Manufacturing method of papermaking felt and papermaking felt

Abstract

The invention discloses a manufacturing method of a papermaking felt and the papermaking felt, and the manufacturing method of the papermaking felt comprises the steps that a base cloth layer is formed, and the base cloth layer comprises a plurality of interwoven warp yarns and interwoven weft yarns which are arranged in an interwoven mode; heating and stretching the base cloth layer, and pressurizing and shaping; forming a composite fiber layer on one side of the base cloth layer, and forming a bottom fiber layer on the other side of the base cloth layer to form a semi-finished blanket; and heating and stretching the semi-finished felt, and pressurizing and shaping to form the papermaking felt. According to the implementation mode, the base cloth layer is heated, stretched, pressurized and shaped, so that the flexural wave height of the interwoven warp yarns can be reduced, the flexural wave height of the interwoven weft yarns can be increased, and the risk of extension and narrowing of the papermaking felt in a high-speed and high-line-pressure working state is reduced, so that the specification stability of the papermaking felt on a paper machine is better, and the production efficiency is improved. Meanwhile, the semi-finished felt is heated, stretched, pressurized and shaped, the initial performance of the papermaking felt can be improved, the adaptation period of the brand-new papermaking felt on a machine is shortened, and the production efficiency is improved.

Description

Technical Field

[0001] The present application relates to the technical field of paper processing, and in particular to a method for manufacturing a papermaking felt and a papermaking felt. Background Art

[0002] Papermaking felts are essential and valuable consumables in the press section of paper machines. They support wet paper sheets in the press section to maximize dehydration, and also modify the paper surface and transfer the paper sheets. With the continuous development of the papermaking industry, papermaking machine equipment is developing in the direction of wide width and high speed. In order to improve the operating efficiency of the press section of paper machines, wide-nip pressing forms such as boot-type and large roller diameter are widely used. The linear pressure of this pressing form is generally above 800KN / m, so higher requirements are put forward for papermaking felts. In addition to requiring the felts to meet the requirements of flatness and water permeability of the felt surface, the felts are also required to have good specification stability.

[0003] At present, the specification stability of BOM blankets made by traditional methods is poor, the initial performance is low, and they are prone to elongation and shrinkage under the action of high speed and high line pressure. Summary of the invention

[0004] The main purpose of the present application is to provide a method for manufacturing a papermaking felt and a papermaking felt, aiming to solve the above-mentioned technical problems existing in the prior art.

[0005] To solve the above problems, the present application provides a method for manufacturing a papermaking felt, the manufacturing method comprising: forming a base fabric layer, the base fabric layer comprising a plurality of interwoven warp yarns and interwoven weft yarns; heating and stretching the base fabric layer, and pressurizing and shaping it; forming a composite fiber layer on one side of the base fabric layer and a bottom fiber layer on the other side to form a semi-finished felt; heating and stretching the semi-finished felt, and pressurizing and shaping it to form a papermaking felt.

[0006] In some embodiments, the step of heating, stretching, and pressing the base fabric layer includes: heating, stretching, and pressing the base fabric layer to a first length; the step of heating, stretching, and pressing the semi-finished blanket includes: heating, stretching, and pressing the semi-finished blanket to a second length; wherein the first length and the second length are the same.

[0007] In some embodiments, the base fabric layer includes a bottom base fabric and an upper base fabric, the bottom base fabric is arranged on one side of the bottom fiber layer, and the upper base fabric is arranged on the side of the bottom base fabric away from the bottom fiber layer, the fabric structure of the bottom base fabric is arranged according to a 1 / 3 twill weave, and the fabric structure of the upper base fabric is arranged according to a 1 / 1 plain weave.

[0008] In some embodiments, the base fabric layer further includes a middle base fabric, which is located between the upper base fabric and the bottom base fabric, and the fabric structure of the middle base fabric is interlaced in a 1 / 2 twill weave.

[0009] In some embodiments, the upper interwoven warp density of the upper base fabric is smaller than the lower interwoven warp density of the lower base fabric, and the upper interwoven weft density of the upper base fabric is smaller than the lower interwoven weft density of the lower base fabric.

