CA1327742C - Papermaking fabric - Google Patents
Papermaking fabricInfo
- Publication number
- CA1327742C CA1327742C CA000612064A CA612064A CA1327742C CA 1327742 C CA1327742 C CA 1327742C CA 000612064 A CA000612064 A CA 000612064A CA 612064 A CA612064 A CA 612064A CA 1327742 C CA1327742 C CA 1327742C
- Authority
- CA
- Canada
- Prior art keywords
- machine direction
- fabric layer
- direction yarns
- yarns
- cross machine
- 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 - Fee Related
Links
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F1/00—Wet end of machines for making continuous webs of paper
- D21F1/0027—Screen-cloths
- D21F1/0036—Multi-layer screen-cloths
- D21F1/0045—Triple layer fabrics
Abstract
ABSTRACT
A multi-layer self-stitched papermakers' fabric including a top fabric layer of relatively fine machine direction and cross machine direction yarns and a bottom fabric layer of relatively coarse machine direction and cross machine direction yarns, interwoven to produce ideal seating and self-stitching conditions. In a preferred embodiment, the top fabric layer has a right to left twill on its upper papermaking surface and the bottom fabric layer has a left to right twill on its upper interlacing surface.
A multi-layer self-stitched papermakers' fabric including a top fabric layer of relatively fine machine direction and cross machine direction yarns and a bottom fabric layer of relatively coarse machine direction and cross machine direction yarns, interwoven to produce ideal seating and self-stitching conditions. In a preferred embodiment, the top fabric layer has a right to left twill on its upper papermaking surface and the bottom fabric layer has a left to right twill on its upper interlacing surface.
Description
PAPERMAKING FABRIC
~ACKGROUND OF THE INVENTION
Thls invention relates to woven papermakers' fabrlcs and especlally to forming fabrics, including those known as fourdrinier wlres.
In the conventional fourdrinier papermaking process, a water slurry or suspension of cellulosic fibers, known as the paper "stock", ls fed onto the top of the upper run of a traveling endless belt or fabrlc of woven wire and/or synthetlc material. The belt provides a papermaking surface and operates as a filter to separate the cellulosic fibers from the aqueous medium to form a wet paper web. In forming the paper web, the formlng belt serves as a filter element to separate the aqueous medium from the cellulosic fibers by providing for the dralnage of the aqueous medlum through lts mesh openln~s, also known as dralnage holes. In the conventlonal fourdrlnler machlne, the forming fabrlc also serves as a drlve belt. Accordingly, the machine dlrection yarns are sub~ected to considerable tensile stress and, for this reason, are sometlmes referred to as the load bearin~ yarns. Additionally, the cross machlne direction yarns on the bottom surface of the forming fabric are sub~ected to the abraslve forces of the paper machine elements and, for his reason, are often times referred to as the wear resisting i~., yarns. ~g~
q~ .
Such papermakers' fabrics are manufactured ln two baslc ways to form an endless belt. Flr~t, they can be flat woven by a flat weaving process with thelr ends Joined by any one of a number of well known methods to form the endless belt.
Alternatively, they can be woven directly ln the form of a continuous belt by means of an endless weaving process. In a flat woven papermakers' fabric, the warp yarns extend ln the machine directlon and the filling yarns extend in the cross machine direction. In a papermakers' fabric having been woven in an endless fashion, the warp yarns extend in the cross machine direction and the filling yarns extend in the machine direction. As used herein, the terms "machine direction" and "cross machine direction" refer respectively to a directlon equivalent to the direction of travel of the papermakers' fabric on the papermaking machine and a directlon transverse to this direction of travel. Both methods are well known in the art and the term "endless belt" as used herein refers to belts made by el~her method.
Effective sheet support and mlnimal wire marklng are important goals in papermaking, especially for the belt in the section of the papermaking machine where the wet web i~ formed.
The fibers in the slurry to form the paper are generally of relatively short length. Accordingly, in order to ensure good paper quality, the side of the papermakers' fabric which contacts the paper stock should provide high support for the stock, preferably in the cross machine direction because paper fibers delivered from the headbox to the forming fabric are generally aligned ln the machlne dlrectlon more ~o than they are allgned ln the cross machlne dlrectlon. Retalnlng these paper fibers on the top of the formlng fabrlc durlng the dralnage process ls more effectively accompllshed by provldlng a permeable structure wlth a paper contactlng surface grld conflguratlon that lncreases the probablllty that paper flbers will be supported. Thus the grld spans ln both dlrectlons should be shorter than the paper fibers so that a high percentage of brldglng occurs.
However, lf the grid configuratlon of papermakers' fabrlc were deslgned wlth only flber retentlon ln mlnd, such formlng fabrics would probably be dellcate and lack stabllity ln the machlne dlrection and cross machine direction, leading to a short service life. As noted above, abrasive wear caused by contact wlth the papermaklng machlne equlpment ls a real problem. The slde of the papermakers' fabrlc whlch contacts the paper machlne equipment must be tough and durable. These quallties, however, most often are not compatlble with the good drainage and fiber supporting characterlstics desired for the sheet side of the papermakers' fabrlc.
Hen~e, the ldeal papermaking fabrlc must be flne enough to support and retaln a high percentage of the deposited paper fibers, durable enough ~o withstand wear and glve adequate life, strong enough to resist tensile forces to minimize ~tretchlng, and open enough to provlde dralnage and to slmpllfy cleanlng. Meetlng these multlple crlterla generally requlres s 1 3~7742 that two layers of fabrlc be woven at once by utillzing thread~
of dlfferent size and/or count per lnch for the sheet making portlon and the wear/stretch resisting portlon respectively.
In fabrlcs thus created from two distinct fabrics, the final fabrlc would have the deslrable papermaklng quallties on the surface that faces the paper web and the deslrable wear resistance properties on the machine contacting surface. In practlce, such papermakers' fabrics are produced from two separate fabrlcs, one havlng the qualltles deslred for the paper contacting slde and the other wlth the qualitles deslred on the machlne contactlng slde and then the two fabrlcs are stltched together by addltlonal stltchlng yarns as a slngle papermakers' fabric. Thls type fabric is commonly called a triple-layer or TRI-X fabric.
The main problem with so-called triple-layer or TRI-X
fabrics wherein the two fabrlc layers are connected wlth additlonal stitchlng yarns 19 that an optlmum geometry relatlonshlp between the two fabrlc layers 18 not generally achlevable. In practlce, the two fabrlc layers nest together wlth the bottom surface of the top fabrlc down ln the top ~urface o~ the bottom fabrlc, that is the yarn sy~tems in both directions, machlne dlrection and cross machine directlon, in both fabrlc~, the top fabrlc and the bottom fabrlc, are unstacked relatlve to each other. Therefore, although the drainage hole~ ln the top fabrlc may be uniform, the individual dralnage paths through the composite structure can vary due to ' , . . ..
the nesting nature of the totally unstacked structure. Thls unequal or non-unlform dralnage path conditlon can be further aggravated through the addltlon of the lndependent stltchlng yarns requlred to tie both fabrlcs together.
Other undeslrable aspects of lndependently stitched and totally unstacked or lntlmately nested so-called triple-layer forming fabrlcs lnclude reduction in potential permeabillty and susceptlblllty to stltch yarn fallure and subsequent ply separatlon. The lessened permeablllty can adversely affect slurry dralnage, sheet knockoff capability and fabric cleaning efficiency. The stltching yarn failure can occur externally, that ls on the sheet slde surface or on the machlne slde surface, or lnternally, that ls wlthln or between the top fabrlc and the bottom fabric, depending upon the degree of burial below the respective surfaces in the one case and the amount of movement between the two fabrics in the other case.
For obvious geometrlc reasons the stltchlng yarn in an independently stitched triple-layer fabric must be a relatively small diameter yarn; hence it is often hard pressed to withstand the imposed tensile and abrasive forces. Yet another drawback of independently stitched so-called triple-layer formlng fabrics is increased production costs. Where the stitching yarns are inserted as picks or shutes the weaving time is at a minimum increased in direct proportion to the number of additional strands per inch required to achieve a satisfactory, from the marking standpoint and the structural standpolnt, stitching pattern. In the case of a flat woven -product (which essentially all triple-layer products have been to date), the subsequent cost of joining needed to make the product endless for operation on the papermaking machine is also increased.
To date no known fabrlc has incorporated at one time all the ~ualities, that is maximum fiber support, uniform drainage paths, high permeability, good stretch resistance, and long life potential desirable, for the production of superior paper. It has long been desired to devise such a product for an economical cost that falls within the criteria established in the brown paper market. Since brown paper must be produced at a relatively low cost as compared to other papers, such a fabric would be ldeal, and cost effectlve, for all types of paper.
