INCORPORATION BY REFERENCE

[0001] The following documents are incorporated herein by reference as if fully set forth: U.S. Provisional Patent Application No. 62/234,909, filed September 30, 2015.

BACKGROUND

[0002] The invention relates to industrial textiles, and more particularly to papermaking fabrics.

[0003] Numerous weaves are known in the art which are employed to achieve different results for different applications.

SUMMARY

[0004] The invention concerns an industrial textile suitable for use as a dryer fabric in a papermaking machine. The industrial textile is woven according to a 2 ½ weft layer weave construction in which a first set of weft yarns is located to the paper side (PS) surface, a second set is located to the machine side (MS) surface and a third set is positioned intermediate to and adjacently between each of the yarns of the first and second weft yarn sets (i.e.: to provide the 2 ½ layer construction; if all of the weft were stacked directly over one another, the fabric would have a 3 weft layer construction as shown in Figure 5A).

[0005] These three sets of weft yarns are interwoven into a unified fabric using two independent, vertically stacked warp yarn systems. Each warp system is interwoven with the weft yarns according to identical but inverted patterns relative to one another. The term "vertically stacked" refers to the relative vertical position of the warp yarns of each of the first and second warp yarn systems in the textile: each warp yarn of the first warp yarn system is located directly over and is vertically aligned with a warp yarn in the second warp yarn system. The first warp yarn system interweaves with the first and third sets of weft yarns to form a first outer layer of the fabric (which could be either the PS or MS layer). The second warp yarn system interweaves with the second and third weft yarn sets to form the second outer layer of the fabric (which would be the opposite MS layer in the first instance). Both warp systems interweave with the centrally located (or intermediate) third weft yarn set to bind the two outer layers together as a unified fabric.

[0006] The warp yarns preferably have a generally rectangular cross- sectional shape as this contributes to the stability of the fabric and its smoothness. The yarns may be grooved and/or profiled in the manner described by Kuckart US 6773786 to assist in rendering the fabric contamination resistant. The weft yarns preferably have a circular cross- section shape, but other shapes (e.g. ovate) may be employed.

[0007] The resulting construction is a rugged and wear resistant industrial textile that is highly stable (meaning it is resistive to out of plane distortion due in part to its stiffness). The fabric is adaptable to a wide range of applications by appropriate selection of warp and weft yarn types, sizes and shapes. For example, air permeability of the fabric is easily adjusted according to need; the fabric can be rendered temperature or contamination resistant by appropriate selection of the warp yarn materials and sizes. In addition the fabric exhibits high seam strength due to the stacked warp construction which utilizes 100% of the warp yarns to form the seam, and which also provides the fabric with a 200% warp fill. The term "warp fill" refers to the amount of warp yarns in a given space relative to total space considered. Warp fill can be over 100% when there are more warp strands jammed into the available space than the space can dimensionally accommodate in a single plane. A fabric with 200% warp fill or more may have two layers of warp yarns each woven at at least 100% warp fill. The fabric is highly stable, and resists creasing and distortion due to the fact that the warp yarns in each layer are woven at 100% warp fill, or more, and are thus immediately adjacent to, and braced against one another. The 2 ½ layers of weft yarns further contribute to fabric stability by augmenting cross-machine direction (CD) stiffness. [0008] The unique construction of the industrial textile is efficient to manufacture as it uses 35% less weft yarns than would comparable three weft layer fabric constructions (such as prior art Figure 5). The fabric is easy to weave using existing looms and does not require re-setting the loom from existing stacked warp products (e.g. such as those produced according to Lee US 5, 117,865 and others - known by product name MonoTier® from the present assignee, AstenJohnson, Inc.). A further benefit provided by the unique fabric construction is that, because the fabric is symmetrical (top and both are the same) it is amenable to automated seaming so as to form seaming loops at each opposing end for a pin seam to join the fabric and render it endless. Certain fabric designs, such as that shown in Fig. 5A and 5B cannot be seamed by machine; seams for those fabrics must be formed manually which may require several days and will drive up the manufacturing costs substantially. The ability to apply automated seaming technology to the fabric design provides a substantial saving in labor and associated manufacturing costs.