[0010] In some embodiments, the upper interlaced warp yarns include multiple upper warp yarn strands, which are formed by winding along the circumferential direction of the upper interlaced warp yarns and synchronously along the axial direction of the upper interlaced warp yarns; and / or, the upper interlaced weft yarns include multiple upper weft yarn strands, which are formed by winding along the circumferential direction of the upper interlaced weft yarns and synchronously along the axial direction of the upper interlaced weft yarns.

[0011] In some embodiments, the upper interlaced warp yarns include a plurality of upper warp yarn monofilaments, which are formed by winding along the circumferential direction of the upper interlaced warp yarns and synchronously along the axial direction of the upper interlaced warp yarns; and / or, the upper interlaced weft yarns include a plurality of upper weft yarn monofilaments, which are formed by winding along the circumferential direction of the upper interlaced weft yarns and synchronously along the axial direction of the upper interlaced weft yarns.

[0012] In some embodiments, the composite fiber layer includes a surface fiber layer and an inner fiber layer, the inner fiber layer is located on a side of the base fabric layer away from the bottom fiber layer, and the surface fiber layer is located on a side of the inner fiber layer away from the base fabric layer.

[0013] In some embodiments, the step of forming a composite fiber layer on one side of the base fabric layer and a bottom fiber layer on the other side to form a semi-finished blanket includes: entangling the composite fiber layer and the bottom fiber layer with the base fabric layer by needle-punching and flocking.

[0014] In order to solve the above problems, the present application also provides a papermaking felt, which is prepared by the above-mentioned method for manufacturing the papermaking felt.

[0015] Compared with the prior art, the present application provides a method for manufacturing a papermaking felt, comprising: forming a base fabric layer, the base fabric layer comprising a plurality of interwoven warp yarns and interwoven weft yarns; heating and stretching the base fabric layer, and pressurizing and shaping it; forming a composite fiber layer on one side of the base fabric layer, and forming a bottom fiber layer on the other side to form a semi-finished felt; heating and stretching the semi-finished felt, and pressurizing and shaping it to form a papermaking felt. Through the above-mentioned implementation, heating, stretching, and pressurizing the base fabric layer can reduce the buckling wave height of the interwoven warp yarns, and increase the buckling wave height of the interwoven weft yarns, and reduce the risk of elongation and narrowing of the papermaking felt under high-speed and high-line pressure working conditions, thereby making the papermaking felt more stable in specifications on the paper machine. At the same time, heating, stretching, and pressurizing the semi-finished felt can reduce the initial air permeability of the papermaking felt, increase the flatness of the papermaking felt, and thereby improve the initial performance of the papermaking felt, shorten the adaptation period of a new papermaking felt on the machine, and improve production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0017] Figure 1 is a schematic diagram of the structure of a papermaking felt provided according to one or more embodiments of the present application;

[0018] Figure 2 is a schematic flow chart of a method for manufacturing a papermaking felt according to one or more embodiments of the present application;

[0019] Figure 3 is a state schematic diagram of step S12 in the method for manufacturing a papermaking felt provided according to one or more embodiments of the present application;

[0020] Figure 4 It is a state diagram of step S14 in the method for manufacturing a papermaking felt provided according to one or more embodiments of the present application.

[0021] Figure numbers: papermaking felt 1; base fabric layer 10; interwoven warp yarns 11; interwoven weft yarns 12; bottom base fabric 13; bottom interwoven warp yarns 131; bottom interwoven weft yarns 132; upper base fabric 14; upper interwoven warp yarns 141; upper interwoven weft yarns 142; middle base fabric 15; composite fiber layer 20; surface fiber layer 21; inner fiber layer 22; bottom fiber layer 30; tensioning roller 2; hot roller 3; pressure roller 4; semi-finished felt 5. DETAILED DESCRIPTION

[0022] The following embodiments of the technical solution of the present application are described in detail in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present application, and are therefore only used as examples, and cannot be used to limit the scope of protection of the present application.

[0023] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by technicians in the technical field to which this application belongs; the terms used herein are only for the purpose of describing specific embodiments and are not intended to limit this application; the terms "including" and "having" in the specification and claims of this application and the above-mentioned figure descriptions and any variations thereof are intended to cover non-exclusive inclusions.

[0024] In the description of the embodiments of the present application, the technical terms "first", "second", etc. are only used to distinguish different objects, and cannot be understood as indicating or implying relative importance or implicitly indicating the number, specific order or primary and secondary relationship of the indicated technical features. In the description of the embodiments of the present application, the meaning of "multiple" is more than two, unless otherwise clearly and specifically defined.