Accordingly, the present invention seeks to provide a papermakers' forming fabric sultable for, but not restrlcted to, the formation of brown paper.
The present inventlon also seeks to provide a papermakers' formlng fabrlc havlng a papermaklng surface wlth a high fiber support for effectlve forming and efflclent release of the paper web.
The present invention also seeks to provide a papermakers' forming fabric havlng uniform dralnage paths through the structure from the sheet side surface to the machlne side surface.
The present lnventlon also seeks to provide a papermakers' forming fabric wlth hlgh permeablllty and high stretch resistance for effective draining and efficient cleaning with trouble-free running.
B
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The present invention further seeks to provide such a papermakers' forming fabric whlle maintainlng a durable wear resistant machine element contacting surface.
The present invention additionally seeks to provide a papermakers' forming fabric, the economics of which fall well within that of even brown paper parameters.
SUMMARY OF THE INVENTION
The present invention provides an endless papermaking fabric comprising:
a top fabric layer including relatively fine machlne direction yarns interwoven with relatively fine cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the top fabric layer cross machine direction yarns inclùding stitching and non-stitching cross machine direction yarns;
a bottom fabric layer including relatlvely coarse machlne dlrectlon yarns interwoven with relatively coarse cross machlne dlrectlon yarns in a repeating pattern to form an upper surface and a lower surface;
the number of the relatively flne top fabric layer cross machlne direction yarns belng approximately twice that of the relatively coarse bottom fabric layer cross machine direction yarns~
wherein said top fabric layer cross machine direction yarns travel singly and engage selected machine directlon yarns of the bottom fabric layer at a hlghest elevatlon relative to the elevatlon of the machlne dlrectlon yarns of the bottom fabrlc layer other than sald selected machlne dlrectlon yarns to blnd the 7a 71727-56 fabric layers together.
The present invention also provldes an endless papermaking fabric comprising:
a top fabric layer including relative fine machine direction yarns interwoven with relatively fine cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the top fabric layer cross machine direction yarns including stitching and non-stitching cross machine direction yarns the upper surface including machine direction and cross machine direction floats and the lower surface including machine direction and cross machine direction floats;
a bottom fabric layer including relatively coarse machine direction yarns interwoven with relatively coarse cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the upper surface including machine direction and cross machine direction floats and the lower surface including machine dlrection and cross machine direction floats;
the number of relatively fine top fabric layer cross machine direction yarns being approxlmately twice that of the relatively 0 coarse bottom fabric layer cross machine direction yarn~;
wherein said top fabric layer cross machine direction yarns engage selected machine direction yarns of the bottom fabric layer at a highest elevation relative to the elevation of the machine direction yarns of the bottom fabric layer other than said selected machine direction yarns to bind the fabric layers together~ and wherein the lower surface machine direction floats of the upper fabric layer contact the upper surface cross machine i ~' 1 3277 4~
7b direction floats of the bottom fabric layer ln a maxlmum contact same plane configuration.
The present invention is a multi-layer papermakers' forming fabric, partlcularly useful for the productlon of brown paper. The fabric, which could be classified as a true dual-layer fabric, incorporates a top papermaking surface fabric formed of relatively fine machine direction and cross machine direction yarns and a bottom machine equipment contacting surface fabric formed of relatively coarse machine direction and cross machine direction yarns. The fabric is a .
t 327742 self-stitched constructlon in which selected top fabric cross machlne directlon yarns will descend to the bottom fabrlc and wrap around certain bottom fabrlc machlne dlrectlon yarns to bind the two fabrics together. The optimum geometrlc structure is achleved by designing and matching the top fabrlc and the bottom fabric such that ideal seating conditions and ideal self-stitching conditions are realized.
The ideal self-stitching conditlon between the top fabrlc and the bottom fabric ls one in which the path of the self-stitch yarn is symmetrlcal and the elongatlon of the self-stltch yarn 1B mlnlmal for the ~artlcular weave pattern comblnation. In an optimum locatlon for the self-stitchlng, the distortion of the top fabric sheet surface will be minimized and the burial of the self-stitch yarn relative to the bottom fabric machlne surface wlll be maxlmlzed. The proper self-stltch pattern wlll also produce a composlte fabrlc having the required amount of structural lntegrity.
In a further embodiment Or the fabrlc Or the present lnvention, the ideal interface symmetry between the top fabrlc and the bottom fabrlc is one where the weaves are posltioned such that the machlne direction floats Or the one fabrlc are lnterfaced against the cross machine directlon floats of the other rabrlc in a 90 degree cross-shaped orlentation made. It 1~ this seating arrangement that optlmizes the uniform drainage paths and the permeabillty needed to produce a good drainlng and easily cleaned forming fabrlc.
.
, -The lnventlon wlll be further descrlbed wlth reference to the accompanylng drawlng, ln whlch like reference numbers refer to like members throughout the varlous views.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. la-lc lllustrate the upper papermaking surface, a machine direction section, and a cross machine direction section, respectively, of the top fabrlc of one embodlment of the fabric of the present invention.
FIGS. 2a-2d lllustrate the bottom fabrlc top interfacing surface, a machine direction section, and two cross machlne direction sections, respectively, of one embodiment of the fabrlc of the present invention.
FIG. 3 illustrates the possible and ideal seatlng arrangements for the cross machine direction yarn floats of the top fabric layer and the bottom fabric layer for the fabric of the present invention.
FIG. 4 illustrates the relatlonshlp between the papermaklng surface of the top fabrlc layer and the interfaclng surface of the bottom fabric layer utilized in the fabrlc of the present invention.
FIG. 5 illustrates the relationshl~ between the bottom surface imprlnt of the top fabric layer and the top surface imprint of the bottom fabric layer of the fabrlc of the present invention.
FIGS. 6a-6e lllustrate the sheet making surface, two machine direction sections and two cross machine direction sections, respectively, of the preferred embodiment of the fabric of the present invention.
FIG. 7 illustrates the papermaking surface view of the preferred embodiment of the fabric, as also shown in FIGS.
6a-6e, with the top fabric layer overlald on the bottom fabrlc layer.
FIG. 8a illustrates a cross machine section of the fabric of FIG. 7, taken along the line 8a-8a in FIG. 7 and FIG. 8b a cross machlne section of the fabric of FIG. 7, taken along the line of 8b-8b in FIG. 7.
DET~ILED DESCRIPTION OF THE INVENTION
The lnvention wlll lnltlally be de8crlbed broadly, wlth a more detailed description following.
The present invention is a papermakers' forming fabric particularly useful for, but not restricted to, the formation of brown paper. The fabric has a high fiber support, uniform 1? 1 32774~
drainage paths, hlgh permeablllty, hlgh stretch reslstance, good abrasion resistance, and can be produced at a cost that makes it economical as a brown paper formlng fabrlc.
The fabrlc of the present lnventlon ls a self-stitched construction includlng two essentially dlstlnct fabrlc layers, one on top of the other. The top layer that wlll form the papermaklng surface lncorporates relatlvely fine yarns ln both the machlne directlon and the cross machlne dlrectlon, whlch, ln the preferred embodlment, are woven ln a 2 x 2 weave pattern. The bottom layer that will contact the machlne elements lncorporates relatively coarse yarns ln the machlne dlrectlon and the cross machlne dlrectlon, also preferably ln a 2 x 2 weave pattern. Thls fabrlc ls essentlally a hybrld double-layer structure ln that each layer contalns lts own system of machlne dlrectlon yarns and cross machlne dlrection yarns. The only dlscontlnulty ln elther layer occurs when selected cross machlne dlrectlon yarns from the top fabric dive down and engage selected machlne dlrectlon yarns from the bottom fabrlc to create the composite structure by blnding the two layers together. No addltlonal blndin~ thread ls neces~ary. The requlred ldeal seatlng condltlon and ldeal self-stitching condition are descrlbed wlth reference to the drawlng below.
The machlne dlrectlon yarns and the cross machlne dlrectlon yarns used in the present lnventlon are preferably synthètic yarns of materlals conventionally used in such fabrlcs, such as polyamldes (Nylon), polyesters (Dacron), and acryllc flbers (Orlon, Dynel and Acrllan), or co-polymers (Saran). The machine directlon yarns and the cross machlne direction yarns may be in the form of monofilament, multlfllament or staple yarns or plied or wrapped yarns. The speclfic ph~sical propertles of the selected yarns, for example, modulus, elongation, free shrink and thermal shrlnk can be chosen to optimize the geometry conflguratlon of the flnal fabric product.
