Structured fabric with long warp knots

Abstract

Described herein is an industrial fabric that exhibits advantageous properties for forming a product thereon, such as a tissue. The present invention relates to a structured fabric having a forming side surface and a machine side surface and comprising interwoven warp and weft yarns. The structured fabric also includes at least one long warp knot at the forming side surface and at least one weft knot near the forming side surface of the fabric.

Description

TECHNICAL FIELD

[0001] The present invention relates to an industrial fabric, such as a fabric for a structured tissue machine, having a combination of weft knuckles or cross-machine direction knuckles near the forming side surface of the industrial fabric and long warp knuckles or machine direction knuckles at the forming side surface of the industrial fabric. BACKGROUND

[0002] Soft, absorbent disposable paper products, such as facial tissue, toilet tissue, and paper towels, are a common feature of daily life. While there are many methods for making these products, generally their manufacture begins with the formation of a web of cellulosic fibers in a forming section of a papermaking machine. The web of cellulosic fibers is formed by depositing a slurry of fibers, i.e., a water dispersion of cellulosic fibers, onto a moving forming fabric in the forming section of the papermaking machine. A substantial amount of water is drained from the slurry through the forming fabric, leaving a web of cellulosic fibers on the surface of the forming fabric.

[0003] In the case of through-air drying, the wet web can be dewatered and dried by non- compressive means. That is, there is vacuum dewatering and thorough drying. Through-air drying can be accomplished with a vacuum section after the forming section, where the vacuum can have a vacuum box that sucks air and removes water. After the vacuum is pulled, the web can then be transferred to a through-air drying (TAD) fabric, which can carry the web through a through-air dryer and a Yankee dryer.

[0004] One type of through-air drying is referred to as energy efficient technologically advanced drying, or "eTAD," which is similar to the above, the eTAD tissue production process consists of a paper machine with a forming section, a press section, a rapid transfer / shaping section, and a drying section. However, no actual through-air drying is involved. The forming section typically forms a sheet by depositing or laying down a mixture of fibers and water from a headbox into a space between a forming fabric and a press fabric. A web is formed on the forming fabric as the accompanying water drains through the forming fabric. The sheet formed from the web is then carried on the press fabric around a suction turn roll, where more water is removed from the sheet by vacuum, and then it is sent to a shoe press nip for further mechanical dewatering. The backing roll, which is opposite the shoe press shoe, is a dryer cylinder that is steam heated and provides some thermal drying. With the eTAD process, the sheet is then transferred via a rapid transfer to an eTAD structured fabric, where the surface speed of the backing roll can be up to 30% faster than the surface speed of the eTAD structured fabric. In this transfer, the sheet is mechanically forced into the pockets of the eTAD structured fabric, creating bulk and softness in the sheet. The sheet is then transferred to a Yankee dryer, where it is dried with conductive heat transfer from the Yankee dryer and convective heat transfer from a hot air hood that surrounds the Yankee dryer. Finally, the sheet is creped off the Yankee dryer with a creping blade and wound onto a reel.

[0005] While there are many methods for making bulk tissue products, the foregoing description should be understood as an overview of the general steps shared by some methods. For example, the use of a Yankee dryer is not always required, as in a given situation, no preliminary shortening can be required, or other means such as "wet creping" can have been taken to pre-shorten the web.

[0006] It should be understood that TAD and eTAD fabrics can take the form of endless loops on the paper machine and function in a conveyor belt fashion. It should also be understood that paper making is a continuous process that is conducted at considerable speed. For example, the fiber slurry is continuously deposited onto the forming fabric in the forming section of the paper machine, while the newly manufactured paper sheet is continuously wound onto a roll after drying.

[0007] Those skilled in the art will understand that woven fabrics are created by weaving and have a weave pattern that repeats in both the warp or longitudinal direction (MD) and the weft or cross direction (CD). Woven fabrics take many different forms. For example, they can be woven in an endless fashion, or flat woven and then presented in an endless fashion with seams. Furthermore, any pattern marking imparted to the formed paper product by the woven fabric will affect the properties of the paper.

[0008] Paper-processed fabrics are produced in a wide variety of patterns designed to meet the requirements of the paper processing machine in which they are installed for the grade of paper being manufactured. Typically, they consist of a base fabric woven from monofilaments and can be single-layered or multi-layered. The yarns are typically extruded from any of several synthetic polymer resins (such as polyamides and polyester resins) used for this purpose by those skilled in the art of paper-processed fabrics.

[0009] When used for their intended purpose, especially when the product is facial tissue or toilet paper, paper towel, sanitary napkin or diaper, the properties of absorbency, strength, softness and aesthetic appearance are important for many products.

[0010] When producing sheets of tissue paper, napkins, and towels, bulkiness, tensile strength, absorbency, and softness are particularly important properties. To produce paper products with these properties, the fabric is typically constructed such that the top surface exhibits morphological variations. These morphological variations are usually measured as the planarity difference between the ply strands on the fabric surface. For example, planarity difference is typically measured as the height difference between raised weft ply strands and raised warp ply strands, or the height difference between MD and CD sections, on the fabric surface. Often, the fabric surface will have concave sections; in this case, the planarity difference can be measured as the depth of the concavity.

[0011] Both warp and weft yarns can be major factors in creating the depth of the recess, thus limiting the thickness (caliper) produced. Ideally, TAD or eTAD fabrics should provide contact with both the MD and CD sides of the cellulosic fiber or web product, thereby facilitating sheet transfer to the Yankee dryer, enhancing the handling of TAD and eTAD fabrics during the manufacturing process, and improving wrinkling at the end of the process. Summary of the Invention

[0012] This invention relates to a structured fabric, which is a woven fabric having a shaped side surface and a machine side surface, and multiple longitudinal (MD) yarns.

[0013] Multiple transverse (CD) yarns are arranged in a first layer and a second layer, wherein the first layer is located on the forming side surface of the structured fabric and the second layer is located on the machine side surface of the structured fabric. At least a portion of the MD yarns are interwoven with the CD yarns such that the MD yarns cross at least two CD yarns of the first layer, thereby forming long warp knots at the forming side surface. Additionally, at least a portion of the CD yarns are interwoven with the MD yarns such that the CD yarns of the first layer cross at least one MD yarn, thereby forming weft knots near the forming side surface of the structured fabric.