[0025] Reference to "embodiments" herein means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase in various locations in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0026] In the description of the embodiments of the present application, the term "and / or" is only a description of the association relationship of the associated objects, indicating that there may be three relationships. For example, A and / or B can represent: A exists alone, A and B exist at the same time, and B exists alone. In addition, the character " / " in this article generally indicates that the associated objects before and after are in an "or" relationship.

[0027] In the description of the embodiments of the present application, the term "multiple" refers to more than two (including two). Similarly, "multiple groups" refers to more than two groups (including two groups), and "multiple pieces" refers to more than two pieces (including two pieces).

[0028] In the description of the embodiments of the present application, the technical terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, which are only for the convenience of describing the embodiments of the present application and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the embodiments of the present application.

[0029] In the description of the embodiments of the present application, unless otherwise clearly specified and limited, technical terms such as "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be the internal connection of two elements or the interaction relationship between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the embodiments of the present application can be understood according to the specific circumstances.

[0030] Papermaking felts are essential and valuable consumables in the press section of paper machines. They support wet paper sheets in the press section to maximize dehydration, and also modify the paper surface and transfer the paper sheets. With the continuous development of the papermaking industry, papermaking machine equipment is developing in the direction of wide width and high speed. In order to improve the operating efficiency of the press section of paper machines, wide-nip pressing forms such as boot-type and large roller diameter are widely used. The linear pressure of this pressing form is generally above 800KN / m, so higher requirements are put forward for papermaking felts. In addition to requiring the felts to meet the requirements of flatness and water permeability of the felt surface, the felts are also required to have good specification stability.

[0031] At present, the specification stability of BOM blankets made by traditional methods is poor, the initial performance is low, and they are prone to elongation and shrinkage under the action of high speed and high line pressure.

[0032] For example, air permeability is a very important parameter for paper felts. If the air permeability of a paper felt is too high, it will lead to low vacuum system vacuum, excessive water content in the paper felt, difficulty in removing water from the paper sheets, and felt pulp penetration. If the air permeability of the selected paper felt is too low, it will lead to felt vibration, excessive load on the vacuum system, increased felt wear, and difficulty in dehydrating paper sheets. In the actual production process, the air permeability of paper felts is not constant. For example, the initial air permeability of an unused new paper felt, the air permeability of a paper felt in use, and the air permeability of a paper felt that has failed are all different. Under normal circumstances, the air permeability of a paper felt will gradually decrease with the increase of usage time. Therefore, the initial air permeability of a brand new and unused papermaking felt should be slightly greater than the air permeability of the papermaking felt in normal use. However, this will cause the initial air permeability of the new papermaking felt when it is put on the machine to be larger than the air permeability during normal production, and the paper sheets will not reach the dryness during normal papermaking. Generally, it takes 3-5 days of adaptation period before the normal speed can be increased and normal production can be carried out. Therefore, the initial performance of the new papermaking felt, such as the initial air permeability, is poor, resulting in a too long adaptation period for the new papermaking felt to be put on the machine, which reduces production efficiency.

[0033] Therefore, the present application provides a method for manufacturing a papermaking felt to solve the above problems.

[0034] Please refer to Figure 1 , Figure 1 It is a schematic diagram of the structure of a papermaking felt provided according to one or more embodiments of the present application.

[0035] To solve the above problems, the present application provides a papermaking felt 1, which can be installed on a papermaking machine and used to contact the paper to be processed to process the paper to be processed. The papermaking felt 1 is prepared by the above-mentioned papermaking felt manufacturing method.

[0036] Please refer to Figure 1-Figure 4 , Figure 2 is a schematic flow chart of a method for manufacturing a papermaking felt according to one or more embodiments of the present application; Figure 3 is a state schematic diagram of step S12 in the method for manufacturing a papermaking felt provided according to one or more embodiments of the present application; Figure 4 It is a state diagram of step S14 in the method for manufacturing a papermaking felt provided according to one or more embodiments of the present application.

[0037] To solve the above problems, the present application provides a method for manufacturing a papermaking felt comprising the following steps:

[0038] Step S11: forming a base fabric layer 10, wherein the base fabric layer 10 comprises a plurality of interwoven warp yarns 11 and interwoven weft yarns 12.

