends/5 cm, weft density: 42 picks/5 cm, length ratio:
100% and plain weave, then the foundation fabric is joined and formed to an endless form according to a conventional method as hereinbefore described. These fabrics were extended tightly on a needle punching machine by laying one over the other as shown in Figure 4. The foundation fabric and the layer of polyamide staple fiber/wool blended fibers were subjected to needling while the batt was supp]ied over the surface of foundation fabric in four layers to form a felt. This felt was subjected to the conventional drying and singeing processes. Thus a needle punched papermaking felt was obtained. The respective water contents of wet papers after squeezing with the needle punched felt of this embodiment and with a conventional needle punched felt comprising a single sheet of double layer fabric of 1/3 broken twill weave outside and plain weave inside, were 56~ and 58%, which verified the superiority of the felt of the present in-vention to the conventional felt in the dewatering ability.
No mark was observed over the surface of squeezed paper.
Furthermore the cost of equipment was reduced remarkably, since the installation of any special heavy loom was not necessary.

Embodiment 2:
An outside foundation fabric was woven in an endless form with an ordinary loom by using polyamide staple fiber spun yarns of 6's in a construction of a warp density:
56 ends/5 cm, weft dens~ty: 48 picks/5 cm, length ratio:
102% and plain weave. An inside foundation fabric was woven in much the same means to the outside one by using the twisted yarns consisting of two 840 denier polyester ,, n ~ ~

monofilament yarns in a construction of a warp density:
48 ends/S cm, weft density: 40 picks/5 cm, length ratio:
100% and plain weave. The outside foundation fabric and the inside foundation fabric were laid one over the other and extended tightly on a needle punching machine in the manner as described hereinbefore. The foundation fabric and the layers of batt of polyacrylonitrile staple fibers were subjected to needling while the batt was supplied over the surface of the foundation fabric in five layers to form a felt. The felt was subjected to four cycles of needling after the batt supply had been interrupted.
Thus a needle punched felt was obtained. ~his felt exhibited excellent dimensional stability and good dewater-ing ability. The use of an ordinary loom provided the same advantageous effect with that of Embodiment 1.

Embodiment 3:
An outside foundation fabric was woven with an ordi-nary loom by using 640 denier polyamide monofilament yarns in a construction of a warp density: 54 ends/5 cm, weft density: 50 picks/5 cm, length ratio: 101% and 1/3 broken twill weave. An inside fabric was woven in much the same means to the outside one by using 1000 denier polyamide monofilament in a construction o~ a warp density;
50 ends/5 cm, weft density: 42 picks/5 cm, length ratio:

~ r~ fi~S9 ~ 1 100% and plain weave. The outside foundation fabric and the inside foundation fabric were extended tightly on a needle punching machine in the manner as described here-inbefore. The foundation fabric and batts of 50% polyamide staple fiber/50% wool were subjected to needling while the batt was supplied over the surface of the foundation fabric in five layers, and then were needled to three-cycles after the batt supply had been interrupted. Thus a needle punched papermaking felt was manufactured. This needle punched felt exhibited excellent dewatering ability and good dimensional stability and its life was twice as long as that of the conventional felt.

Embodiment 4:
An outside foundation fabric was woven in a long woven form with an ordinary loom by using the twisted yarns of two 420 denier polyacrylonitrile multifilament yarns as warps and polypropylene staple fiber/wool blended spun yarns of 5's as wefts in a construction of a warp density: 60 ends/5 cm, weft density: 56 picks/5 cm, length ratio: 101% and weft backed weave which is a woven construction that can relatively easily formed as for multiple layer fabric. An inside foundation fabric was woven in a long woven form with the same loom by using 1800 denier polyester monofilament yarns in a construction of a warp density: 50 ends/5 cm, weft density: 42 picks/
5 cm, length ratio: 101% and plain weave. Both founda-tion fabrics were formed in the endless forms respectively by joining the respective opposite edges, and then were S extended tightly on a needle punching machine in the manner as described hereinbefore. The foundation fabric and the layer of batts of polyester staple fiber/wool blended fibers were subjected to needling while the batt was suppIied over~the surface of the foundation fabric in four layers, and then the foundation fabric was turned inside out, then subjected to needling while a layer of the batt was supplied over the inside surface of the foundation fabric. The outside surface and inside surface of felt were subjected to additional a single cycle of needling respectively after the supply of the batt had been inter-rupted to cause the component fibers to be entangled firmly with each other, then the felt was subjected to melamine resin treatment. Thus the needle punched paper-making felt was manufactured. The water content of wet paper squeezed by this felt was 55% which was smaller by
2% as compared with that of a paper squeezed by a conven-tional papermaking felt of the same specification except that the foundation fabric of the felt was of a triple layer fabric woven with a special heavy loom, which verified the superiority of the felt of the present ~ 168911 invention in respect of dewatering ability. The present felt was excellent in marking by the preventing property and the dimensional stability. This embodiment also reduced the cost of equipment remarkably, since the foundation fabric could be woven with an ordinary loom.