[0014] In some implementations, the MD yarn is configured in two or more layers.

[0015] In other embodiments, the CD yarn is configured in three or more layers.

[0016] In some implementations, the MD yarn passes over at least three, at least five, at least seven, or at least 18 CD yarns in the first layer.

[0017] In some implementations, the CD yarn of the first layer passes over at least two, at least three, or at least 18 MD yarns.

[0018] In some embodiments, the fabric has one or more woven and / or nonwoven machine side layers.

[0019] In other embodiments, the fabric has one or more recesses having a CD width equal to the diameter of at least one MD yarn. In some other embodiments, the fabric has one or more recesses having a longitudinal (MD) length equal to the diameter of at least one CD yarn.

[0020] In some implementations, the structured fabric is an eTAD fabric.

[0021] In other embodiments, the shaped side surface faces the fiber web.

[0022] In some other embodiments, the MD yarn and / or CD yarn comprise materials selected from the group consisting of: carbon, polyamide, rayon, glass fiber, cotton, ceramic, aramid, polyester, metal, polyethylene, polypropylene, polycyclohexanedimethyl terephthalate (PCT), copolyester of terephthalic acid and cyclohexanediol (PCTA), polyphenylene sulfide (PPS), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and polyethylene naphthalate (PEN).

[0023] In other embodiments, the diameter of the MD yarn is between 0.20 mm and 1.1 mm. In a particular embodiment, the diameter of the MD yarn is 0.40 mm.

[0024] In some embodiments, the diameter of the CD yarn is between 0.20 mm and 1.1 mm. In a particular embodiment, the diameter of the CD yarn is 0.30 mm.

[0025] In some embodiments, the warp joints at the forming side surface have a length between 2.0 mm and 5.0 mm. In other embodiments, the weft joints near the forming side surface have a length between 0.40 mm and 1.60 mm.

[0026] In some embodiments, the planarity difference between the top surface of the long warp joint and the top surface of the weft joint is between 0.05 mm and 1.0 mm. In some embodiments, the planarity difference between the top surface of the long warp joint and the top surface of the weft joint is at most 0.50 mm. In still other embodiments, the planarity difference between the top surface of the long warp joint and the top surface of the weft joint is between 0.25 mm and 0.50 mm.

[0027] In some other embodiments, the fabric has one or more recesses having an MD length between 1.0 mm and 5.0 mm. In some embodiments, the structured fabric includes one or more recesses having a CD width between 0.3 mm and 2.0 mm.

[0028] In other embodiments, the fabric includes a recess depth, wherein the plane difference between the top surface plane of a long warp or portion thereof defining the length or width boundary of the recess and the top surface plane of one or more of the weft yarns, warp yarns, warp or weft knots defining the bottom of the recess has a depth range between 0.01 mm and 1.0 mm.

[0029] In some implementations, one or more of the MD yarns and / or CD yarns are not flat and / or not smooth.

[0030] In some embodiments, the first layer of CD yarn includes a first CD yarn and a second CD yarn. In other embodiments, the first CD yarn differs from the second CD yarn in diameter, shape, and / or material.

[0031] In some embodiments, the structured fabric is a woven fabric having a shaped side surface and a machine side surface, and multiple CD yarns and multiple MD yarns disposed in a first layer and a second layer, wherein the first layer is on the shaped side surface of the structured fabric, and the second layer is on the machine side surface of the structured fabric. At least a portion of the MD yarns interweaves with the CD yarns such that the MD yarns of the first layer cross at least two CD yarns, thereby forming long warp knots at the shaped side surface, and at least a portion of the CD yarns interweaves with the MD yarns such that the CD yarns cross at least one MD yarn of the first layer, thereby forming weft knots near the shaped side surface of the structured fabric. Attached Figure Description

[0032] Figure 1 This is a diagram illustrating the eTAD machine.

[0033] Figure 2 A top view image of the shaped side surface of the fabric of the present invention is shown.

[0034] Figure 3 It shows Figure 2A top view of the bottom surface (machine side) of the fabric.

[0035] Figure 4 Depicting in Figure 2 The weft yarns form a woven pattern near the shaped side surface of the fabric.

[0036] Figure 5 Depicting in Figure 2 The fabric has a woven pattern of long warp yarns forming on the shaped side surface.

[0037] Figure 6 It shows the combination of longitude nodes and latitude nodes. Figure 2 The recesses formed in the shaped side surface of the fabric.

[0038] Figure 7A and Figure 7B yes Figure 2 A cross-sectional view of the fabric.

[0039] Figure 8 It shows the long meridian in Figure 2 The marked sheet side recesses formed in the fabric.

[0040] Figures 9-10 It shows Figure 2 Measurement of flatness difference in fabric.

[0041] Figure 11 A top view image of the shaped side surface of the fabric according to the present invention is shown.

[0042] Figure 12 A top view image of the shaped side surface of the fabric according to the present invention is shown.

[0043] Figure 13 It is QRT ® A diagram illustrating the process.

[0044] Figure 14A , Figure 14B and Figure 14C Depicting Figure 2 Measurement of the depth of the concave portion of the fabric.

[0045] Figure 15A , Figure 15B and Figure 15C Depicting Figure 2 Measurement of the depth of the concave portion of the fabric.

[0046] Figure 16A , Figure 16B , Figure 16C and Figure 16D The fabric weave pattern of the present invention is depicted, which includes stacked weft yarns (a first and second layer of CD yarns) and a layer of MD yarn. Figure 16AThe weaving pattern of MD yarn is depicted, which forms long warp knots on the shaped side surface of the fabric. Figure 16B The weaving pattern of CD yarn in the second (machine side) layer of CD yarn is depicted. Figure 16C and Figure 16D The weaving pattern of the first CD yarn and the second CD yarn in the first (forming side) layer of CD yarn is depicted. Detailed Implementation

[0047] The terms “comprising” and “including” in this disclosure may mean “to include as a part of” or “to make into a part of”, or may have the meaning that the terms “comprising” or “including” are generally given under U.S. patent law. If the terms “substantially constitutes” or “substantially consists of” are used in the claims, they have the meaning as considered under U.S. patent law. Other aspects of the invention are described in or will be apparent from the following disclosure (and within the scope of the invention).