The dlameter of the yarns employed in the fabrlc for the present lnventlon ls determlned by the posltlon ln the fabrlc structure. The machine direction yarns and the cross machlne dlrectlon yarns ln the top fabrlc layer are approxlmately equal in dlameter and approxlmately half the slze of the machlne dlrectlon yarns and the cross machlne dlrectlon yarns ln the bottom fabric layer, those yarns also belng approxlmately e~ual ln diameter. In a preferred embodlment, the top fabrlc layer lncorporates yarns that are .16 mllllmeter (machine dlrectlon) by .18 mllllmeter (cross machlne dlrectlon) and the bottom fabrlc layer lncorporates yarns that are .34 mllllmeter (machlne dlrectlon) by .36 mlllimeter (cross machlne dlrectlon). The size of the yarns ln both ~ystems can be lncreased or decreased to sult the lndlvldual requlrements of a partlcular appllcatlon for the papermaking fabric.
The weave pattern used in the preferred embodlment ofthe fabric of the present lnvention is a twlll weave characterized by a diagonal line on the face of the fabric. Both the top fabric layer and the bottom fabric layer are 2 x 2 twill, meaning that the machine direction yarns go over two cross machine direction yarns and under two cross machine direction yarns in a repeating pattern. To achieve the stated goals of the ideal seating arrangement and the ideal self-stitching arrangement of the present invention, the twills in the mating fabrics will have a reverse orientation relative to each other, that is the upper surface of the top fabric layer is a right to left twill while the upper surface of the bottom fabric layer is a left to right twill or vlce versa. In comblnatlon wlth the above-mentioned reversed twill crlterla, the top fabrlc layer and the bottom fabric layer must be positioned relative to each other such that the relationship between the lower surface machlne dlrectlon floats of the top fabric layer interface wlth the upper surface cross machine direction floats of the bottom fabrlc layer ln a maxlmum contact same plane, essentlally 90 degree cross shaped orlentatlon mode, which provldes ldeal lnterface symmetry.
Turnlng now to the drawlngs, FIG. la lllustrates the upper papermaklng surface of the top fabrlc layer, EIG. lb ls a machlne dlrectlon sectlon (taken along llne lb-lb ln FIG. la), and FIG. lc ls a cross machlne dlrectlon section ~taken along llne lc-lc ln FIG. la), respectlvely, of the top fabrlc layer of one embodlment of the present invention. As stated above, the top fabric layer 10 includes relatively fine machine direction 12 and cross machlne directlon 14 yarns lnterwoven in a 2 x 2 twill weave pattern. The cross machine dlrectlon float 14 can be seen across the papermaking surface view. Consistent with the 2 x 2 twlll weave, these floats ascend from right to left across the fabrlc 10, constituting a right to left twill.
FIG. 2a illustrates the upper interfacing surface of the bottom layer fabric, FIG. 2b a machine direction section (taken along the line 2b-2b in FIG. 2a), and FIGS. 2c and 2d illustrate cross machine direction sections (taken along the lines 2c-2c and 2d-2d in FIG. 2a), respectively, of the bottom fabric used in one embodiment of the fabric of the present invention. Again, the bottom fabric layer 20 includes relatively coarse machine direction 22 and croæs machlne direction 24 yarns interwoven in a 2 x 2 twill pattern. The floats of cross machine direction 24 can be seen across the interfacing surface view in FIG. 2a.
Consistent with the 2 x 2 twill weave, these floats ascend from left to right across the fabric 20 constltutlng a left to rlght twill which is the reverse of that ln the top fabrlc layer 10.
Wlthln the teachlngs of the present lnventlon, a top fabrlc layer havlng a left to rlght twill could be mated wlth a bottom fabrlc layer having a rlght to left twill. The polnts marked "S" in three vlews represent a typlcal polnt where the flne cross machine dlrectlon yarn from the top fabrlc layer could descend to bind around the coarse machlne dlrection yarn ln the lower fabrlc layer 20. Examlnation of these views wlll reveal a number of other "S"
type locatlons which would satl~fy the ldeal self-stltch polnt requlrements. The number of such locations actually utilized in the ultimate composlte fabrlc ls agaln dependent upon the stitchlng frequency needs determined feaslble for the product , ,, ~ .
.
application.
FIGS. 3a to 3e lllustrate the posslble and the ldeal seating arrangements between the top fabric layer 10 and the bottom fabric layer 20 at the stacked or overlylng cross machine directlon yarns. In each of these views, the top fabrlc machlne direction yarns 12 and the bottom fabric machine directlon yarns 22 are unstacked, that ls each bottom fabrlc machine directlon yarn 22 is lntermediately spaced between a pair of top fabric machine direction yarns 12. Conversely, the non-stitching cross machine direction yarns 14 of the top fabric layer and the cross machine dlrectlon yarns 24 of the bottom fabric layer are stacked.
That is the bottom fabric layer cross machlne direction yarns is directly under the top fabrlc cross machine direction yarns 14.
This is lllustrated in FIG. 3a and FIG. 3e. There are twice as many cross machine dlrection yarns 14 ln the top fabric layer 10 as there are cross machine dlrection yarnæ 24 in the bottom fabric layer 20. Only selected top fabrlc layer cross machlne dlrectlon yarns will descend to the bottom fabrlc layer and wrap around certain bottom fabric layer machlne dlrectlon yarns to bind the two fabric layers together. Those selected cross machine direction yarns which descend ~"stltchers") alternate wlth cross machlne dlrectlon yarns whlch do not descend ("non-stitchers").
FIGS. 3a-3e show positlons of only a non-stltchlng cross machlne dlrectlon yarn of the top fabrlc layer relatlve to a cross machlne dlreation yarn of the bottom fabric layer. This dl~tlnctlon ls further explalned by comparing FIGS. 3a-3e to FIGS. 6b and 6c.
~ Wlthln these bounds, the top fabrlc 10 can then be posltloned ,, ,,g~,.
.
., .
~" .
1 3277~2 relative to the bottom fabrlc 20 ln four locals, labeled Ideal, One-Left, Two-Left, Three-Left, and Ideal agaln respectlvely, It should also be noted that only ln the ideal posltion are the top fabric 10 and the bottom fabrlc 20 oriented such that both lower surface machine direction floats of the top fabric 10 interface with the upper surface cross machine direction floats of the bottom fabric ln the prescribed maxlmum contact same plane, essentially 90 degree cross shaped orientation mode, as shown below in FIG. 5.
FIG. 4 illustrates the relationship between the papermaking surface of the top fabric 10 and the lnterfacing surface of the bottom fabrlc 20 where the above-descrlbed seating arrangement has been achieved. For further famlllarlzatlon of the ldeal self-stltch polnt concept, the self-stltching points used in the composite fabric structure of one embodiment of the present invention have been marked with an "S". Once again, more or less self-stitching points could be utilized, provided they meet the ideal location criteria, dependlng upon the overall papermaklng and structural requirements of the flnal composlte forming fabric product.
PIG. 5 illustrates the relatlonship between the lower surface imprlnt of the to~ fabrlc 10 and the upper surface lmprlnt of the bottom fabrlc 20 utlllzed ln one embodlment of the present lnventlon. The matlng of these respective imprints indicate the areas where the yarns of the two fabrics lnterface. Speclflcally, when the ideal seating arrangement has been achieved, the lower machine direction float~ 12 of the top fabric 10 contact the upper cross machine direction floats 24 of the bottom fabric 20 in a maximum contact same plane, essentially 90 degree cross shaped orientation mode, the cross shape being shown in FIG. 5; this ideal interface is clrcled in FIGS. 3a and 6b. Additionally, a typical ideal self-stitching point "S" where the fine cross machine direction yarn 14 can most easily dip down, specifically dip further down from its already down position, to engage the machine direction yarn 22 of the bottom fabric 20 at its highest most accessible point is indicated by the "S" label. Once again, both the ideal seating arrangement and the ideal self-stitching points are representative typical positions which occur frequently within a pattern repeat. In a properly designed composite fabric, all the interfacing areas should satisfy the ideal seating arrangement criteria. However, the number of ideal self-stltchlng points "S" actually utilized within a pattern repeat will depend upon the ultimate ob~ectives for the product.
FIG. 6a lllustrates the comblned structure, speciflcally the relatlonshlp between the sheet maklng upper surface of the top fabric layer 10, and lnterfaclng surface of the bottom fabrlc layer 20 of the preferred embodlment of the present inventlon where the above-described ldeal seatlng arrangement has been aahleved. For further famlliarlzatlon of the ldeal ln the composite fabrlc structure of one embodlment of the present lnventlon have been marked with an "o" and labelled "S". Once agaln, more or fewer self-stltchlng points could be utillzed, provlded they meet the ideal location criterla, depending upon the ,:
~`
.
overall papermaking and structural requirements of the final composite forming fabric product. FIG. 6b, taken along line 6b-6b in FIG. 6a, and FIG. 6c, taken along line 6c-6c in FIG. 6a, illustrate two cross machine direction sections and FIG. 6d, taken along line 6d-6d in FIG. 6a, and FIG. 6e, taken along line 6e-6e in FIG. 6a, two machine direction sections of the preferred embodiment of the present invention.