[0039] Specifically, the base fabric layer 10 can be woven by a wide circular loom, and the material of the base fabric layer 10 can include but is not limited to nylon, polypropylene, etc. The multiple interlaced warp yarns 11 and interlaced weft yarns 12 of the base fabric layer 10 can be composed of monofilaments or strands, and the base fabric layer 10 can be composed of two or three layers of interlaced warp yarns 11 and interlaced weft yarns 12, wherein the radial dimension of the interlaced warp yarns 11 is greater than the radial dimension of the interlaced weft yarns 12. Further, the base fabric layer 10 can be an annular base fabric connected end to end.

[0040] Step S12: heating and stretching the base fabric layer 10 and applying pressure to shape it.

[0041] Specifically, the base fabric layer 10 can be heated and stretched by the hot roller 3 and the stretching device. For example, during preparation, the pre-woven base fabric layer 10 is wound on the hot roller 3, and circulating oil is stored inside the hot roller 3. The temperature of the surface of the hot roller 3 is increased by heating the oil inside the hot roller 3, and then the base fabric layer 10 wound on the hot roller 3 is stretched by the stretching device to shape the base fabric layer 10. Among them, the stretching device can include a tensioning roller 2, and the base fabric layer 10 can be wound on the hot roller 3 and the tensioning roller 2 at the same time. The distance between the tensioning roller 2 and the hot roller 3 can be adjusted according to actual needs, so as to stretch the base fabric layer 10 and stretch the base fabric layer 10 to a certain length. In this application scenario, the temperature of the surface of the hot roller 3 is ensured by heating the oil inside the hot roller 3. Since the oil is fluid, the temperature difference on the surface of the hot roller 3 is small and the temperature is uniform, which is reflected in the uniform temperature of the surface of the base fabric layer 10. Finally, the overall structure of the base fabric layer 10 after the shaping treatment is stable, which ensures the stability of the structure of the papermaking felt 1 and the small deformation on the papermaking machine. Further, the base fabric layer 10 can be pressurized and shaped by the pressure roller 4. For example, the pressure roller 4 can be arranged relative to the hot roller 3, and the base fabric layer 10 is located between the pressure roller 4 and the hot roller 3, so that the pressure roller 4 rolls the base fabric layer 10 to pressurize and shape the base fabric layer 10. It should be noted that when the base fabric layer 10 is tensioned and stretched, the interwoven warp yarns 11 are in a taut state, and the interwoven weft yarns 12 are in a free and relaxed state. By heating, stretching and pressurizing the base fabric layer 10, the buckling wave height of the interwoven warp yarns 11 of the base fabric layer 10 can reach a minimum value, and the buckling wave height of the interwoven weft yarns 12 of the base fabric layer 10 can reach a maximum value. This improves the specification stability of the papermaking felt 1 on the paper machine and reduces the risk of elongation and narrowing of the papermaking felt 1 under high-speed and high-line pressure working conditions. It should be noted that the specific pressurized, heated, stretched and pressurized shaping methods are not limited here.

[0042] Step S13: forming a composite fiber layer 20 on one side of the base fabric layer 10 and forming a bottom fiber layer 30 on the other side to form a semi-finished blanket 5.

[0043] Specifically, the materials of the composite fiber layer 20 and the bottom fiber layer 30 include but are not limited to nylon and polypropylene. The coarseness of the bottom fiber layer 30 and the composite fiber layer 20 is between 6.67D and 66D (Dtex, decitex). It should be noted that other properties such as air permeability and blanket quantity can also be combined to select materials of appropriate coarseness and fineness for the bottom fiber layer 30 and the composite fiber layer 20, and lay them in layers. In some implementation scenarios, during the preparation process of the materials of the bottom fiber layer 30 and the composite fiber layer 20, the fiber materials are first combed into a web by a carding machine, and then needled into a wool web by a pre-punching machine, thereby forming the bottom fiber layer 30 and the composite fiber layer 20. The side of the composite fiber layer 20 facing away from the base fabric layer 10 can be used to contact the paper to be processed.

[0044] Step S14: The semi-finished felt 5 is heated, stretched, and pressurized to form a papermaking felt 1.