[0048] The term "yarn" as used in the following disclosure may refer to monofilament yarn, multifilament yarn, twisted yarn, textured yarn, coated yarn, bicomponent yarn, and yarn made from stretch-breakable fibers of any material known to those skilled in the art. Yarn may be made from carbon, polyamide, rayon, glass fiber, cotton, ceramic, aramid, polyester, metal, polyethylene, polypropylene, and / or other materials exhibiting the desired physical, thermal, chemical, or other properties. Other examples of suitable materials include, for example, polyethylene terephthalate (PET), polycyclohexanedimethyl terephthalate (PCT), copolyester of terephthalic acid and cyclohexanediol (PCTA), polyphenylene sulfide (PPS), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyethylene naphthalate (PEN), and yarns of various modified heat-resistant, hydrolysis-resistant, and / or stain-resistant polyesters disclosed, for example, in U.S. Patent No. 5,169,499 (which is incorporated herein by reference).

[0049] The terms “longitudinal” (MD) and “transverse” (CD) used in the following disclosure are used according to their meanings well known in the art. That is, the MD of an industrial fabric (such as a belt) refers to the direction in which the industrial fabric moves during a manufacturing process (such as a paper towel, towel, or nonwoven manufacturing process), while the CD refers to the direction perpendicular to the MD of the industrial fabric.

[0050] The term "forming side" or "sheet side" in industrial fabrics refers to the side of an industrial fabric that contacts or faces the sheet, paper, or web product on which it is processed. The forming side surface is the surface of an industrial fabric that faces the newly formed sheet or paper web when it is running on a paper processing machine.

[0051] The term "machine side" or "wear side" in industrial fabrics refers to the side of the fabric opposite to the forming side, and is the side of the fabric that contacts or faces the machine components (such as rollers in paper processing machines).

[0052] As used herein, a "knuckle" generally refers to the length of a woven warp or weft yarn that forms the top or bottom surface of a fabric, crossing (floating) over one or more adjacent weft or warp yarns. A knuckle can be located on or below the plane of the shaped or machine-side surface of the fabric. A "warp knuckle" or "MD knuckle" refers to a warp yarn that forms the top or bottom surface by crossing over one or more adjacent weft yarns. A "weft knuckle" or "CD knuckle" refers to a weft yarn that forms the top or bottom surface by crossing over one or more adjacent warp yarns. Generally, a "short" knuckle refers to a surface yarn that crosses (floats) over another adjacent yarn, while a "long" knuckle refers to a surface yarn that crosses (floats) over two or more adjacent yarns.

[0053] The planar difference in the woven fabric of the present invention can be the difference between the top of the first strand and the top of the second strand (such as the top of the warp and the top of the weft) in the fabric. For example, in some embodiments, the planar difference is the difference between the top of the highest warp node at the shaped side surface of the fabric and the top of the highest weft node at the shaped side surface of the fabric.

[0054] As used herein, a "recess" refers to the space between adjacent nodes or portions thereof (e.g., adjacent meridian and parallel nodes). For example, a recess may be defined in length by a first parallel node and a second parallel node, or portions thereof, and in width by a first meridian node and a second meridian node, or portions thereof, wherein the meridian and parallel nodes are adjacent to each other. In some embodiments, a recess may be defined in length by a first meridian node and a second meridian node, or portions thereof, and in width by a first parallel node and a second parallel node, or portions thereof, wherein the meridian and parallel nodes are adjacent to each other. In some embodiments, a recess may be defined in length by a first meridian node and a second meridian node, or portions thereof, and in width by a third meridian node and a fourth meridian node, or portions thereof, wherein the meridian nodes are adjacent to each other. In some embodiments, the recess is defined in length by a first and a second lattice segment or a portion thereof by the first and a second lattice segment, and in width by a third and a fourth lattice segment or a portion thereof by the third and a fourth lattice segment, wherein the lattice segments are adjacent to each other.

[0055] In some embodiments, the recess may be formed having a length defined by the distance between two latitudinal nodes or portions thereof and a width defined by the distance between two longitudinal nodes or portions thereof. In some embodiments, the recess may be formed having a length defined by the distance between two longitudinal nodes or portions thereof and a width defined by the distance between two latitudinal nodes or portions thereof. In other embodiments, the recess may be formed having a length defined by the distance between a first pair of latitudinal nodes or portions thereof and a width defined by the distance between a second pair of latitudinal nodes or portions thereof. In other embodiments, the recess may be formed having a length defined by the distance between a first pair of longitudinal nodes or portions thereof and a width defined by the distance between a second pair of longitudinal nodes or portions thereof. In some embodiments, the recess may be formed having a length defined by two latitudinal nodes or two longitudinal nodes or portions thereof and a width defined by one longitudinal node and one latitudinal node or portion thereof. In other embodiments, the recess may be formed having a width defined by two latitudinal nodes or two longitudinal nodes or portions thereof and a length defined by one longitudinal node and one latitudinal node or portion thereof. In other embodiments, the recess may be formed having a length defined by both longitudinal nodes and latitudinal nodes or portions thereof and a width defined by both longitudinal nodes and latitudinal nodes or portions thereof.

[0056] The repeating weave pattern in the fabric of the present invention can produce recesses defined by the repeating weave pattern.

[0057] The recess depth is the distance from the top of the highest knot on the top or shaped side surface of the fabric to the lower or lowest point within the recess. For example, the recess depth can be determined based on the distance from the plane of the top surface of the highest warp knot on the shaped side surface of the fabric to the top surface of the lowest weft knot within the recess. In some embodiments, the recess depth can be determined based on the distance from the plane of the top surface of the warp knot defining the length or width boundary of the recess to the plane of the top surface of the warp or weft yarn located below and between the knot or portion thereof defining the length and width of the recess. In some embodiments, the recess depth can include the distance from the plane of a first top surface of the yarn constituting the knot defining the length or width boundary of the recess (such as a warp knot) to the plane of a second top surface of the same yarn, wherein the second top surface is located below the first top surface and below and between the knot or portion thereof defining the length and width boundary of the recess.