FIGS 6b and 6c illustrate the paths of two cross machine direction yarns, and clearly show the role and positloning of alternatlng cross machlne dlrectlon yarns ln this fabric. The typlcal ldeal seatlng arrangement previously descrlbed is apparent ln the cross machine direction section in Fig. 6b where there is a stacked relationship between the cross machine direction yarns 14 of the top fabric layer 10 and the cross machine direction yarns 24 of the bottom fabric layer 20. In one yarn, as shown in FIG. 6c, no bottom fabric cross machine direction yarn 24 sits below the top fabric cross machine direction yarns 14. The ad~acent, and all alternatlng top fabric cross machine direction yarns 14 thus become the stltching yarns. The typlcal ldeal self-stitching point marked "S" is apparent in FIG. 6a, FIG. 6c and lnFIG. 6e. In the embodiment of the present invention shown in FIGS. 6a-6e, the self-stitching is done by each self-stitching top fabric cros~ machine direction yarn 14 on every eighth bottom fabric machine direction yarn 22 so that, with the alternating nature of the stitching pattern, every machine direction yarn 22 in the bottom fabric layer is eventually interlaced with every other cross machlne direction yarn 14 from the top fabric layer 10 within the confines of one pattern repeat. It can also be seen ~;
, 19 that the self-stitch provided by every other fine cross machine direction yarn 14 from the top fabrlc layer 10 ls merely an extension from its already down or under float posltlon whlch allows lt to descend somewhat further down to lnterlace wlth the machlne directlon yarn 22 ln the bottom fabric layer 20 whlch ls at that point ln its highest position. At its highest position, or elevation, in its weave repeat, the machine direction yarn 22 in the bottom fabric 20 is optimally accessible. The elevation of representative machine direction yarns relative to each other in a weave repeat is shown in FIG. 2d. As can be seen in that figure, a possible stitch point occurs when the machine direction yarn is at a highest elevation compared to the other machlne direction yarns in the weave repeat. This comblnation glves the mlnlmal elongatlon of the self-stitch yarn over a symmetrically unlform path. Having the self-stltch cross machlne directlon yarns 14 of the top fabric layer 10 located midway between the surroundlng cross machlne direction yarns 24 in the bottom fabric layer 20 also contributes to the structural integrlty of the resultant composlte fabric (see FIG. 6e).
FIG. 7 lllustrates the comblned structure with papermaking surface view of the top fabrlc layer 10 overlald on the lnterfaclng surface of the bottom fabric layer 20 and the self-stltch polnts marked as "S". A typlcal ldeal seatlng arrangement wlll produce a situatlon where the lower floats of the machlne direction yarns 12 ln the top fabric layer 10 interface wlth the upper float of the cross machine dlrectlon yarns 24 in the bottom fabric layer 20 ln the requlred 90 degree cross-shaped orlentatlon mode, as shown within the clrcled area. The skllled observer can see that this ideal seating arrangement condltlon occurs numerous times within a pattern repeat of the pre~ent invention. The ideal self-stitchlng polnts, labelled "S"
typlcally, also occur qulte frequently withln a pattern repeat.
However, in the preferred embodiment of the present invention, the utilized frequency of these ideal self-stitching points which exist along every other fine cross machine direction yarn 14 in the top fabric layer 10 is once every sixteen machine direction yarns 12 in the top fabric layer 10 and once every eight machine direction yarns 22 in the bottom fabric layer 20. Given the staggered nature of the self-stitching pattern, the net result i5 that at some point along every machine direction yarn 22 in the bottom fabric layer 10 an interlace is achieved with the top fabrlc layer 10 wlthin a pattern repeat. This self-stitching frequency can be increased or decreased, always using the ideal self-stltchlng polnts only, depending upon the partlcular applicatlon for the final product.
FIGS. 8a and 8b illustrate the two configurations for the cros~ machine direction yarns of the top fabric layer 10 as they relate to the bottom fabric layer 20 in the preferred embodiment of the present invention. FIG. 8a illustrates the cross machlne direction yarns 14 of the composite fabric taken along line 8a~8a in FIG. 7 at the stac~ed non-stitchlng posltlon and FIG. 8b, taken along llne 8b-8b in FIG. 7, shows the lntermedlately spaced self-stltchlng yarns cross machlne dlrectlon yarn 14 of the top fabrlc layer 10. The typical ideal seating arrangement is circled and the typical ideal self-stltchlng polnt ls labelled ~S".
., .
,. .
1 3~77~2 Wlthln the context of the present lnventlon, only fabrics having 2 x 2 twlll weaves have been lllustrated hereln;
however, the teachings descrlbed herein are not restrlcted to ~ust 2 x 2 twlll weaves. In other words, the prlnclples of ldeal seating arrangement, self-stitch allgnment, and lnterface symmetry can be successfully applled over a broad range of weave patterns, not necessarlly the same for each layer, ln creatlng similar composlte papermaking fabrlcs. Where the espoused guldellnes are ~udlclously applled, a superior papermaking product can be produced. While the fabric hereln descrlbed constltutes the preferred embodlment of the inventlon, it is to be understood that the inventlon 18 not llmited to the precise fabrlc described and that changes may be made hereln wlthout departlng from the scope of the invention.
~) ~' .
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~ACKGROUND OF THE INVENTION
Thls invention relates to woven papermakers' fabrlcs and especlally to forming fabrics, including those known as fourdrinier wlres.
In the conventional fourdrinier papermaking process, a water slurry or suspension of cellulosic fibers, known as the paper "stock", ls fed onto the top of the upper run of a traveling endless belt or fabrlc of woven wire and/or synthetlc material. The belt provides a papermaking surface and operates as a filter to separate the cellulosic fibers from the aqueous medium to form a wet paper web. In forming the paper web, the formlng belt serves as a filter element to separate the aqueous medium from the cellulosic fibers by providing for the dralnage of the aqueous medlum through lts mesh openln~s, also known as dralnage holes. In the conventlonal fourdrlnler machlne, the forming fabrlc also serves as a drlve belt. Accordingly, the machine dlrection yarns are sub~ected to considerable tensile stress and, for this reason, are sometlmes referred to as the load bearin~ yarns. Additionally, the cross machlne direction yarns on the bottom surface of the forming fabric are sub~ected to the abraslve forces of the paper machine elements and, for his reason, are often times referred to as the wear resisting i~., yarns. ~g~
q~ .
Such papermakers' fabrics are manufactured ln two baslc ways to form an endless belt. Flr~t, they can be flat woven by a flat weaving process with thelr ends Joined by any one of a number of well known methods to form the endless belt.
Alternatively, they can be woven directly ln the form of a continuous belt by means of an endless weaving process. In a flat woven papermakers' fabric, the warp yarns extend ln the machine directlon and the filling yarns extend in the cross machine direction. In a papermakers' fabric having been woven in an endless fashion, the warp yarns extend in the cross machine direction and the filling yarns extend in the machine direction. As used herein, the terms "machine direction" and "cross machine direction" refer respectively to a directlon equivalent to the direction of travel of the papermakers' fabric on the papermaking machine and a directlon transverse to this direction of travel. Both methods are well known in the art and the term "endless belt" as used herein refers to belts made by el~her method.
Effective sheet support and mlnimal wire marklng are important goals in papermaking, especially for the belt in the section of the papermaking machine where the wet web i~ formed.
The fibers in the slurry to form the paper are generally of relatively short length. Accordingly, in order to ensure good paper quality, the side of the papermakers' fabric which contacts the paper stock should provide high support for the stock, preferably in the cross machine direction because paper fibers delivered from the headbox to the forming fabric are generally aligned ln the machlne dlrectlon more ~o than they are allgned ln the cross machlne dlrectlon. Retalnlng these paper fibers on the top of the formlng fabrlc durlng the dralnage process ls more effectively accompllshed by provldlng a permeable structure wlth a paper contactlng surface grld conflguratlon that lncreases the probablllty that paper flbers will be supported. Thus the grld spans ln both dlrectlons should be shorter than the paper fibers so that a high percentage of brldglng occurs.
However, lf the grid configuratlon of papermakers' fabrlc were deslgned wlth only flber retentlon ln mlnd, such formlng fabrics would probably be dellcate and lack stabllity ln the machlne dlrection and cross machine direction, leading to a short service life. As noted above, abrasive wear caused by contact wlth the papermaklng machlne equlpment ls a real problem. The slde of the papermakers' fabrlc whlch contacts the paper machlne equipment must be tough and durable. These quallties, however, most often are not compatlble with the good drainage and fiber supporting characterlstics desired for the sheet side of the papermakers' fabrlc.