[0045] Specifically, the semi-finished blanket 5 can be heated and stretched by the hot roller 3 and the stretching device. For example, during preparation, the pre-woven semi-finished blanket 5 is wound on the hot roller 3, and circulating oil is stored inside the hot roller 3. The temperature of the surface of the hot roller 3 is increased by heating the oil inside the hot roller 3, and then the semi-finished blanket 5 wound on the hot roller 3 is stretched by the stretching device to shape the semi-finished blanket 5. Among them, the stretching device can include a tensioning roller 2, and the semi-finished blanket 5 can be wound on the hot roller 3 and the tensioning roller 2 at the same time. The distance between the tensioning roller 2 and the hot roller 3 can be adjusted according to actual needs, so as to stretch the semi-finished blanket 5 and stretch the semi-finished blanket 5 to a certain length. It can be understood that heating, stretching, and pressurizing the semi-finished felt 5 can make the fiber materials between the same fiber layers bond together, and at the same time, the adjacent fiber layers and the base cloth layer 10 bond together, so that the papermaking felt surface is not easy to pilling, the performance stability period is long, and the service life is long. At the same time, the initial air permeability of the papermaking felt 1 can be reduced, the flatness of the papermaking felt 1 can be improved, and the initial performance of the papermaking felt 1 can be improved.

[0046] Through the above-mentioned implementation mode, the base fabric layer 10 is heated, stretched and pressurized to reduce the buckling wave height of the interwoven warp yarns 11 and increase the buckling wave height of the interwoven weft yarns 12, thereby reducing the risk of elongation and narrowing of the papermaking felt 1 under high-speed and high-line pressure working conditions, thereby making the papermaking felt 1 more stable in specifications on the paper machine. At the same time, the semi-finished felt 5 is heated, stretched and pressurized to reduce the initial air permeability of the papermaking felt 1 and increase the flatness of the papermaking felt 1, thereby improving the initial performance of the papermaking felt 1, shortening the adaptation period of the new papermaking felt 1 on the machine, and improving production efficiency.

[0047] In some embodiments, the above step S12 includes: heating and stretching the base fabric layer 10 to a first length, and pressing and shaping. The above step S14 includes: heating and stretching the semi-finished blanket 5 to a second length, and pressing and shaping; wherein the first length and the second length are the same. Exemplarily, when the base fabric layer 10 and the semi-finished blanket 5 are heated, stretched, and pressed and shaped by the hot roller 3, the tensioning roller 2, and the pressure roller 4, the stretching length can be adjusted by adjusting the distance between the tensioning roller 2 and the hot roller 3. It can be understood that the base fabric layer 10 or the semi-finished blanket 5 is wound around the tensioning roller 2 and the hot roller 3. The larger the distance between the rotation axis of the tensioning roller 2 and the rotation axis of the hot roller 3, the longer the stretching length of the base fabric layer 10 or the semi-finished blanket 5. Among them, the second length of the semi-finished felt 5 stretched is the same as the first length of the base fabric layer 10 stretched. Therefore, through two times of heating, stretching and pressurizing, the risk of the interwoven warp yarns 11 of the base fabric layer 10 recovering to the tension before stretching and pressing is alleviated, thereby further improving the specification stability of the papermaking felt 1 and improving the initial performance of the papermaking felt 1.

[0048] In some embodiments, the base fabric layer 10 includes a bottom base fabric 13 and an upper base fabric 14, the bottom base fabric 13 is arranged on one side of the bottom fiber layer 30, and the upper base fabric 14 is arranged on the side of the bottom base fabric 13 away from the bottom fiber layer 30, and the fabric structure of the bottom base fabric 13 is interlaced according to 1 / 3 twill weave, and the twill weave refers to the situation where 1 / 3 twill weave refers to the fabric weave, four threads form a cycle, one upper interlaced warp yarn 141 is on the top, and three upper interlaced weft yarns 142 are on the bottom; 2 / 2 twill weave refers to the fabric weave, four threads form a cycle, two upper interlaced warp yarns 141 are on the top, and two upper interlaced weft yarns 142 are on the bottom. The fabric structure of the upper base fabric 14 is interlaced according to 1 / 1 plain weave. The base fabric layer 10 woven with twill weave has a certain degree of softness while ensuring a certain strength, and the warp and weft yarns of the plain weave are interlaced in a regular pattern of one up and one down. That is, every other warp and weft yarn is staggered, so there are the most interlacing points and the most yarn bending points, making the fabric strong, wear-resistant, stiff and smooth.