[0058] In other embodiments, the recess depth is a range of depths based on the distance from a plane on the top surface of the segment defining the length or width boundary of the recess to the various planes located below and between the segment or portion defining the length and width boundaries of the recess and the top surface of the segment. In further embodiments, the recess depth is the average depth derived from a measured depth range. In other embodiments, the recess depth is a nominal depth based on a target depth range. In some embodiments, the recess depth is the maximum measured depth of the recess.

[0059] As described herein, the present invention relates to an industrial fabric, such as a structured fabric, having CD sections near the shaped side surface of the industrial fabric and at least one long MD section at the shaped side surface.

[0060] More specifically, the structured fabric of the present invention comprises one or more long warp knots on its shaped side surface. Weft knots are typically not located at the highest plane of the shaped side surface of the fabric, but rather near the highest plane, for example, below the top surface of the long warp knot. This height difference between the tops of the warp and weft knots on the shaped side surface results in a plane difference between the tops of the long warp knots and the tops of the weft knots on the shaped side surface.

[0061] This invention provides an improved structured fabric, such as an eTAD fabric, which exhibits advantageous properties for forming tissue paper and related products in embodiments of the invention. For example, an eTAD fabric including a support weft design according to an embodiment of the invention allows CD sections to be higher or lower in the forming side plane to allow for better sheet transfer at the interface of the crease roller or backing roller. Without CD sections, sheet paper may be difficult to transfer during manufacturing. In embodiments of the invention, adding higher CD section components to the forming side plane of this industrial fabric design allows for better sheet transfer from the backing roller to the industrial fabric. The support weft design in embodiments of the invention allows the CD sections to be high enough in the forming side plane to facilitate sheet transfer, but still low enough below the highest fabric plane so that it does not affect the softness of the sheet. For example, in some embodiments, the invention relates to an eTAD fabric having long MD sections at the forming side surface, and to adding CD sections by adding support wefts (weft yarns) to the fabric to help grip the sheet from the backing roller, thereby facilitating the transfer of the sheet onto the eTAD fabric.

[0062] In addition, in some embodiments, the fabric design of the present invention described herein results in a reduction of the number of openings in the sheet product produced on the fabric, while maintaining good transfer of the sheet product to the fabric.

[0063] The structured fabrics of this invention can be woven in various weave patterns, such as complex or simple ones, and can be single-layer or multi-layer fabrics. Examples of weave patterns that can be used to form the structured fabrics of this invention include plain weave, twill weave, basket weave, and / or satin weave patterns. The structured fabrics of this invention can be woven from monofilament, ply monofilament, multifilament, and / or ply multifilament yarns. The yarns used in the fabrics of this invention can be extruded from any of several synthetic polymer resins (such as polyamide and polyester resins) used for this purpose by those skilled in the art of mechanical textiles. The structured fabrics can be made into a single layer of supporting weft yarns or any design or weave pattern, wherein the shaped side length MD section can exist together with the CD section in the higher plane.

[0064] In some embodiments, the fabric of the present invention includes a double-layer support weft design (i.e., a double-layer weft design that includes additional weft yarns (weft threads) in the forming side layer of the fabric, such that the number of weft yarns in the top (forming side) layer of the fabric is at least twice the number of weft yarns in the bottom (machine side) layer of the fabric). In some embodiments, the fabric of the present invention may include a double layer of weft yarns having a weft yarn ratio of 2:1, 3:1, or 3:2 between the number of weft yarns in the forming side layer and the wear side (machine side) layer of the fabric. In a support weft fabric design, “support” weft yarns may be added between holes, which may exist between weft yarns (which can be considered “main” weft yarns) on which the warp yarns float. Support weft yarns typically have a different profile than the main weft yarns in the fabric and may differ from the main weft yarns in any number of ways (such as material, shape, and / or diameter, e.g., crimp). For example, in some embodiments, the support weft yarns will have a smaller diameter than the main weft yarns in the same layer.

[0065] In some embodiments, the fabric of the present invention includes a double-supported weft design comprising two layers of CD yarns and one layer of MD yarns, wherein the first layer of CD yarns is a forming side layer and includes first CD yarns and second CD yarns that are at least different from each other in diameter, and wherein the second layer of CD yarns is a machine side layer comprising yarns with the same or similar diameter to the first CD yarns of the first layer. In some embodiments, increasing the diameter of the first CD yarns above the second CD yarns of the first layer results in an increase in the warp length at the forming side surface of the fabric, resulting in increased softness of paper products (such as facial tissues, toilet paper, or paper towels) produced thereon. In some other embodiments, increasing the diameter of the second CD yarns above the first CD yarns of the first layer results in an increase in the warp height and recess depth of the forming side, resulting in an increase in the thickness of fiber-based products produced thereon (e.g., the sheet thickness will be thicker), and therefore more fluffy.

[0066] In some embodiments, the fabric comprises at least one layer of MD yarn and at least one layer of CD yarn. In other embodiments, the fabric may comprise one layer of MD yarn and two layers of CD yarn. In yet another embodiment, the fabric may comprise three layers of MD yarn and two layers of CD yarn. In some embodiments, the fabric of the present invention may comprise two layers of MD yarn and one layer of CD yarn.

[0067] In one embodiment, the present invention provides an eTAD fabric having good sheet transfer from the backing roller to the eTAD fabric and from the eTAD fabric to the Yankee dryer. Figure 1A schematic diagram of an eTAD machine is provided. In some embodiments, CD sections near the forming side surface of the eTAD fabric of the present invention facilitate good sheet transfer from the backing rollers to the eTAD fabric. This allows for less interruption in eTAD machine operation due to sheet transfer problems. In another embodiment, long MD sections on the forming side surface of the eTAD fabric provide good sheet transfer from the eTAD fabric to the Yankee dryer. The long MD sections also provide good sheet contact with the Yankee dryer, which allows for better wrinkling by the Yankee dryer, resulting in, for example, better sheet softness. The present invention optimizes the CD and MD sections so that no compromise between the CD and MD sections is required.