Hen~e, the ldeal papermaking fabrlc must be flne enough to support and retaln a high percentage of the deposited paper fibers, durable enough ~o withstand wear and glve adequate life, strong enough to resist tensile forces to minimize ~tretchlng, and open enough to provlde dralnage and to slmpllfy cleanlng. Meetlng these multlple crlterla generally requlres s 1 3~7742 that two layers of fabrlc be woven at once by utillzing thread~
of dlfferent size and/or count per lnch for the sheet making portlon and the wear/stretch resisting portlon respectively.
In fabrlcs thus created from two distinct fabrics, the final fabrlc would have the deslrable papermaklng quallties on the surface that faces the paper web and the deslrable wear resistance properties on the machine contacting surface. In practlce, such papermakers' fabrics are produced from two separate fabrlcs, one havlng the qualltles deslred for the paper contacting slde and the other wlth the qualitles deslred on the machlne contactlng slde and then the two fabrlcs are stltched together by addltlonal stltchlng yarns as a slngle papermakers' fabric. Thls type fabric is commonly called a triple-layer or TRI-X fabric.
The main problem with so-called triple-layer or TRI-X
fabrics wherein the two fabrlc layers are connected wlth additlonal stitchlng yarns 19 that an optlmum geometry relatlonshlp between the two fabrlc layers 18 not generally achlevable. In practlce, the two fabrlc layers nest together wlth the bottom surface of the top fabrlc down ln the top ~urface o~ the bottom fabrlc, that is the yarn sy~tems in both directions, machlne dlrection and cross machine directlon, in both fabrlc~, the top fabrlc and the bottom fabrlc, are unstacked relatlve to each other. Therefore, although the drainage hole~ ln the top fabrlc may be uniform, the individual dralnage paths through the composite structure can vary due to ' , . . ..
the nesting nature of the totally unstacked structure. Thls unequal or non-unlform dralnage path conditlon can be further aggravated through the addltlon of the lndependent stltchlng yarns requlred to tie both fabrlcs together.
Other undeslrable aspects of lndependently stitched and totally unstacked or lntlmately nested so-called triple-layer forming fabrlcs lnclude reduction in potential permeabillty and susceptlblllty to stltch yarn fallure and subsequent ply separatlon. The lessened permeablllty can adversely affect slurry dralnage, sheet knockoff capability and fabric cleaning efficiency. The stltching yarn failure can occur externally, that ls on the sheet slde surface or on the machlne slde surface, or lnternally, that ls wlthln or between the top fabrlc and the bottom fabric, depending upon the degree of burial below the respective surfaces in the one case and the amount of movement between the two fabrics in the other case.
For obvious geometrlc reasons the stltchlng yarn in an independently stitched triple-layer fabric must be a relatively small diameter yarn; hence it is often hard pressed to withstand the imposed tensile and abrasive forces. Yet another drawback of independently stitched so-called triple-layer formlng fabrics is increased production costs. Where the stitching yarns are inserted as picks or shutes the weaving time is at a minimum increased in direct proportion to the number of additional strands per inch required to achieve a satisfactory, from the marking standpoint and the structural standpolnt, stitching pattern. In the case of a flat woven -product (which essentially all triple-layer products have been to date), the subsequent cost of joining needed to make the product endless for operation on the papermaking machine is also increased.
To date no known fabrlc has incorporated at one time all the ~ualities, that is maximum fiber support, uniform drainage paths, high permeability, good stretch resistance, and long life potential desirable, for the production of superior paper. It has long been desired to devise such a product for an economical cost that falls within the criteria established in the brown paper market. Since brown paper must be produced at a relatively low cost as compared to other papers, such a fabric would be ldeal, and cost effectlve, for all types of paper.
Accordingly, the present invention seeks to provide a papermakers' forming fabric sultable for, but not restrlcted to, the formation of brown paper.
The present inventlon also seeks to provide a papermakers' formlng fabrlc havlng a papermaklng surface wlth a high fiber support for effectlve forming and efflclent release of the paper web.
The present invention also seeks to provide a papermakers' forming fabric havlng uniform dralnage paths through the structure from the sheet side surface to the machlne side surface.
The present lnventlon also seeks to provide a papermakers' forming fabric wlth hlgh permeablllty and high stretch resistance for effective draining and efficient cleaning with trouble-free running.
B
.
The present invention further seeks to provide such a papermakers' forming fabric whlle maintainlng a durable wear resistant machine element contacting surface.
The present invention additionally seeks to provide a papermakers' forming fabric, the economics of which fall well within that of even brown paper parameters.
SUMMARY OF THE INVENTION
The present invention provides an endless papermaking fabric comprising:
a top fabric layer including relatively fine machlne direction yarns interwoven with relatively fine cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the top fabric layer cross machine direction yarns inclùding stitching and non-stitching cross machine direction yarns;
a bottom fabric layer including relatlvely coarse machlne dlrectlon yarns interwoven with relatively coarse cross machlne dlrectlon yarns in a repeating pattern to form an upper surface and a lower surface;
the number of the relatively flne top fabric layer cross machlne direction yarns belng approximately twice that of the relatively coarse bottom fabric layer cross machine direction yarns~
wherein said top fabric layer cross machine direction yarns travel singly and engage selected machine directlon yarns of the bottom fabric layer at a hlghest elevatlon relative to the elevatlon of the machlne dlrectlon yarns of the bottom fabrlc layer other than sald selected machlne dlrectlon yarns to blnd the 7a 71727-56 fabric layers together.
The present invention also provldes an endless papermaking fabric comprising:
a top fabric layer including relative fine machine direction yarns interwoven with relatively fine cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the top fabric layer cross machine direction yarns including stitching and non-stitching cross machine direction yarns the upper surface including machine direction and cross machine direction floats and the lower surface including machine direction and cross machine direction floats;
a bottom fabric layer including relatively coarse machine direction yarns interwoven with relatively coarse cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the upper surface including machine direction and cross machine direction floats and the lower surface including machine dlrection and cross machine direction floats;
the number of relatively fine top fabric layer cross machine direction yarns being approxlmately twice that of the relatively 0 coarse bottom fabric layer cross machine direction yarn~;
wherein said top fabric layer cross machine direction yarns engage selected machine direction yarns of the bottom fabric layer at a highest elevation relative to the elevation of the machine direction yarns of the bottom fabric layer other than said selected machine direction yarns to bind the fabric layers together~ and wherein the lower surface machine direction floats of the upper fabric layer contact the upper surface cross machine i ~' 1 3277 4~
7b direction floats of the bottom fabric layer ln a maxlmum contact same plane configuration.
The present invention is a multi-layer papermakers' forming fabric, partlcularly useful for the productlon of brown paper. The fabric, which could be classified as a true dual-layer fabric, incorporates a top papermaking surface fabric formed of relatively fine machine direction and cross machine direction yarns and a bottom machine equipment contacting surface fabric formed of relatively coarse machine direction and cross machine direction yarns. The fabric is a .
t 327742 self-stitched constructlon in which selected top fabric cross machlne directlon yarns will descend to the bottom fabrlc and wrap around certain bottom fabrlc machlne dlrectlon yarns to bind the two fabrics together. The optimum geometrlc structure is achleved by designing and matching the top fabrlc and the bottom fabric such that ideal seating conditions and ideal self-stitching conditions are realized.
The ideal self-stitching conditlon between the top fabrlc and the bottom fabric ls one in which the path of the self-stitch yarn is symmetrlcal and the elongatlon of the self-stltch yarn 1B mlnlmal for the ~artlcular weave pattern comblnation. In an optimum locatlon for the self-stitchlng, the distortion of the top fabric sheet surface will be minimized and the burial of the self-stitch yarn relative to the bottom fabric machlne surface wlll be maxlmlzed. The proper self-stltch pattern wlll also produce a composlte fabrlc having the required amount of structural lntegrity.
In a further embodiment Or the fabrlc Or the present lnvention, the ideal interface symmetry between the top fabrlc and the bottom fabrlc is one where the weaves are posltioned such that the machlne direction floats Or the one fabrlc are lnterfaced against the cross machine directlon floats of the other rabrlc in a 90 degree cross-shaped orlentation made. It 1~ this seating arrangement that optlmizes the uniform drainage paths and the permeabillty needed to produce a good drainlng and easily cleaned forming fabrlc.
.
, -The lnventlon wlll be further descrlbed wlth reference to the accompanylng drawlng, ln whlch like reference numbers refer to like members throughout the varlous views.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. la-lc lllustrate the upper papermaking surface, a machine direction section, and a cross machine direction section, respectively, of the top fabrlc of one embodlment of the fabric of the present invention.