[0049] In some embodiments, the base fabric layer 10 further includes a middle base fabric 15, which is located between the upper base fabric 14 and the bottom base fabric 13, and the fabric structure of the middle base fabric 15 is interlaced according to a 1 / 2 twill weave. The 1 / 2 twill weave refers to a fabric weave, three threads form a cycle, one upper interlaced warp yarn 141 is on top, and two upper interlaced weft yarns 142 are on the bottom. Furthermore, the bottom base fabric 13 and the middle base fabric 15 can be woven from a plurality of interlaced monofilaments, wherein the radial dimension of the monofilament can be between 0.3 mm and 0.5 mm, and specifically, the radial dimension of the monofilament can be 0.3 mm, 0.35 mm, 0.4 mm, 0.46 mm, 0.5 mm, etc.

[0050] In some embodiments, the density of the upper interwoven warp yarns 141 of the upper base fabric 14 is less than the density of the bottom interwoven warp yarns 131 of the bottom base fabric 13, and the density of the upper interwoven weft yarns 142 of the upper base fabric 14 is less than the density of the bottom interwoven weft yarns 132 of the bottom base fabric 13. Further, the specific densities of the upper interwoven warp yarns 141 and the interwoven weft yarns 12 of the upper base fabric 14 can be adjusted according to actual conditions. Optionally, the specific densities of the upper interwoven warp yarns 141 and the interwoven weft yarns 12 can be adjusted to obtain a larger paper tightness coefficient as much as possible.

[0051] In some embodiments, the upper interlaced warp yarn 141 includes a plurality of upper warp yarn strands, which are formed by winding along the circumferential direction of the upper interlaced warp yarn 141 and synchronously along the axial direction of the upper interlaced warp yarn 141. That is, one upper interlaced warp yarn 141 is formed by tightening a plurality of upper warp yarn strands in a manner similar to a hemp rope. Among them, the radial size of the upper warp yarn strands can be between 0.15mm-0.2mm, specifically, the radial size of the upper warp yarn strands can be 0.15mm, 0.16mm, 0.17mm, 0.18mm, 0.19mm and 0.2mm, etc. For example, one upper interlaced warp yarn 141 can be formed by tightening four upper warp yarn strands with a diameter of 0.2mm.

[0052] And / or, the upper interwoven weft yarn 142 includes a plurality of upper weft yarn strands, which are wound along the circumferential direction of the upper interwoven weft yarn 142 and synchronously along the axial direction of the upper interwoven weft yarn 142. That is, one upper interwoven weft yarn 142 is formed by tightening a plurality of upper weft yarn strands together in a manner similar to a hemp rope. Among them, the radial dimension of the upper weft yarn strands can be between 0.15mm and 0.2mm, specifically, the radial dimension of the upper weft yarn strands can be 0.15mm, 0.16mm, 0.17mm, 0.18mm, 0.19mm and 0.2mm, etc. For example, one upper interwoven weft yarn 142 can be formed by tightening four upper weft yarn strands with a diameter of 0.2mm.

[0053] In some embodiments, the upper interlaced warp yarn 141 includes a plurality of upper warp yarn monofilaments, which are formed by winding along the circumferential direction of the upper interlaced warp yarn 141 and synchronously along the axial direction of the upper interlaced warp yarn 141; and / or, the upper interlaced weft yarn 142 includes a plurality of upper weft yarn monofilaments, which are formed by winding along the circumferential direction of the upper interlaced weft yarn 142 and synchronously along the axial direction of the upper interlaced weft yarn 142. The radial dimensions of the upper warp yarn monofilaments and the upper weft yarn monofilaments may be between 0.25 mm and 0.3 mm, and specifically, the radial dimensions of the upper warp yarn monofilaments may be 0.25 mm, 0.26 mm, 0.27 mm, 0.28 mm, 0.29 mm, 0.3 mm, etc.

