Fabric

Abstract

A fabric having a first direction and a second direction and two opposing first and second surfaces in a thickness direction of the fabric, the fabric extending from a first edge to a second edge in the second direction, where at least part of the warp yarns forming the first surface have a polygonal cross-section, the polygonal cross-section has a width and a height, the width being greater than the height, and four corners, where: a first pair of opposing corners have an angle greater than 90 degrees and a second pair of opposing corners have an angle less than 90 degrees, where four sides connecting the four corners are recessed toward a center of the polygonal cross-section, and where the first pair of opposing corners have an angle greater than 90 degrees and the second pair of opposing corners have an angle less than 90 degrees. Two sides of the warp adjacent to the first pair of opposing corners form two opposing first and second surfaces of the fabric.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a fabric, and in particular to a fabric for a fiber web machine. BACKGROUND

[0002] The material of the conventional fabric is polyethylene terephthalate (PET), PPS (polyphenylene sulfide), etc. These materials all come from petroleum (fossil energy), so the large demand for these materials by the conventional fabric is not sustainable development. And a large amount of greenhouse gas (CO2) is emitted in the production of these conventional materials, which also damages the environment.

[0003] The fabric needs to be washed by high-pressure washing liquid to flush the residual fibers attached thereto when used in the fiber web machine. Due to the problems of the material and structure of the conventional fabric, the washing result is insufficient and the yarn is damaged. The yarn damage in turn leads to frequent replacement of new fabric, and the mass production of new fabric consumes a large amount of petroleum (fossil energy) and emits a large amount of greenhouse gas (CO2), thereby generating a large amount of environmental problems. CONTENT OF THE INVENTION

[0004] According to one aspect of the present application, compared with the prior art, the shape and structure of the fabric are improved to have high resistance to high-pressure spraying and save materials, thereby improving the service life of the fabric and being conducive to environmental protection (energy saving and emission reduction).

[0005] According to another aspect of the present application, compared with the prior art, the material composition of the fabric is improved to have good anti-sticking performance and thus be easy to clean and have good wear resistance, thereby improving the service life of the fabric.

[0006] According to still another aspect of the present application, compared with the prior art, the material composition of the fabric is improved to reduce dependence on petroleum (fossil energy) and be sustainable development.

[0007] According to still another aspect of the present application, compared with the prior art, the weaving structure of the fabric is improved to improve the performance and service life of the fabric.

[0008] The utility model provides a kind of fabric, with first direction and second direction and two opposite first surfaces and second surfaces in the thickness direction of the fabric, the fabric extends from first edge to second edge in the second direction, wherein, at least part of the warp yarn forming the first surface has polygonal cross section, the polygonal cross section has: width and height, the width is greater than the height, and four corners, wherein: first pair of opposite corners has angle more than 90 degrees, and second pair of opposite corners has angle less than 90 degrees, wherein, four edges connecting four corners are concave to the center of the polygonal cross section, two edges of the warp yarn adjacent to the first pair of opposite corners form two opposite first surfaces and second surfaces of the fabric.

[0009] In an embodiment, the fabric is a double warp weave structure, and the warp yarns include first upper and lower warp yarns and second upper and lower warp yarns, the first upper and lower warp yarns are substantially one over the other.

[0010] In an embodiment, the cross section of at least some of the weft yarns forming the fabric is circular, and the weft yarns are composed of bio-based polyethylene terephthalate or recycled polyethylene terephthalate.

[0011] In an embodiment, at least one of the four corners is rounded, and the warp yarns forming the first and / or second surfaces are composed of a material with low surface tension.

[0012] In an embodiment, all of the four corners are rounded, and the warp yarns forming the first and / or second surfaces are composed of polyketone or modified PET.

[0013] In an embodiment, a seam is formed between the warp yarns at the two ends of the fabric in the first direction to join the two ends of the fabric in the first direction together.

[0014] In an embodiment, at least some of the warp yarns forming the second surface have the polygonal cross section.

[0015] In an embodiment, 70% of the total matrix polymer mass of the warp yarns forming the first surface is composed of thermoplastic aliphatic polyketone or modified PET.