[0068] In some embodiments, the fabrics of the present invention can be used in QRT. ® Machine (Valmet's Advantage™ QRT) ® (Technical machines). Figure 13 The text describes QRT. ® Process.

[0069] Additionally, in some embodiments, the yarns in the industrial fabric of the present invention may be structurally uneven and / or non-smooth. In some embodiments, some yarns may be uneven and / or non-smooth, while others may be flat and / or smooth. Due to the planar difference between the MD and CD sections at the formed side surface of the fabric of the present invention, uneven and / or non-flat yarns particularly contribute to the technical advantage of better sheet transfer in embodiments of the present invention. Uneven and / or non-smooth yarns can facilitate this transfer because such yarns create a fabric surface on which the sheet product fibers can be more easily twisted during sheet transfer. In contrast, flat yarns would have a larger surface area for the fiber web to be laid on, and therefore may be more difficult to transfer.

[0070] The MD yarns in the fabrics of the present invention can be of any suitable size. For example, the MD yarns can have diameters of, for example, 0.20 mm, 0.25 mm, 0.30 mm, 0.35 mm, 0.40 mm, 0.45 mm, 0.50 mm, 0.55 mm, 0.60 mm, 0.65 mm, 0.70 mm, 0.80 mm, 0.90 mm, 1.00 mm, 1.10 mm, or values ​​between these. In some embodiments, the diameter of the MD yarns in the fabrics of the present invention is uniform. In other embodiments, the diameter of the MD yarns varies within a single fabric. For example, in a single fabric, some MD yarns may have a diameter of 0.30 mm, while others may have a diameter of 0.40 mm.

[0071] The CD yarns in the fabrics of the present invention can be of any suitable size. For example, the CD yarns can have diameters of, for example, 0.20 mm, 0.25 mm, 0.30 mm, 0.35 mm, 0.40 mm, 0.45 mm, 0.50 mm, 0.55 mm, 0.60 mm, 0.65 mm, 0.70 mm, 0.80 mm, 0.90 mm, 1.00 mm, 1.10 mm, or values ​​between these. In some embodiments, the diameter of the CD yarns of the present invention is uniform. In other embodiments, the diameter of the CD yarns varies within a single fabric. For example, in a single fabric, some CD yarns may have a diameter of 0.30 mm, while others may have a diameter of 0.40 mm.

[0072] In some embodiments, all MD yarns and all CD yarns have the same diameter. In other embodiments, a portion of the MD yarns and a portion of the CD yarns have the same diameter, while other portions of the MD yarns and CD yarns in the same fabric have different diameters. In still other embodiments, the diameter of all MD yarns is different from that of all CD yarns.

[0073] In some embodiments, the MD yarn count in the fabric of the present invention can be, for example, 20 yarns / cm, 30 yarns / cm, 40 yarns / cm, or a value between thereof. In other embodiments, the MD section length can be, for example, 2.00 mm, 3.00 mm, 4.00 mm, 5.00 mm, or a value between thereof.

[0074] In some embodiments, the count of CD yarns in the fabric of the present invention can be 10 yarns / cm, 20 yarns / cm, 30 yarns / cm, 40 yarns / cm, 50 yarns / cm, or values ​​between these values. In some embodiments, the CD section length can be, for example, 0.40 mm, 0.50 mm, 0.60 mm, 0.70 mm, 0.80 mm, 0.90 mm, 1.00 mm, 1.10 mm, 1.20 mm, 1.30 mm, 1.40 mm, 1.50 mm, 1.60 mm, or values ​​between these values. In other embodiments, the CD section length is 1 to 4 times the diameter of the MD warp.

[0075] In some embodiments, the plane difference between warp and weft points (measured from the plane at the top of the MD point to the plane at the top of the CD point) can be, for example, 0.05 mm, 0.10 mm, 0.15 mm, 0.20 mm, 0.25 mm, 0.30 mm, 0.35 mm, 0.40 mm, 0.45 mm, 0.50 mm, or values ​​between these values. In some embodiments, the plane difference can be between 0.05 mm and 0.95 mm. In some embodiments, the plane difference creates a recess in the industrial fabric.

[0076] Compared to determining the planarity difference of the shaped side surface in the fabric of the present invention, the recess depth does not necessarily depend on the arrangement of the highest CD section at the shaped side surface, while the planarity difference of the shaped side surface depends on the arrangement of the highest CD section relative to the highest MD section at the shaped side surface of the fabric.

[0077] In some embodiments, one or more recesses in the structured fabric of the present invention have the same depth. In other embodiments, one or more recesses in the structured fabric have different depths. In other embodiments, some recesses in the structured fabric have the same depth, while other recesses in the same structured fabric have different depths.

[0078] In some embodiments, the length of the recesses in the industrial fabric of the present invention can be, for example, 1.0 mm, 2.0 mm, 3.0 mm, 4.0 mm, 5.0 mm, or a value between these values. In some embodiments, all recesses in the industrial fabric have the same length. In other embodiments, all recesses in the industrial fabric have different lengths. And in other embodiments, some recesses in the industrial fabric have the same length, while other recesses in the same fabric have different lengths.

[0079] In some embodiments, the width of the recesses in the industrial fabric of the present invention can be, for example, 0.25 mm, 0.50 mm, 0.75 mm, 1.0 mm, 1.25 mm, 1.50 mm, 1.75 mm, 2.0 mm, or values ​​between these values. In some embodiments, all recesses in the industrial fabric have the same width. In other embodiments, all recesses in the industrial fabric have different widths. And in other embodiments, some recesses in the industrial fabric have the same width, while other recesses in the same fabric have different widths.

[0080] In various embodiments, fibers from fiber-based products produced on the industrial fabric of the present invention can be formed at different depths of the recesses in the fabric. For example, in some embodiments, fibers will penetrate to certain depths of the recess, but not to the deepest depth of the recess. For instance, fibers may penetrate below the plane of the long warp knots at the shaped side surface of the fabric and form within the depth created by the plane at the top of the weft and / or warp yarns found within the recess, but not within the depth created by the plane at the top of the weft and / or warp yarns, which are the lowest points in the recess. Thus, in some embodiments, fibers may be formed in a portion of the recesses in the fabric of the present invention, while other portions of the recesses (e.g., the lowest depth of the recess) do not contain fibers from the products produced thereon.