FIGS. 2a-2d lllustrate the bottom fabrlc top interfacing surface, a machine direction section, and two cross machlne direction sections, respectively, of one embodiment of the fabrlc of the present invention.
FIG. 3 illustrates the possible and ideal seatlng arrangements for the cross machine direction yarn floats of the top fabric layer and the bottom fabric layer for the fabric of the present invention.
FIG. 4 illustrates the relatlonshlp between the papermaklng surface of the top fabrlc layer and the interfaclng surface of the bottom fabric layer utilized in the fabrlc of the present invention.
FIG. 5 illustrates the relationshl~ between the bottom surface imprlnt of the top fabric layer and the top surface imprint of the bottom fabric layer of the fabrlc of the present invention.
FIGS. 6a-6e lllustrate the sheet making surface, two machine direction sections and two cross machine direction sections, respectively, of the preferred embodiment of the fabric of the present invention.
FIG. 7 illustrates the papermaking surface view of the preferred embodiment of the fabric, as also shown in FIGS.
6a-6e, with the top fabric layer overlald on the bottom fabrlc layer.
FIG. 8a illustrates a cross machine section of the fabric of FIG. 7, taken along the line 8a-8a in FIG. 7 and FIG. 8b a cross machlne section of the fabric of FIG. 7, taken along the line of 8b-8b in FIG. 7.
DET~ILED DESCRIPTION OF THE INVENTION
The lnvention wlll lnltlally be de8crlbed broadly, wlth a more detailed description following.
The present invention is a papermakers' forming fabric particularly useful for, but not restricted to, the formation of brown paper. The fabric has a high fiber support, uniform 1? 1 32774~
drainage paths, hlgh permeablllty, hlgh stretch reslstance, good abrasion resistance, and can be produced at a cost that makes it economical as a brown paper formlng fabrlc.
The fabrlc of the present lnventlon ls a self-stitched construction includlng two essentially dlstlnct fabrlc layers, one on top of the other. The top layer that wlll form the papermaklng surface lncorporates relatlvely fine yarns ln both the machlne directlon and the cross machlne dlrectlon, whlch, ln the preferred embodlment, are woven ln a 2 x 2 weave pattern. The bottom layer that will contact the machlne elements lncorporates relatively coarse yarns ln the machlne dlrectlon and the cross machlne dlrectlon, also preferably ln a 2 x 2 weave pattern. Thls fabrlc ls essentlally a hybrld double-layer structure ln that each layer contalns lts own system of machlne dlrectlon yarns and cross machlne dlrection yarns. The only dlscontlnulty ln elther layer occurs when selected cross machlne dlrectlon yarns from the top fabric dive down and engage selected machlne dlrectlon yarns from the bottom fabrlc to create the composite structure by blnding the two layers together. No addltlonal blndin~ thread ls neces~ary. The requlred ldeal seatlng condltlon and ldeal self-stitching condition are descrlbed wlth reference to the drawlng below.
The machlne dlrectlon yarns and the cross machlne dlrectlon yarns used in the present lnventlon are preferably synthètic yarns of materlals conventionally used in such fabrlcs, such as polyamldes (Nylon), polyesters (Dacron), and acryllc flbers (Orlon, Dynel and Acrllan), or co-polymers (Saran). The machine directlon yarns and the cross machlne direction yarns may be in the form of monofilament, multlfllament or staple yarns or plied or wrapped yarns. The speclfic ph~sical propertles of the selected yarns, for example, modulus, elongation, free shrink and thermal shrlnk can be chosen to optimize the geometry conflguratlon of the flnal fabric product.
The dlameter of the yarns employed in the fabrlc for the present lnventlon ls determlned by the posltlon ln the fabrlc structure. The machine direction yarns and the cross machlne dlrectlon yarns ln the top fabrlc layer are approxlmately equal in dlameter and approxlmately half the slze of the machlne dlrectlon yarns and the cross machlne dlrectlon yarns ln the bottom fabric layer, those yarns also belng approxlmately e~ual ln diameter. In a preferred embodlment, the top fabrlc layer lncorporates yarns that are .16 mllllmeter (machine dlrectlon) by .18 mllllmeter (cross machlne dlrectlon) and the bottom fabrlc layer lncorporates yarns that are .34 mllllmeter (machlne dlrectlon) by .36 mlllimeter (cross machlne dlrectlon). The size of the yarns ln both ~ystems can be lncreased or decreased to sult the lndlvldual requlrements of a partlcular appllcatlon for the papermaking fabric.
The weave pattern used in the preferred embodlment ofthe fabric of the present lnvention is a twlll weave characterized by a diagonal line on the face of the fabric. Both the top fabric layer and the bottom fabric layer are 2 x 2 twill, meaning that the machine direction yarns go over two cross machine direction yarns and under two cross machine direction yarns in a repeating pattern. To achieve the stated goals of the ideal seating arrangement and the ideal self-stitching arrangement of the present invention, the twills in the mating fabrics will have a reverse orientation relative to each other, that is the upper surface of the top fabric layer is a right to left twill while the upper surface of the bottom fabric layer is a left to right twill or vlce versa. In comblnatlon wlth the above-mentioned reversed twill crlterla, the top fabrlc layer and the bottom fabric layer must be positioned relative to each other such that the relationship between the lower surface machlne dlrectlon floats of the top fabric layer interface wlth the upper surface cross machine direction floats of the bottom fabrlc layer ln a maxlmum contact same plane, essentlally 90 degree cross shaped orlentatlon mode, which provldes ldeal lnterface symmetry.
Turnlng now to the drawlngs, FIG. la lllustrates the upper papermaklng surface of the top fabrlc layer, EIG. lb ls a machlne dlrectlon sectlon (taken along llne lb-lb ln FIG. la), and FIG. lc ls a cross machlne dlrectlon section ~taken along llne lc-lc ln FIG. la), respectlvely, of the top fabrlc layer of one embodlment of the present invention. As stated above, the top fabric layer 10 includes relatively fine machine direction 12 and cross machlne directlon 14 yarns lnterwoven in a 2 x 2 twill weave pattern. The cross machine dlrectlon float 14 can be seen across the papermaking surface view. Consistent with the 2 x 2 twlll weave, these floats ascend from right to left across the fabrlc 10, constituting a right to left twill.
FIG. 2a illustrates the upper interfacing surface of the bottom layer fabric, FIG. 2b a machine direction section (taken along the line 2b-2b in FIG. 2a), and FIGS. 2c and 2d illustrate cross machine direction sections (taken along the lines 2c-2c and 2d-2d in FIG. 2a), respectively, of the bottom fabric used in one embodiment of the fabric of the present invention. Again, the bottom fabric layer 20 includes relatively coarse machine direction 22 and croæs machlne direction 24 yarns interwoven in a 2 x 2 twill pattern. The floats of cross machine direction 24 can be seen across the interfacing surface view in FIG. 2a.
Consistent with the 2 x 2 twill weave, these floats ascend from left to right across the fabric 20 constltutlng a left to rlght twill which is the reverse of that ln the top fabrlc layer 10.
Wlthln the teachlngs of the present lnventlon, a top fabrlc layer havlng a left to rlght twill could be mated wlth a bottom fabrlc layer having a rlght to left twill. The polnts marked "S" in three vlews represent a typlcal polnt where the flne cross machine dlrectlon yarn from the top fabrlc layer could descend to bind around the coarse machlne dlrection yarn ln the lower fabrlc layer 20. Examlnation of these views wlll reveal a number of other "S"
type locatlons which would satl~fy the ldeal self-stltch polnt requlrements. The number of such locations actually utilized in the ultimate composlte fabrlc ls agaln dependent upon the stitchlng frequency needs determined feaslble for the product , ,, ~ .
.
application.
FIGS. 3a to 3e lllustrate the posslble and the ldeal seating arrangements between the top fabric layer 10 and the bottom fabric layer 20 at the stacked or overlylng cross machine directlon yarns. In each of these views, the top fabrlc machlne direction yarns 12 and the bottom fabric machine directlon yarns 22 are unstacked, that ls each bottom fabrlc machine directlon yarn 22 is lntermediately spaced between a pair of top fabric machine direction yarns 12. Conversely, the non-stitching cross machine direction yarns 14 of the top fabric layer and the cross machine dlrectlon yarns 24 of the bottom fabric layer are stacked.
That is the bottom fabric layer cross machlne direction yarns is directly under the top fabrlc cross machine direction yarns 14.
This is lllustrated in FIG. 3a and FIG. 3e. There are twice as many cross machine dlrection yarns 14 ln the top fabric layer 10 as there are cross machine dlrection yarnæ 24 in the bottom fabric layer 20. Only selected top fabrlc layer cross machlne dlrectlon yarns will descend to the bottom fabrlc layer and wrap around certain bottom fabric layer machlne dlrectlon yarns to bind the two fabric layers together. Those selected cross machine direction yarns which descend ~"stltchers") alternate wlth cross machlne dlrectlon yarns whlch do not descend ("non-stitchers").