Embodiment 5:
The outside foundation fabric was woven in an endless form with an existing special heavy loom by using epoxy resin treated polyester staple fiber/polyamide staple fiber blended spun yarns of 6's in a construction of a warp density: 58 ends/5 cm, weft density: 52 picks/5 cm, length ratio: 102% and weft backed weave. An inside foundation fabric was woven in a long woven form with an ordinary loom by using epoxy resin treated 1800 denier single twisted polyamide multifilament yarns in a const-ruction of a warp density: 50 ends/5 cm, weft density:
42 picks/5 cm, length ratio: lG0% and plain weave, and then formed in an endless form by joining the opposite edges according to the conventional method. First the inside foundation fabric was extended tightly on a needle punching machine and subjected to needling while a thin layer of a batt of polyester staple fiber/wool fiber was supplied, then loosened and the outside foundation fabric was laid over the inside foundation fabric carrying a thin 15 ~

~ ~ 6~9 1 1 layer of needle punched batt, and then foundation fabrics were retightened. The fabrics thus combined were subjected to needling while five layers of the batts were being formed over the surface of the outside foundation fabric.
S The combination of the foundation fabrics and the batts were subjected further to two cycles of needling after the supply of the batt had been interrupted to finish the papermaking felt. The compon~nt fabrics of the felt were made to adhere firmly to each other. The present felt had an elasticity greater than that of the conventional felts and exhibited good dimensional stability and appro-ximately the same dewatering ability with that of the conventional felts.

- ~6 -

Claims (2)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A needle punched papermaking felt, comprising a plurality of layers of foundation fabrics formed in an endless form by joining the opposite edges of long woven form foundation fabrics or foundation fabrics woven in an endless form, each of said foundation fabrics consisting of synthetic filament yarns, synthetic fiber spun yarns, synthetic fibers-natural fiber blended spun yarns and mixtures thereof, laying over one or both sides of said foundation fabrics batts consisting of synthetic fibers or natural fibers or mixtures thereof, and by felting by a needle punching process to cause the component fibers to be entangled with each other wherein a thin layer of said batts con-sisting of synthetic fibers, natural fibers or mixtures thereof, is interposed between the adjacent layers of said foundation fabrics and wherein the adjacent layers of said foundation fabrics are characterized by the outermost layer having yarns of relatively high elasticity in a relatively dense construction, and the innermost layer having relatively non-compressible yarns in a relatively coarse construction.
2. A method of manufacturing a needle punched papermaking felt, comprising the steps of placing in a needle punching machine under tension, a plurality of 1) foundation fabrics in a long woven form, the res-pective opposite edges thereof being joined to form endless fabrics having seams, or a plurality of 23 re-latively easily woven foundation fabrics in an endless form, or a plurality of both of said foundation fabrics 1) and said foundation fibers 2), applying and laying batts consisting of synthetic fibers or natural fibers or mixtures thereof over said foundation fabrics while said foundation fabrics are being advanced in said needle punching machine, and needle punching the combination of said superimposed foundation fabrics and said batts while under tension so that the component fibers are caused to be entangled with each other wherein a thin layer of said batts consisting of synthetic fibers, natural fibers or mixtures thereof, is interposed be-tween said adjacent fabrics and the method comprises needle punching a first mixed layer of the first one of said foundation fabric and a first thin layer of said batts while said batts are delivered over the surface of said first foundation fabric, interrupting the de-livery of said batts, laying the second one of said foundation fabric over said first mixed layer of said first foundation fabric and said first thin layer of batts, delivering a second layer of batts over the sur-face of said second foundation fabric, needle punching said combination of said first mixed layer and said second foundation fabric and a second thin layer of said batts and repeating said procedure wherein the adjacent layers of said foundation fabrics are char-acterized by the outermost layer having yarns of re-latively high elasticity in a relatively dense construction and the innermost layer having relatively non-compres-sible yarns in a relatively coarse construction.
CA000396627A 1981-04-23 1982-02-19 Needle punched papermaking felt and method of manufacturing the same Expired CA1168911A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP60686/1981 1981-04-23
JP6068681A JPS57176295A (en) 1981-04-23 1981-04-23 Papermaking needle felt and method

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CA1168911A true CA1168911A (en) 1984-06-12

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US (1) US4425392A (en)
JP (1) JPS57176295A (en)
KR (1) KR850001410B1 (en)
AU (1) AU550584B2 (en)
CA (1) CA1168911A (en)
FI (1) FI820558L (en)

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JP4948611B2 (en) * 2010-02-05 2012-06-06 ワン,チア−レイ Water polo filling device with knotting assist function
DE102011009227A1 (en) * 2011-01-22 2012-07-26 Trützschler Nonwovens Gmbh Apparatus for producing a nonwoven fabric composite
CN103556397A (en) * 2013-11-08 2014-02-05 江苏丹毛纺织股份有限公司 Antibacterial needle-punched cotton and preparation method thereof
US20210108365A1 (en) * 2019-10-11 2021-04-15 L&P Property Management Company Imitation leather vinyl, knits, and other woven fabrics with elastomeric properties and methods thereof

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AU8060082A (en) 1982-10-28
AU550584B2 (en) 1986-03-27
FI820558L (en) 1982-10-24
KR850001410B1 (en) 1985-09-30
US4425392A (en) 1984-01-10
KR830009315A (en) 1983-12-19
JPS57176295A (en) 1982-10-29

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