[0081] In some embodiments, the recesses in a single fabric may typically be consistent for measurements of one or more of the planarity difference, recess length, and / or recess width between MD and CD sections. In other embodiments, one or more of the planarity difference, recess length, and / or recess width between MD and CD sections may vary among recesses in the same fabric.

[0082] In some embodiments, the structured fabric is a multilayered fabric. For example, one or more woven or nonwoven layers may be attached to the machine-side surface of a woven fabric having near-surface CD knots and long MD knots at the forming side surface. The one or more layers added to the machine-side surface may be chemically, thermally, or mechanically attached or bonded thereto. For example, the one or more added layers may be fused, laminated, glued, or woven to the machine side of a woven fabric having long warp knots at the forming side surface and weft knots near the forming side surface. In some embodiments, the one or more layers added to the machine-side surface may be an extruded mesh, a knitted structure, or other nonwoven structure, such as a film, foil, or spunbond layer.

[0083] Switch to the attached image. Figure 2 A top view image depicting the shaped side surface of the first or top layer of the double-layer supported weft fabric of the present invention is shown. Figure 2 As shown, and according to one embodiment of the invention, in the first layer, at least one MD warp knot (102, 112) is present on the shaped side surface of the fabric formed from MD yarns (e.g., 100). The MD warp knot (102, 112) is located on a plane of the shaped side surface of the fabric, where the web contacts the fabric. Figure 2 In this design, multiple MD warp points have a repeating pattern in the fabric. MD warp points (102) float above or cross five weft or CD yarns (103, 104, 105, 106, and 107). Figure 2 In the fabric, CD yarns with two different diameters are used. Some CD yarns have a first diameter (103, 105, 107), while others have a second diameter (101, 104, 106) smaller (fineer) than the first diameter. The finer CD yarns float above the MD yarns and create near-surface CD knots. For example, when the weft yarn (101) floats above the two MD warp yarns, the CD weft yarn (101) is in a plane close to the forming side surface, but not at the highest plane of the forming side surface of the fabric. The CD yarns (103, 105, 107) with the larger diameter are woven below the MD warp yarns. Figure 2 In the middle, the MD warp yarn and CD weft yarn repeat the weaving pattern of the MD long warp pile (102) and CD weft yarn (101).

[0084] Figure 3 It shows Figure 2The second or bottom surface layer of the fabric. The bottom surface has an 8-shed weave pattern. The first layer ( Figure 2 ) and the second layer ( Figure 3 It is connected by an interwoven double weft yarn pattern.

[0085] Table I below provides information about Figure 2 and Figure 3 The information permeable to the fabric, and specifically to the exemplary double-layered supported weft fabric of the present invention, includes information on the yarn count, yarn count, air permeability, thickness, warp, weft, and supporting weft. Based on the average of five different measurements from the highest forming side surface MD section to the highest forming side CD section of the fabric, the planarity difference of this particular design is approximately 0.316 mm.

[0086] Table I

[0087]

[0088] Figure 2 The fabric of the present invention exemplifies a double-layered supported weft knit pattern with a weft ratio of 2:1 (the weft yarns in the forming-side weft layer are twice the number of weft yarns in the abrasion (machine)-side weft layer), wherein the MD yarns float above five CD yarns to form long MD knots on the top of the fabric or on the forming side. In some embodiments, the weft ratio of the double-layered weft knit can be, for example, 3:1. Figure 2 The yarn materials for the MD and CD yarns of the fabric include polyester. The yarns are not smooth and are not flat, which in particular contributes to the technical advantage of better sheet transfer through the planar difference between the long MD and CD sections in the formed side surface.

[0089] Figure 2 The diameter of the MD yarn in the fabric is 0.40 mm. Figure 2 The diameters of the CD yarns used are different. Specifically, two types of CD yarns are used: one with a diameter of 0.30 mm (support weft yarn) and the other with a diameter of 0.50 mm (main weft yarn).

[0090] Figure 2 The yarn count of the MD yarn in the fabric is 33cm. Figure 2 The MD knot length of the fabric is specified as 4.0 mm. Figure 2 The yarn count of the CD yarn in the fabric is 21cm. Figure 2 The length of the CD section of the fabric is in the range of 0.5mm to 1.0mm.

[0091] Figure 2 The shaped side recesses in the fabric (e.g., such as Figure 6The recess shown has a nominal flatness difference of 0.25 mm. The nominal flatness difference of 0.25 mm is determined based on the average of at least five measurements taken on the sheet forming surface from the top of the highest MD section to the top of the highest CD section. Figure 2 The recess in (e.g., such as) Figure 6 The length of the recess shown is specified as 2.5 mm, and the width of the recess is specified as 0.5 mm.

[0092] Figure 4 It shows Figure 2 A schematic diagram of the cross-section of the fabric. In Figure 4 In the middle, the weft pattern of the weft yarn (108) is in the CD direction. Figure 4 The weft yarn (108) is shown woven in a repeating pattern above two MD yarns, below one MD yarn, above one MD yarn, below one MD yarn, and above two MD yarns. This weave pattern is consistent with... Figure 2 It is associated with CD yarns (101, 104, 106) with a smaller diameter.

[0093] Figure 5 It shows Figure 2 A schematic diagram of the cross-section of the fabric. In Figure 5 The diagram shows the weaving pattern of the MD warp (100) in the MD direction. It also shows portions of the MD warp (100) forming long warp knots (112) on the shaped surface side of the fabric.

[0094] Figure 6 It shows Figure 2 The fabric has a shaped side surface and three exemplary recesses. Each recess (109, 110, 111) is formed by the boundaries of two MD warp knots at the fabric surface and two CD weft knots adjacent to them near the fabric surface. The three exemplary recesses (109, 110, 111) are formed by... Figure 6 The shaded area in the diagram indicates the recessed MD length. The MD length is three CD yarn diameters (two main weft yarns and one support weft yarn) plus the space between the CD yarns defined by the weft knots. The CD width is one MD yarn diameter plus the space defined by the long warp knots (e.g., on the right and left sides of the MD yarns).