[0009] The weave pattern of the novel fabric provides it with relatively longer floats of the warp yarns on both exterior surfaces; these floats enhance its ability to resist abrasive wear. The fabric design can be adapted for many different applications by proper warp and weft selection which will allow the fabric to obtain a wide range of air permeabilities. Although fabric caliper (thickness) can be made low to allow for use in high speed applications, the stability of the textile is maintained due to the warp yarn bracing and high CD stiffness provided by the layers of weft yarns. The two independent warp systems provide a further benefit in that the materials used in each can be optimized to resist the environmental effects to which each fabric surface exposed. For example, the monofilament warp yarns used to form a first fabric surface can be comprised of PPS (polyphenylene sulfide) or PCTA (polycylcohexane dimethanol terephthalic acid) polymers which are more resistant to thermal and hydrolytic degradation than PET (polyethylene terephthalate) yarns (and more expensive). Warp yarns formed from PET polymer could be utilized on the PS of the textile where heat and hydrolysis resistance are less critical properties; these yarns may be grooved or otherwise profiled for contamination resistance.

[0010] Fabrics according to the invention such as are shown in the

Figures were woven using rectangular cross-section polymeric monofilament warp yarns whose dimensions are 0.25 x 1.05mm or 0.36 x 1.07mm to obtain a width to height ratio of between 4: 1 and 3: 1 but other cross -sectional shapes and ratios may be employed. The weft yarns used in these fabrics have a generally circular cross-sectional shape and ranged in size from about 0.50mm to 1.0mm; other sizes may be employed depending upon need. The fabric was woven at 40 picks per inch (weft yarns per inch).

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The foregoing Summary and the following detailed description will be better understood when read in conjunction with the appended drawings, which illustrate a preferred embodiment of the invention. In the drawings:

[0012] Figure 1 is a cross-sectional view of a fabric according to the invention taken parallel to the warp yarns;

[0013] Figure 2 is a perspective view of a first surface of the fabric shown in Figure 1;

[0014] Figure 3 is a plan view of a first surface of the fabric shown in

Figures 1 or 2 (both fabric surfaces are identical);

[0015] Figure 4A presents a weave diagram showing one full repeat of the fabric; Figure 4B presents multiple repeats of the weave pattern of the one fabric surface;

[0016] Figure 5A is a cross-sectional view taken parallel to the warp yarns of a prior art three weft layer fabric construction;

[0017] Figure 5B is the weave diagram and pattern of the prior art fabric shown in Figure 5A;

[0018] Figure 6A is a cross-sectional view taken parallel to the warp yarns of a second prior art fabric having a 2 ½ weft layer construction; and [0019] Figure 6B is the weave diagram and pattern of the prior art fabric shown in Figure 6A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] Certain terminology is used in the following description for convenience only and is not limiting. The fabric according to the invention is an industrial textile, which can have many industrial applications, such as conveyor belts, filter fabrics, etc. The words "paper side" and "machine side" designate surfaces of the fabric with reference to their use in one preferred application in a papermaking machine; however, these terms merely represent first and second or upper and lower surfaces of the planar fabric. "Yarn" is used to generically identify a monofilament or multifilament fiber. "Warp" and "weft" are used to designate yarns or monofilaments based on their position in the loom that extend in perpendicular directions in the fabric and either could be a machine direction (MD) or cross-machine direction (CMD) yarn in the fabric once it is installed on a papermaking machine, depending on whether the fabric is flat woven or continuously woven. In the preferred arrangement, the fabric is flat woven and seamed at the warp ends in order to form a continuous belt, so that the warp yarns are MD yarns and the weft yarns are CMD yarns.

[0021] One preferred application of the fabrics according to the invention is on a papermaking machine, and the fabric could have application as a forming fabric, a press fabric, or a dryer fabric for use in the corresponding forming, press, and dryer sections of a papermaking machine. These are generally all referred to as a "papermaking fabric" regardless of the position of use in a papermaking machine.