[0054] In some embodiments, the composite fiber layer 20 includes a surface fiber layer 21 and an inner fiber layer 22, wherein the inner fiber layer 22 is located on the side of the base fabric layer 10 away from the bottom fiber layer 30, and the surface fiber layer 21 is located on the side of the inner fiber layer 22 away from the base fabric layer 10. The material coarseness of the surface fiber layer 21 affects the flatness of the surface of the papermaking felt 1. The finer the material, the flatter the papermaking felt 1. The material coarseness of the inner fiber layer 22 affects the water filtering effect of the papermaking felt 1. The coarser the material, the better the water filtering performance of the papermaking felt 1. The material coarseness of the bottom fiber layer 30 affects the friction performance between the papermaking felt 1 and the papermaking machine parts. Therefore, in order to improve the water filtering effect of the papermaking felt 1, make it less likely to slip on the papermaking machine, and ensure the surface flatness of the papermaking felt 1, the material coarseness of the inner fiber layer 22 is greater than the material coarseness of the bottom fiber layer 30, and the material coarseness of the bottom fiber layer 30 is greater than the material coarseness of the surface fiber layer 21. For example, when the materials of the bottom fiber layer 30, the inner fiber layer 22 and the surface fiber layer 21 are all nylon fibers, the thickness of the nylon fibers of the inner fiber layer 22 is greater than that of the bottom fiber layer 30, and the thickness of the nylon fibers of the bottom fiber layer 30 is greater than that of the surface fiber layer 21. In one application scenario, the inner fiber layer 22 uses 30D-66D nylon fibers, such as 30D, 40D, 50D, 60D or 66D nylon fibers, the bottom fiber layer 30 uses 30D-40D nylon fibers, such as 30D, 35D or 40D nylon fibers, and the surface fiber layer 21 uses 6D-20D nylon fibers, such as 6D, 13D or 20D nylon fibers. It should be noted that in other application scenarios, other properties such as air permeability may also be combined to select materials of appropriate coarseness and fineness for the bottom fiber layer 30 , the inner fiber layer 22 , and the surface fiber layer 21 .

[0055] In some embodiments, the above step S13 includes: entangle the composite fiber layer 20 and the bottom fiber layer 30 with the base fabric layer 10 by means of needle flocking. The needle flocking process refers to repeatedly needle-punching the fluffy fiber web using a needle with a triangular cross-section (or other shapes) and barbed edges. The barbs on the needle carry some fibers on the surface and inner layer of the fiber web and pass through the fiber web layer with the needle, so that the fibers are entangled with each other during the movement. At the same time, due to the action of friction and the up and down displacement of the fibers, the fiber web is squeezed to a certain extent, so that the fiber web is compressed. When the needle withdraws from the fiber web, the fibers are separated from the barbs and remain in the fiber web in a nearly vertical state, just like many fiber bundles "pins" nailed into the fiber web, so that the compressed fiber web will not return to its original state, forming a needle-punched nonwoven material with a certain thickness and strength. Exemplarily, when the composite fiber layer 20 includes a surface fiber layer 21 and an inner fiber layer 22 , the inner fiber layer 22 and the surface fiber layer 21 are formed by needle-punching and flocking on one side of the base fabric layer 10 , and the bottom fiber layer 30 is formed by needle-punching and flocking on the other side of the base fabric layer 10 .

[0056] In summary, the present application provides a method for manufacturing a papermaking felt, comprising: forming a base fabric layer 10, the base fabric layer 10 comprising a plurality of interwoven warp yarns 11 and interwoven weft yarns 12; heating and stretching the base fabric layer 10, and pressurizing and shaping it; forming a composite fiber layer 20 on one side of the base fabric layer 10, and forming a bottom fiber layer 30 on the other side to form a semi-finished felt 5; heating and stretching the semi-finished felt 5, and pressurizing and shaping it to form a papermaking felt 1. Through the above-mentioned implementation, the base fabric layer 10 is heated, stretched and pressurized to shape, which can reduce the buckling wave height of the interwoven warp yarns 11 and increase the buckling wave height of the interwoven weft yarns 12, reducing the risk of elongation and narrowing of the papermaking felt 1 under high-speed and high-line pressure working conditions, thereby making the papermaking felt 1 more stable in specifications on the paper machine. At the same time, the semi-finished felt 5 is heated, stretched and pressurized to shape, which can reduce the initial air permeability of the papermaking felt 1 and improve the flatness of the papermaking felt 1, thereby improving the initial performance of the papermaking felt 1, shortening the adaptation period of the new papermaking felt 1 on the machine, and improving production efficiency. Compared with other methods for manufacturing papermaking felts, the papermaking felt 1 manufactured by the papermaking felt manufacturing method of the present application has better specification stability, stronger initial performance, and a shorter adaptation period on the machine.