FIGS. 3a-3e show positlons of only a non-stltchlng cross machlne dlrectlon yarn of the top fabrlc layer relatlve to a cross machlne dlreation yarn of the bottom fabric layer. This dl~tlnctlon ls further explalned by comparing FIGS. 3a-3e to FIGS. 6b and 6c.
~ Wlthln these bounds, the top fabrlc 10 can then be posltloned ,, ,,g~,.
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1 3277~2 relative to the bottom fabrlc 20 ln four locals, labeled Ideal, One-Left, Two-Left, Three-Left, and Ideal agaln respectlvely, It should also be noted that only ln the ideal posltion are the top fabric 10 and the bottom fabrlc 20 oriented such that both lower surface machine direction floats of the top fabric 10 interface with the upper surface cross machine direction floats of the bottom fabric ln the prescribed maxlmum contact same plane, essentially 90 degree cross shaped orientation mode, as shown below in FIG. 5.
FIG. 4 illustrates the relationship between the papermaking surface of the top fabric 10 and the lnterfacing surface of the bottom fabrlc 20 where the above-descrlbed seating arrangement has been achieved. For further famlllarlzatlon of the ldeal self-stltch polnt concept, the self-stltching points used in the composite fabric structure of one embodiment of the present invention have been marked with an "S". Once again, more or less self-stitching points could be utilized, provided they meet the ideal location criteria, dependlng upon the overall papermaklng and structural requirements of the flnal composlte forming fabric product.
PIG. 5 illustrates the relatlonship between the lower surface imprlnt of the to~ fabrlc 10 and the upper surface lmprlnt of the bottom fabrlc 20 utlllzed ln one embodlment of the present lnventlon. The matlng of these respective imprints indicate the areas where the yarns of the two fabrics lnterface. Speclflcally, when the ideal seating arrangement has been achieved, the lower machine direction float~ 12 of the top fabric 10 contact the upper cross machine direction floats 24 of the bottom fabric 20 in a maximum contact same plane, essentially 90 degree cross shaped orientation mode, the cross shape being shown in FIG. 5; this ideal interface is clrcled in FIGS. 3a and 6b. Additionally, a typical ideal self-stitching point "S" where the fine cross machine direction yarn 14 can most easily dip down, specifically dip further down from its already down position, to engage the machine direction yarn 22 of the bottom fabric 20 at its highest most accessible point is indicated by the "S" label. Once again, both the ideal seating arrangement and the ideal self-stitching points are representative typical positions which occur frequently within a pattern repeat. In a properly designed composite fabric, all the interfacing areas should satisfy the ideal seating arrangement criteria. However, the number of ideal self-stltchlng points "S" actually utilized within a pattern repeat will depend upon the ultimate ob~ectives for the product.
FIG. 6a lllustrates the comblned structure, speciflcally the relatlonshlp between the sheet maklng upper surface of the top fabric layer 10, and lnterfaclng surface of the bottom fabrlc layer 20 of the preferred embodlment of the present inventlon where the above-described ldeal seatlng arrangement has been aahleved. For further famlliarlzatlon of the ldeal ln the composite fabrlc structure of one embodlment of the present lnventlon have been marked with an "o" and labelled "S". Once agaln, more or fewer self-stltchlng points could be utillzed, provlded they meet the ideal location criterla, depending upon the ,:
~`
.
overall papermaking and structural requirements of the final composite forming fabric product. FIG. 6b, taken along line 6b-6b in FIG. 6a, and FIG. 6c, taken along line 6c-6c in FIG. 6a, illustrate two cross machine direction sections and FIG. 6d, taken along line 6d-6d in FIG. 6a, and FIG. 6e, taken along line 6e-6e in FIG. 6a, two machine direction sections of the preferred embodiment of the present invention.
FIGS 6b and 6c illustrate the paths of two cross machine direction yarns, and clearly show the role and positloning of alternatlng cross machlne dlrectlon yarns ln this fabric. The typlcal ldeal seatlng arrangement previously descrlbed is apparent ln the cross machine direction section in Fig. 6b where there is a stacked relationship between the cross machine direction yarns 14 of the top fabric layer 10 and the cross machine direction yarns 24 of the bottom fabric layer 20. In one yarn, as shown in FIG. 6c, no bottom fabric cross machine direction yarn 24 sits below the top fabric cross machine direction yarns 14. The ad~acent, and all alternatlng top fabric cross machine direction yarns 14 thus become the stltching yarns. The typlcal ldeal self-stitching point marked "S" is apparent in FIG. 6a, FIG. 6c and lnFIG. 6e. In the embodiment of the present invention shown in FIGS. 6a-6e, the self-stitching is done by each self-stitching top fabric cros~ machine direction yarn 14 on every eighth bottom fabric machine direction yarn 22 so that, with the alternating nature of the stitching pattern, every machine direction yarn 22 in the bottom fabric layer is eventually interlaced with every other cross machlne direction yarn 14 from the top fabric layer 10 within the confines of one pattern repeat. It can also be seen ~;
, 19 that the self-stitch provided by every other fine cross machine direction yarn 14 from the top fabrlc layer 10 ls merely an extension from its already down or under float posltlon whlch allows lt to descend somewhat further down to lnterlace wlth the machlne directlon yarn 22 ln the bottom fabric layer 20 whlch ls at that point ln its highest position. At its highest position, or elevation, in its weave repeat, the machine direction yarn 22 in the bottom fabric 20 is optimally accessible. The elevation of representative machine direction yarns relative to each other in a weave repeat is shown in FIG. 2d. As can be seen in that figure, a possible stitch point occurs when the machine direction yarn is at a highest elevation compared to the other machlne direction yarns in the weave repeat. This comblnation glves the mlnlmal elongatlon of the self-stitch yarn over a symmetrically unlform path. Having the self-stltch cross machlne directlon yarns 14 of the top fabric layer 10 located midway between the surroundlng cross machlne direction yarns 24 in the bottom fabric layer 20 also contributes to the structural integrlty of the resultant composlte fabric (see FIG. 6e).
FIG. 7 lllustrates the comblned structure with papermaking surface view of the top fabrlc layer 10 overlald on the lnterfaclng surface of the bottom fabric layer 20 and the self-stltch polnts marked as "S". A typlcal ldeal seatlng arrangement wlll produce a situatlon where the lower floats of the machlne direction yarns 12 ln the top fabric layer 10 interface wlth the upper float of the cross machine dlrectlon yarns 24 in the bottom fabric layer 20 ln the requlred 90 degree cross-shaped orlentatlon mode, as shown within the clrcled area. The skllled observer can see that this ideal seating arrangement condltlon occurs numerous times within a pattern repeat of the pre~ent invention. The ideal self-stitchlng polnts, labelled "S"
typlcally, also occur qulte frequently withln a pattern repeat.
However, in the preferred embodiment of the present invention, the utilized frequency of these ideal self-stitching points which exist along every other fine cross machine direction yarn 14 in the top fabric layer 10 is once every sixteen machine direction yarns 12 in the top fabric layer 10 and once every eight machine direction yarns 22 in the bottom fabric layer 20. Given the staggered nature of the self-stitching pattern, the net result i5 that at some point along every machine direction yarn 22 in the bottom fabric layer 10 an interlace is achieved with the top fabrlc layer 10 wlthin a pattern repeat. This self-stitching frequency can be increased or decreased, always using the ideal self-stltchlng polnts only, depending upon the partlcular applicatlon for the final product.
FIGS. 8a and 8b illustrate the two configurations for the cros~ machine direction yarns of the top fabric layer 10 as they relate to the bottom fabric layer 20 in the preferred embodiment of the present invention. FIG. 8a illustrates the cross machlne direction yarns 14 of the composite fabric taken along line 8a~8a in FIG. 7 at the stac~ed non-stitchlng posltlon and FIG. 8b, taken along llne 8b-8b in FIG. 7, shows the lntermedlately spaced self-stltchlng yarns cross machlne dlrectlon yarn 14 of the top fabrlc layer 10. The typical ideal seating arrangement is circled and the typical ideal self-stltchlng polnt ls labelled ~S".
., .
,. .
1 3~77~2 Wlthln the context of the present lnventlon, only fabrics having 2 x 2 twlll weaves have been lllustrated hereln;
however, the teachings descrlbed herein are not restrlcted to ~ust 2 x 2 twlll weaves. In other words, the prlnclples of ldeal seating arrangement, self-stitch allgnment, and lnterface symmetry can be successfully applled over a broad range of weave patterns, not necessarlly the same for each layer, ln creatlng similar composlte papermaking fabrlcs. Where the espoused guldellnes are ~udlclously applled, a superior papermaking product can be produced. While the fabric hereln descrlbed constltutes the preferred embodlment of the inventlon, it is to be understood that the inventlon 18 not llmited to the precise fabrlc described and that changes may be made hereln wlthout departlng from the scope of the invention.