[0022] Figure 1 shows a cross-section taken parallel to the warp yarns in a portion of an industrial textile according to the invention. As shown, the fabric 100 includes a first system of warp yarns of which yarns 2Wa and 4Wa are exemplary, and a second system of warp yarns of which yarns lWa and 3Wa are exemplary. The fabric also includes three sets of weft yarns; a first weft yarn set 20 is located proximate to a first surface of the fabric, a second weft yarn set 22 is located proximate to a second surface of the textile while an intermediate weft yarn set 21 is located intermediate to the first and second weft yarn sets. Figure 1 shows several repeats of the warp yarn interweaving pattern, the entirety of which is presented in the weave diagram of Figure 4A.

[0023] As shown in Figures 1 and 4A, warp yarn IWa passes under weft

1 (of the first weft yarn set 20), over weft 2 (of second set 22), over weft 3 (of intermediate set 21), under weft 4, over weft 5 and then under wefts 6 through 12 at which point the pattern repeats. In the same repeat, warp yarn 2Wa passes over wefts 1 through 6, under weft 7, over weft 8, under weft 9 (of intermediate weft yarn set 21), under weft 10 (of the first weft yarn set 20) and over wefts 11 and 12 (of the second weft yarn set 22) to complete the pattern. Adjacent warp yarn 4Wa follows a similar pattern but is offset longitudinally in the fabric by 3 weft yarns; similarly warp 3Wa follows the same patterns as warp IWa but offset by 3 weft yarns. In each repeat of the warp interweaving pattern, each warp ties into/wraps around a weft yarn of the intermediate weft yarn set 21; warp IWa wraps around weft yarn 3 of intermediate weft yarn set 21, while warp yarn 2Wa wraps around weft yarn 9 of intermediate weft yarn set 21, thus tying the outside layers of the fabric together into a unified structure.

[0024] Inspection of Figure 1 shows that the warp yarns such as 2Wa and 4Wa forming a first surface of the fabric 100, are interwoven with weft yarns from weft yarn sets 20 and 21, while the warp yarns such as IWa and 3Wa which form a second surface of the textile 100 are interwoven with the weft yarns of weft yarn sets 22 and 21. Because both systems of warp interweave with the weft yarns of the intermediate weft yarn set 21, a unified fabric construction is provided. In addition, the weft yarns of weft yarn sets 20 and 22 are arranged so as to form vertically stacked non-contacting pairs, while the weft yarns of intermediate weft yarn set 21 are offset with respect to each stacked pair of weft yarn sets 20 and 22 and are located in between each.

[0025] The complete weave pattern of the fabric 100 shown in Figure 1 is presented in Figure 4A; the pattern provided in Figure 4B shows the arrangement of the warp yarns on a first (e.g. paper side) surface of the fabric, and is identical to the corresponding arrangement on the opposite second surface. The first set of warp yarns is indicated in Fig. 4A at 2Wa, 4Wa, 6Wa, 8Wa, and the second set of warp yarns is indicated at lWa, 3Wa, 5Wa, 7Wa. This is for an 8 shed weave. However, this is merely exemplary and could be varied.

[0026] Figure 2 shows a perspective view of the textile 100 presented in

Figure 1. As can be seen, the warp yarns 2Wa and 4Wa of the first system of warp yarns are interwoven with the weft yarns of weft yarn sets 20 and 21 to form a first surface of the fabric. Each warp yarn 2Wa and 4Wa forms a "float" over 5 weft yarns of weft yarn sets 20 and 21 as described above in relation to Figure 1; e.g. warp 2Wa passes over weft yarns 1, 3, 4, 6, & 12. In relation to the complete fabric pattern, each of the warp yarns passes over 9 weft in one repeat of the weave pattern; e.g. warp 2Wa passes over weft yarns 1, 2, 3, 4, 5, 6, 8 11 & 12. All of the warp yarns in the fabric are interwoven with the weft yarns in the identical manner as described in the weave diagram presented in Figure 4.