[0095] Figure 7A and Figure 7B It shows along Figure 2 A cross-sectional view of the MD of the fabric. Figure 7A and Figure 7B A smaller white monofilament (117) is shown, which is a supporting weft located on the forming side of the fabric, and Figure 7B The dashed box in the middle depicts Figure 7A The outline of the exemplary recess, the length of which is defined by section CD. Figure 7BThe planar difference (119) shown is approximately 0.50 mm and is the difference between the top of the MD section (116) and the top of each of two different CD sections (117 and 118) at similar shaped side surface heights. More specifically, the planar difference between the top of the MD section (116) and the first CD section (117) is approximately 0.50 mm, and similarly, the planar difference between the top of the MD section (116) and the second CD section (118) is also approximately 0.50 mm. Figure 7A and Figure 7B In this context, the planarity difference between the surface longitude line and the CD section can also be determined based on, for example, the average of the distance differences between the top plane of MD section 116 and the top plane of each of CD sections 117 and 118. This planarity difference measurement of approximately 0.50 mm is determined by averaging at least five measurements from the top of the highest MD section to the top of the highest CD section on the sheet forming surface. Figure 2 One of the five values ​​used when the nominal 0.25mm plane difference is obtained.

[0096] When considering recess depth, the bottom measurements used to determine recess depth can include a range of measurements that allow for the minimum planar variation associated with the different yarns constituting the bottom of the recess. For example, while the top plane of the recess can be easily determined based on the top of the MD section indicating the width of the recess, the bottom of the recess can be determined based on a range of planes measured from the top of the different warp, weft, and / or sections located below and between the sections indicating the length and width boundaries of the recess.

[0097] Figure 8 It shows Figure 2 ( Figure 7A / Figure 7B The marked recess in the shaped side surface of the fabric, the length and width of which are defined by the portion of the long warp knot at the shaped side surface.

[0098] Figures 9-10 It shows Figure 2 A top view of the planar differences in the side surface of the fabric sheet. Figure 9 ) and measured values ​​( Figure 10 The measured plane difference was 0.323 mm. As mentioned above, the plane difference can be a measurement from the top of one section to the top of another. Here, at the shaped side surface of the fabric, it is from the top of the long MD section to the top of the CD section. Figure 10 In the diagram, the x-axis represents the distance across the measured fabric, which corresponds to the distance across... Figure 9 The distance indicated by the slanted arrows in the middle of the fabric. The y-axis represents the measured fabric thickness. The top thick horizontal line corresponds to the highest point of the long warp joint, and the bottom thick horizontal line corresponds to the highest point of the CD joint at the formed side surface. Therefore, Figure 10The 0.323 mm plane difference shown corresponds to along... Figure 9 The distance measured by the arrow is the difference between the highest point in the topmost MD section and the highest point in the topmost CD section.

[0099] Figure 11 A fabric according to the invention is shown. Figure 11 In this process, the MD yarn floats above two CD yarns (120, 121) in a repeating pattern and forms a long MD section (123). The long MD section (123) is located on the forming side surface, and the CD yarns (120, 121) interweave to form corresponding CD sections (115, 133) near the forming side surface.

[0100] Figure 12 A fabric according to the invention is shown. Figure 12 In this fabric, the MD yarn floats above three CD yarns (124, 125, 126) in a repeating pattern and forms a long MD knot (127). The long MD knot (127) is located at the forming side surface, and the CD yarns (124, 125, 126) interweave to form CD knots near the forming side surface. For example, CD yarn 124 forms knot 128 near the forming side surface of the fabric.

[0101] Figure 14A , Figure 14B and Figure 14C It shows Figure 2 The recess depth of the fabric was measured. The recess depth measured in these figures is 0.91 mm and is based on the distance difference between the plane of the highest warp knot on the fabric surface and the top plane of the warp or weft thread at the lowest point in the recess. Unlike the difference in the plane of the formed side surface in the fabric of the present invention, which determines the plane difference of the formed side surface, the recess depth does not necessarily depend on the arrangement of the highest CD knot on the formed side surface, which depends on the arrangement of the highest CD knot relative to the highest MD knot on the formed side surface of the fabric.

[0102] Similar to Figure 14A , Figure 14B and Figure 14C , Figure 15A , Figure 15B and Figure 15C It shows Figure 2 The concave depth measurement of the fabric, wherein the measurement is based on a single plane difference measurement between the highest warp plane at the surface of the fabric and the top plane of the warp or weft at the lowest point in the concave. Figure 15A , Figure 15B and Figure 15C The recess depth of 1.28 mm is shown, measured from the difference between -1.29 mm (bottom plane measurement) and -0.01 mm (top plane measurement).

[0103] Figure 16A , Figure 16B , Figure 16C and Figure 16D A cross-sectional view of a double-layered support weft fabric of the present invention, comprising two layers of CD yarns and one layer of MD yarns. The first layer of CD yarns is on the forming side of the fabric and includes a first CD yarn and a second CD yarn, wherein the first CD yarn (main weft) has a larger diameter than the second CD yarn (support weft). Figure 16A It is a view along the MD weave pattern of the fabric and depicts a long warp knot at the forming side surface, which floats above the five CD yarns in the first (forming side) CD yarn layer. Figures 16B-16D It is a CD view of the fabric, depicting the weaving patterns of different weft yarns. Figure 16B The weaving pattern of CD yarn in the second (machine side) CD yarn layer is depicted. Figure 16C and Figure 16D The first weft yarn pattern in the first (forming side) CD yarn layer is depicted. Figure 16C ) and second weft pattern ( Figure 16D ).

[0104] Modifications to the foregoing will be obvious to those skilled in the art, but will not cause the invention to depart from its scope. The appended claims should be construed as covering these situations.