~) ~' .
,
Claims (15)
1. An endless papermaking fabric comprising:
a top fabric layer including relatively fine machine direction yarns interwoven with relatively fine cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the top fabric layer cross machine direction yarns including stitching and non-stitching cross machine direction yarns;
a bottom fabric layer including relatively coarse machine direction yarns interwoven with relatively coarse cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface;
the number of the relatively fine top fabric layer cross machine direction yarns being approximately twice that of the relatively coarse bottom fabric layer cross machine direction yarns;
wherein said top fabric layer cross machine direction yarns travel singly and engage selected machine direction yarns of the bottom fabric layer at a highest elevation relative to the elevation of the machine direction yarns of the bottom fabric layer other than said selected machine direction yarns to bind the fabric layers together.
a top fabric layer including relatively fine machine direction yarns interwoven with relatively fine cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the top fabric layer cross machine direction yarns including stitching and non-stitching cross machine direction yarns;
a bottom fabric layer including relatively coarse machine direction yarns interwoven with relatively coarse cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface;
the number of the relatively fine top fabric layer cross machine direction yarns being approximately twice that of the relatively coarse bottom fabric layer cross machine direction yarns;
wherein said top fabric layer cross machine direction yarns travel singly and engage selected machine direction yarns of the bottom fabric layer at a highest elevation relative to the elevation of the machine direction yarns of the bottom fabric layer other than said selected machine direction yarns to bind the fabric layers together.
2. The papermaking fabric of claim 1 wherein the top fabric layer is 2 x 2 twill weave.
3. The papermaking fabric of claim 2 wherein the bottom fabric layer is a 2 x 2 twill weave.
4. The papermaking fabric of claim 3 wherein the top fabric layer machine direction yarns are approximately 0.16 millimeter, the top fabric layer cross machine direction yarns are approximately 0.18 millimeter, the bottom fabric layer machine direction yarns are approximately 0.34 millimeter and the bottom fabric cross machine direction yarns are approximately 0.36 millimeter in diameter.
5. The papermaking fabric of claim 3 wherein the upper surface of the top fabric layer is a right to left twill and the upper surface of the bottom fabric layer is a left to right twill.
6. The papermaking fabric of claim 3 wherein the twill of the upper surface of the top fabric layer is opposite to the twill of the upper surface of bottom fabric layer.
7. The papermaking fabric of claim 2 wherein every other cross machine direction yarn of the top fabric layer engages every eight machine direction yarn in the bottom fabric layer and every machine direction yarn in the bottom fabric layer is interlaced with every other cross machine direction yarn of the top fabric layer within one weave repeat.
8. An endless papermaking fabric comprising:
a top fabric layer including relative fine machine direction yarns interwoven with relatively fine cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the top fabric layer cross machine direction yarns including stitching and non-stitching cross machine direction yarns the upper surface including machine direction and cross machine direction floats and the lower surface including machine direction and cross machine direction floats;
a bottom fabric layer including relatively coarse machine direction yarns interwoven with relatively coarse cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the upper surface including machine direction and cross machine direction floats and the lower surface including machine directon and cross machine direction floats;
the number of relatively fine top fabric layer cross machine direction yarns being approximately twice that of the relatively coarse bottom fabric layer cross machine direction yarns;
wherein said top fabric layer cross machine direction yarns engage selected machine direction yarns of the bottom fabric layer at a highest elevation relative to the elevation of the machine direction yarns of the bottom fabric layer other than said selected machine direction yarns to bind the fabric layers together; and wherein the lower surface machine direction floats of the upper fabric layer contact the upper surface cross machine direction floats of the bottom fabric layer in a maximum contact same plane configuration.
a top fabric layer including relative fine machine direction yarns interwoven with relatively fine cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the top fabric layer cross machine direction yarns including stitching and non-stitching cross machine direction yarns the upper surface including machine direction and cross machine direction floats and the lower surface including machine direction and cross machine direction floats;
a bottom fabric layer including relatively coarse machine direction yarns interwoven with relatively coarse cross machine direction yarns in a repeating pattern to form an upper surface and a lower surface, the upper surface including machine direction and cross machine direction floats and the lower surface including machine directon and cross machine direction floats;
the number of relatively fine top fabric layer cross machine direction yarns being approximately twice that of the relatively coarse bottom fabric layer cross machine direction yarns;
wherein said top fabric layer cross machine direction yarns engage selected machine direction yarns of the bottom fabric layer at a highest elevation relative to the elevation of the machine direction yarns of the bottom fabric layer other than said selected machine direction yarns to bind the fabric layers together; and wherein the lower surface machine direction floats of the upper fabric layer contact the upper surface cross machine direction floats of the bottom fabric layer in a maximum contact same plane configuration.
9. The papermaking fabric of claim 8 wherein the maximum contact same plane configuration is a 90 degree cross-shaped orientation mode.
10. The papermaking fabric of claim 9 wherein the top fabric layer is a 2 x 2 twill weave.
11. The papermaking fabric of claim 10 wherein the bottom fabric layer is a 2 x 2 twill weave.
12. The papermaking fabric of claim 11 wherein the top fabric layer machine direction yarns are approximately 0.16 millimeter, the top fabric layer cross machine direction yarns are approximately 0.18 millimeter, the bottom fabric layer machine direction yarns are approximately 0.34 millimeter and the bottom fabric cross machine direction yarns are approximately 0.36 millimeter in diameter.
13. The papermaking fabric of claim 11 wherein the upper surface of the top fabric layer is a right to left twill and the upper surface of the bottom fabric layer is a left to right twill.
14. The papermaking fabric of claim 11 wherein the twill of the upper surface of the top fabric layer is opposite to the twill of the upper surface of bottom fabric layer.
15. The papermaking fabric of claim 9 wherein every other cross machine direction yarn of the top fabric layer engages every eighth machine direction yarn in the bottom fabric layer and every machine direction yarn in the bottom fabric layer is interlaced with every other cross machine direction yarn of the top fabric layer within one weave repeat.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US309,785 | 1989-02-10 | ||
| US07/309,785 US5052448A (en) | 1989-02-10 | 1989-02-10 | Self stitching multilayer papermaking fabric |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1327742C true CA1327742C (en) | 1994-03-15 |
Family
ID=23199671
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000612064A Expired - Fee Related CA1327742C (en) | 1989-02-10 | 1989-09-20 | Papermaking fabric |
Country Status (4)
| Country | Link |
|---|---|
| US (2) | US5052448A (en) |
| JP (1) | JP2563842B2 (en) |
| AU (1) | AU626631B2 (en) |
| CA (1) | CA1327742C (en) |
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| DE3705345A1 (en) * | 1987-02-19 | 1988-09-01 | Oberdorfer Fa F | COMPOSITE FABRIC AS A COVER FOR THE SHEET FORMING PART OF A PAPER MACHINE |
| US4759976A (en) * | 1987-04-30 | 1988-07-26 | Albany International Corp. | Forming fabric structure to resist rewet of the paper sheet |
| AU623102B2 (en) * | 1987-10-07 | 1992-05-07 | Tamfelt, Inc. | Papermaker press felt |
| US4921750A (en) * | 1988-05-25 | 1990-05-01 | Asten Group, Inc. | Papermaker's thru-dryer embossing fabric |
| FI81624C (en) * | 1988-12-08 | 1990-11-12 | Tamfelt Oy Ab | PAPPERSMASKINDUK. |
| US5013330A (en) * | 1989-12-04 | 1991-05-07 | Asten Group, Inc. | Multi-layered papermakers fabric for thru-dryer application |
-
1989
- 1989-02-10 US US07/309,785 patent/US5052448A/en not_active Ceased
- 1989-09-20 CA CA000612064A patent/CA1327742C/en not_active Expired - Fee Related
-
1990
- 1990-02-05 AU AU49085/90A patent/AU626631B2/en not_active Ceased
- 1990-02-09 JP JP2031288A patent/JP2563842B2/en not_active Expired - Fee Related
-
1993
- 1993-09-30 US US08/129,674 patent/USRE35777E/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| US5052448A (en) | 1991-10-01 |
| AU626631B2 (en) | 1992-08-06 |
| JP2563842B2 (en) | 1996-12-18 |
| JPH02269891A (en) | 1990-11-05 |
| AU4908590A (en) | 1990-08-16 |
| USRE35777E (en) | 1998-04-28 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKLA | Lapsed |