[0027] Figure 3 is a planar perspective view of the fabric shown in

Figures 1 and 2 and clearly shows the floats of the warp yarns on a first surface of the fabric. The warp yarn floats on the second surface of the fabric will be identical to those on the first. At each surface of the fabric, each warp yarn floats over 5 weft yarns, including two from either weft sets 20 or 22, and three weft yarns from intermediate yarn set 21; the arrangement of the floats on each surface can be adjusted according to requirements. For example, the fabric of Figure 3 is woven to provide a "herringbone" type arrangement of the warp floats, but the floats could also be arranged according to a twill or broken twill pattern by simple adjustment of the weave pattern which would be apparent to one skilled in the art based on the present disclosure.

[0028] Figure 4A presents one weave pattern repeat of the fabric shown in Figures 1 to 3. The interweaving pattern of warp yarns lWa - 8Wa shown in Figure 1 and 2 are indicated. Figure 4B provides the weave pattern of one planar surface of the fabric shown in Figure 4A with warp yarns 2Wa and 4Wa indicated. [0029] The warp yarns lWa - 8Wa preferably have a generally rectangular cross-sectional shape as this contributes to the stability of the fabric and its smoothness. In two preferred arrangements, rectangular cross- section polymeric monofilament warp yarns whose dimensions are 0.25 x 1.05mm or 0.36 x 1.07mm to obtain a width to height ratio (aspect ratio) of between 4: 1 and 3: 1 are used. However, those skilled in the art will recognize that other cross-sectional shapes and ratios may be employed, such as oval or flattened shapes with rounded sides, and aspect ratios of 2: 1 to 6: 1. The weft yarns 1 - 12 used in these fabrics have a generally circular cross-sectional shape and in some preferred arrangements may range in size from 0.6mm, 0.7mm, 0.8mm or 0.9mm; other yarn sizes may be employed to provide satisfactory results depending on the intended end use application of the fabric . Good results may also be obtained by using weft yarns in which a portion of their cross-sectional area is hollow; such hollow yarns may be located in any position (either exterior layer, or intermediate layer) but may be preferentially located to an exterior layer. However, those skilled in the art will recognize that other sizes may be employed depending upon need. In one preferred arrangement, the fabric 100 is woven at 40 picks per inch (weft yarns per inch) (or 15.7 yarns/cm).

[0030] Testing has shown high CD stiffness achieved for 2 ½ layer fabrics according to the preferred arrangement, with fabrics woven with 0.8mm diameter yarns providing the same CD stiffness of the current 3 layer fabrics woven with 0.6mm diameter weft yarns, and fabrics woven with 0.9mm diameter yarns exceeding the CD stiffness of the current 3 layer fabrics.

[0031] The fabric 100 exhibits high seam strength due to the stacked warp construction which utilizes 100% of the warp yarns lWa - 8Wa to form the seam, and which also provides the fabric with a 200% warp fill. The seams can be formed in a known manner by unweaving and back-weaving warp yarns 2Wa, 4Wa, 6Wa, 8Wa from the first surface back into the fabric along the paths of the corresponding stacked one of the warp yarns lWa, 3Wa, 5Wa, 7Wa from the second layer that have been cut back from the end of the fabric to form seam loops at each end of the planar fabric, with the seam loops then being interdigitated and joined by a pintle to form an endless fabric loop. Here the warp fill is preferably about 200% warp fill, with each layer having warp yarns woven at about 100% warp fill. This results in the fabric 100 being highly stable, and resists creasing and distortion due to the fact that the warp yarns IWa - 8Wa in each layer are woven at about 100% warp fill, or more, and are thus immediately adjacent to, and braced against one another. This also maintains the stacked arrangement of the warp yarns in corresponding pairs IWa, 2Wa; 3Wa, 4Wa, etc.

[0032] The two independent warp systems provide a further benefit in that the materials used in each can be optimized to resist the environmental effects to which each fabric surface exposed. For example, the monofilament warp yarns 2Wa, 4Wa, 6Wa, 8Wa used to form a first fabric surface can be comprised of PPS (polyphenylene sulfide) or PCTA (polycylcohexane dimethanol terephthalic acid) polymers which are more resistant to thermal and hydrolytic degradation than PET (polyethylene terephthalate) yarns (and more expensive). The warp yarns IWa, 3Wa, 5Wa, 7Wa of the second set can be formed from PET polymer since the PS of the textile is where heat and hydrolysis resistance are less critical yarn properties. These warp yarns IWa - 8Wa may be grooved, profiled, coated, or otherwise treated for contamination resistance. Those skilled in the art will understand from the present disclosure that these materials are merely exemplary, and that other materials could be used depending on the particular application.