[0057] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them; although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein by equivalents; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application, and they should all be included in the scope of the claims and specification of the present application. In particular, as long as there is no structural conflict, the various technical features mentioned in the various embodiments can be combined in any way. The present application is not limited to the specific embodiments disclosed herein, but includes all technical solutions that fall within the scope of the claims.

Claims

1. A method for manufacturing a papermaking felt, characterized in that: The manufacturing method comprises: forming a base fabric layer, the base fabric layer comprising a plurality of interwoven warp yarns and interwoven weft yarns; The base fabric layer is heated, stretched, and pressurized to set the shape; forming a composite fiber layer on one side of the base fabric layer and forming a bottom fiber layer on the other side to form a semi-finished blanket; The semi-finished felt is heated, stretched, and pressurized to form the papermaking felt.

2. The manufacturing method according to claim 1, characterized in that: The step of heating, stretching, and pressurizing the base fabric layer comprises: The base fabric layer is heated and stretched to a first length, and then pressurized to set the shape; The step of heating, stretching, and pressurizing the semi-finished blanket comprises: heating and stretching the semi-finished blanket to a second length, and pressing and shaping the blanket; The first length and the second length are the same.

3. The manufacturing method according to any one of claims 1 or 2, characterized in that: The base fabric layer includes a bottom base fabric and an upper base fabric, the bottom base fabric is arranged on one side of the bottom fiber layer, and the upper base fabric is arranged on the side of the bottom base fabric away from the bottom fiber layer, the fabric structure of the bottom base fabric is interlaced according to 1 / 3 twill weave, and the fabric structure of the upper base fabric is interlaced according to 1 / 1 plain weave.

4. The manufacturing method according to claim 3, characterized in that: The base fabric layer also includes a middle-layer base fabric, which is located between the upper-layer base fabric and the bottom-layer base fabric. The fabric structure of the middle-layer base fabric is interwoven according to a 1 / 2 twill weave.

5. The manufacturing method according to claim 3, characterized in that: The upper interwoven warp density of the upper base fabric is smaller than the bottom interwoven warp density of the bottom base fabric, and the upper interwoven weft density of the upper base fabric is smaller than the bottom interwoven weft density of the bottom base fabric.

6. The manufacturing method according to claim 5, characterized in that: The upper interlaced warp yarns include a plurality of upper warp yarn strands, and the plurality of upper warp yarn strands are wound along the circumferential direction of the upper interlaced warp yarns and synchronously along the axial direction of the upper interlaced warp yarns; And / or, the upper interwoven weft yarn includes a plurality of upper weft yarn strands, and the plurality of upper weft yarn strands are wound along the circumferential direction of the upper interwoven weft yarn and synchronously along the axial direction of the upper interwoven weft yarn.

7. The manufacturing method according to claim 5, characterized in that: The upper interlaced warp yarns include a plurality of upper warp yarn monofilaments, and the plurality of upper warp yarn monofilaments are formed by winding along the circumferential direction of the upper interlaced warp yarns and synchronously along the axial direction of the upper interlaced warp yarns; And / or, the upper interlaced weft yarn includes a plurality of upper weft yarn monofilaments, and the plurality of upper weft yarn monofilaments are formed by winding along the circumferential direction of the upper interlaced weft yarn and synchronously along the axial direction of the upper interlaced weft yarn.

8. The manufacturing method according to claim 1, characterized in that: The composite fiber layer comprises a surface fiber layer and an inner fiber layer. The inner fiber layer is located on a side of the base fabric layer away from the bottom fiber layer, and the surface fiber layer is located on a side of the inner fiber layer away from the base fabric layer.

9. The manufacturing method according to claim 1, characterized in that: The steps of forming a composite fiber layer on one side of the base fabric layer and forming a bottom fiber layer on the other side to form a semi-finished blanket include: The composite fiber layer and the bottom fiber layer are entangled with the base fabric layer by means of needle-punching flocking.

10. A papermaking felt, characterized in that: The papermaking felt is prepared by the method for manufacturing a papermaking felt according to any one of claims 1 to 9.

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