Claims

1. A structured fabric, wherein the structured fabric is a woven fabric, the woven fabric comprising: (a) Forming side surface and machine side surface; (b) Multiple longitudinal (MD) yarns; and (c) A plurality of transverse (CD) yarns disposed in a first layer and a second layer, wherein the first layer is located on the forming side surface of the structured fabric, and the second layer is located on the machine side surface of the structured fabric. At least a portion of the MD yarn is interwoven with the CD yarn such that the MD yarn passes over at least two of the CD yarns in the first layer, thereby forming a long warp knot at the forming side surface. At least a portion of the CD yarn is interwoven with the MD yarn such that the CD yarn of the first layer passes over at least one of the MD yarns, thereby forming a weft knot near the shaped side surface of the structured fabric.

2. The structured fabric of claim 1, wherein the MD yarn is disposed in two or more layers.

3. The structured fabric according to claim 1 or 2, wherein the CD yarn is configured in three or more layers.

4. The structured fabric according to any one of claims 1 to 3, wherein the MD yarn passes over at least three CD yarns of the first layer.

5. The structured fabric of claim 4, wherein the MD yarn passes over at least five CD yarns of the first layer.

6. The structured fabric of claim 5, wherein the MD yarn passes over at least seven CD yarns of the first layer.

7. The structured fabric according to any one of claims 1 to 6, wherein the CD yarn of the first layer passes over at least two MD yarns.

8. The structured fabric of claim 7, wherein the CD yarn of the first layer passes over at least three MD yarns.

9. The structured fabric according to any one of claims 1 to 8, comprising one or more woven and / or nonwoven machine side layers.

10. The structured fabric according to any one of claims 1 to 9, wherein the fabric includes one or more recesses having a CD width of at least one MD yarn diameter.

11. The structured fabric according to any one of claims 1 to 10, wherein the fabric includes one or more recesses having a longitudinal (MD) length of at least one CD yarn diameter.

12. The structured fabric according to any one of claims 1 to 11, wherein the structured fabric is an eTAD fabric.

13. The structured fabric according to any one of claims 1 to 12, wherein the shaped side surface faces the fiber web.

14. The structured fabric according to any one of claims 1 to 13, wherein the MD yarn comprises a material selected from the group consisting of: carbon, polyamide, rayon, glass fiber, cotton, ceramic, aramid, polyester, metal, polyethylene, polypropylene, polycyclohexanedimethyl terephthalate (PCT), copolyester of terephthalic acid and cyclohexanediol (PCTA), polyphenylene sulfide (PPS), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and polyethylene naphthalate (PEN).

15. The structured fabric according to any one of claims 1 to 14, wherein the CD yarn comprises a material selected from the group consisting of: carbon, polyamide, rayon, glass fiber, cotton, ceramic, aramid, polyester, metal, polyethylene, polypropylene, polycyclohexanedimethyl terephthalate (PCT), copolyester of terephthalic acid and cyclohexanediol (PCTA), polyphenylene sulfide (PPS), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and polyethylene naphthalate (PEN).

16. The structured fabric according to any one of claims 1 to 15, wherein the diameter of the MD yarn is between 0.20 mm and 1.1 mm.

17. The structured fabric of claim 16, wherein the diameter of the MD yarn is 0.40 mm.

18. The structured fabric according to any one of claims 1 to 17, wherein the diameter of the CD yarn is between 0.20 mm and 1.1 mm.

19. The structured fabric according to claim 18, wherein the diameter of the CD yarn is 0.30 mm.

20. The structured fabric according to any one of claims 1 to 19, wherein the long warp knots on the shaped side surface have a length between 2.0 mm and 5.0 mm.

21. The structured fabric according to any one of claims 1 to 20, wherein the weft node near the shaped side surface has a length between 0.40 mm and 1.60 mm.

22. The structured fabric according to any one of claims 1 to 21, wherein the planar difference between the top surface of the long warp node and the top surface of the weft node is at most 0.50 mm.

23. The structured fabric of claim 22, wherein the planar difference between the top surface of the warp node and the top surface of the weft node is between 0.25 mm and 0.50 mm.

24. The structured fabric according to any one of claims 1 to 23, wherein the planar difference between the top surface of the long warp node and the top surface of the weft node is between 0.05 mm and 1.0 mm.

25. The structured fabric according to any one of claims 1 to 24, wherein the structured fabric comprises one or more recesses having an MD length between 1.0 mm and 5.0 mm.

26. The structured fabric according to any one of claims 1 to 25, wherein the structured fabric comprises one or more recesses having a CD width between 0.3 mm and 2.0 mm.

27. The structured fabric of claim 6, wherein the MD yarn passes over at least 18 CD yarns of the first layer.

28. The structured fabric of claim 8, wherein the CD yarn of the first layer passes over at least 18 MD yarns.

29. The structured fabric according to any one of claims 1 to 28, comprising a recess depth, wherein the plane difference between the top surface plane of a long warp node or portion thereof defining the length or width boundary of the recess and the top surface plane of one or more of the weft yarns, warp yarns, warp nodes or weft nodes defining the bottom of the recess comprises a depth range between 0.01 mm and 1.0 mm.

30. The structured fabric according to any one of claims 1 to 29, wherein one or more of the MD yarns and / or CD yarns are not flat and / or not smooth.

31. The structured fabric according to any one of claims 1 to 30, wherein the first layer of the CD yarn comprises a first CD yarn and a second CD yarn.

32. The structured fabric of claim 31, wherein the first CD yarn differs from the second CD yarn in diameter, shape and / or material.

33. A structured fabric, wherein the structured fabric is a woven fabric, the woven fabric comprising: (a) Forming side surface and machine side surface; (b) Multiple longitudinal (MD) yarns disposed in a first layer and a second layer, wherein the first layer is located on the forming side surface of the structured fabric and the second layer is located on the machine side surface of the structured fabric; as well as (c) Multiple transverse (CD) yarns, At least a portion of the MD yarn is interwoven with the CD yarn, such that the MD yarn of the first layer passes over at least two of the CD yarns, thereby forming a long warp knot at the forming side surface, and At least a portion of the CD yarn is interwoven with the MD yarn such that the CD yarn passes over at least one of the MD yarns in the first layer, thereby forming a weft knot near the shaped side surface of the structured fabric.

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