[0033] Additionally, due to the long warp floats, a higher contact area can be achieved that reduces fabric wear rates in comparison to similar fabrics having more defined knuckles due to the weave. The long warp floats also provide for benefits in contamination resistance in comparison to similar weft proud fabrics.

[0034] Figures 5A-5B and 6A-6B each provide examples of prior art industrial textiles. Figure 5A is a photograph of a cross-section taken along the warp yarns of a triple weft layer fabric 200. In this fabric the weft yarns 220, 221 and 222 are all vertically stacked forming first, second (intermediate) and third fabric layers which are interwoven into a unified fabric structure using two sets of warp yarns. Warp yarns 202Wa and 204Wa are representative of warp yarns of the first set and each interweave with the weft yarns 220 and 221 of the first and intermediate layers of weft yarns. Warp yarns 201Wa and 203Wa interweave with the weft yarns 221 and 222 of the second (intermediate) and third layers of weft yarns. The warp yarns 202Wa and 204Wa, and 201Wa and 203Wa of the first and second sets all interweave with the weft yarns of the second (intermediate) layer of weft yarns so as to bind the fabric together. However, in comparison to the inventive fabric shown in Figures 1 to 4, the weft yarns of the second (intermediate) layer 221 are not offset with respect to the weft yarns of the vertically stacked yarns of the first and third layers 220 and 222 and are not located in between each. Further, the warp yarns 201Wa, 203Wa,20 2Wa, and 204Wa form single knuckles on the exterior surfaces of the fabric (and pass over 4 weft yarns in the repeat) whereas, in the fabric 100 of the invention, the warp yarns IWa - 8Wa form floats passing over 5 weft yarns of the respective outer layer. This provides for better support for a paper sheet being carried, longer wear due to the longer surface floats, as well as a reduced caliper for the fabric 100 in comparison with this prior art. Further, it uses less weft yarns, reducing material costs.

[0035] Figure 6 presents a depiction of a second prior art fabric 300. The fabric consists of one set of warp yarns identified as IWa and 2Wa which are interwoven with weft yarns 320, 321 and 322 arranged in a 2 ½ layer construction. Unlike the fabric of the invention, there is only one set of warp which interweave with all of the weft 320, 321 and 322 located in each of the top, intermediate and bottom layers of the fabric (i.e. the warp yarns are not stacked in this construction). In addition, although each warp yarn 301Wa and 302Wa passes over 6 weft in each repeat, 3 weft are from the bottom layer i.e. 322, two are from intermediate layer 321 and one is from top layer 320.

[0036] Fabrics according to the invention were woven using 0.9mm weft yarns in each of the three weft yarn sets and are generally rectangular warp yarns having dimensions 0.25 x 1.05mm; fabrics according to the prior art Figure 5 design were also produced using the same sized warp yarns and weft yarns in each of the top, middle and bottom positions that were 0.6mm in diameter. The stiffness of each fabric was tested; the inventive fabric exhibited a stiffness of 73 daN while the stiffness of the prior art fabric was found to be 56 daN. A second sample of a fabric according to the invention was woven using 0.6mm weft yarns in all positions and was found to have a stiffness of 28 daN. Fabric stiffness increases with increasing weft yarn size.

[0037] Having thus described the present invention in detail, it is to be appreciated and will be apparent to those skilled in the art that many physical changes, only a few of which are exemplified in the detailed description of the invention, could be made without altering the inventive concepts and principles embodied therein. It is also to be appreciated that numerous embodiments incorporating only part of the preferred embodiment are possible which do not alter, with respect to those parts, the inventive concepts and principles embodied therein. The present embodiment and optional configurations are therefore to be considered in all respects as exemplary and/or illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all alternate embodiments and changes to this embodiment which come within the meaning and range of equivalency of said claims are therefore to be embraced therein.

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