[0016] In an embodiment, the first upper warp and the first lower warp and the weft are bound to each other according to a first predetermined pattern; the second upper warp and the second lower warp and the weft are bound to each other according to a second predetermined pattern; the weft comprises at least a first weft, a second weft, a third weft, a fourth weft; the first upper warp and the weft are bound to each other according to the first predetermined pattern such that the first upper warp passes repeatedly above the third weft and the fourth weft and below the first weft and the second weft; the second upper warp, which is immediately adjacent to the first upper warp, passes repeatedly below the third weft and the fourth weft and above the first weft and the second weft; the first lower warp and the weft are bound to each other according to the second predetermined pattern such that the first lower warp passes repeatedly above the fourth weft and below the first weft, the second weft and the third weft; the second lower warp, which is immediately adjacent to the first lower warp, passes repeatedly above the second weft and below the first weft, the third weft and the fourth weft.

[0017] In an embodiment, the fabric is an industrial fabric for pulp making, paper making or waste water treatment. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 A top view schematic is shown illustrating the fabric directions;

[0019] Figure 2 A cross-sectional view schematic is shown along the fabric thickness direction;

[0020] Figure 3 and Figure 4 A cross-sectional view of the warp is shown;

[0021] Figure 5 A perspective view schematic of an embodiment of the fabric is shown;

[0022] Figure 6 A cross-sectional view schematic of another embodiment of the fabric along the fabric thickness direction is shown, illustrating a cross-sectional view of the weft;

[0023] Figure 7 A plan view schematic of another embodiment of the fabric is shown;

[0024] Figure 8 Another cross-sectional view schematic of another embodiment of the fabric along the fabric thickness direction is shown, illustrating a cross-sectional view of the warp;

[0025] Figure 9 A perspective view schematic of another embodiment of the fabric is shown;

[0026] Figure 10 A water flow schematic is shown when the fabric is cleaned with high pressure spraying;

[0027] Figure 11 A color chart of the high-pressure spray test results is shown.

[0028] Reference Signs List

[0029] 1 fabric

[0030] 110 first surface

[0031] 120 Second Surface

[0032] D1 First direction

[0033] D2 Second direction

[0034] E1 First Edge

[0035] E2 Second Edge

[0036] 130 warp yarns

[0037] 11, 12, 13, 14 corners

[0038] 15 sides

[0039] C Center

[0040] U1 First upper warp

[0041] U2 Second upper warp

[0042] L1 first lower warp

[0043] L2 Second lower warp

[0044] 140 weft yarn

[0045] W1 First weft yarn

[0046] W2 Second weft yarn

[0047] W3 third weft yarn

[0048] W4 fourth weft yarn

[0049] S Water Flow

[0050] S1 and S2 tributaries DETAILED DESCRIPTION

[0051] Figure 1 A top view of the fabric 1 is shown. The first surface 110 of the fabric 1 is facing upward (eg Figure 2 As shown in FIG. 1 , the fabric 1 has a first direction D1 and a second direction D2. The second direction D2 corresponds to the weft direction of the fabric 1, and the first direction D1 corresponds to the warp direction of the fabric 1. The fabric 1 extends from a first edge E1 to a second edge E2.

[0052] Figure 2 A cross-sectional view along the thickness direction of the fabric 1 is shown. The fabric 1 has two opposite first and second surfaces 110 and 120 in the thickness direction. The first and second surfaces 110 and 120 are formed by warp yarns 130 extending in a first direction D1, and weft yarns 140 extending in a second direction D2 are located between the first and second surfaces 110 and 120 in the thickness direction of the fabric 1. That is, the fabric 1 has at least three layers from top to bottom: the first surface 110 formed by the warp yarns 130, the middle layer including at least the weft yarns 140, and the second surface 120 formed by the warp yarns 130.

[0053] In an embodiment, the warp yarns 130 forming the first surface 110 contain a low-surface-tension material, such as polyketone (PK) or modified PET, and the remaining part (middle and bottom layers) of the fabric 1 is made of bio-based or recycled polyethylene terephthalate (Bio-PET). The low-surface-tension material can be more easily cleaned. Preferably, 70% of the mass of the entire base polymer of the warp yarns 130 of the first surface 110 is thermoplastic aliphatic polyketone or modified PET. “Bio-based or recycled PET” means made from renewable resources such as sugar cane or corn starch instead of petroleum or made from degradable recycled materials. In the present utility model, it is not limited to which kind of bio-based PET is used, as long as it can replace the traditional “fossil-based PET (plastic made from petroleum)”. Using bio-based or recycled PET has various environmental benefits, such as reducing greenhouse gas (CO2) emissions and dependence on fossil fuels, and also helps to reduce plastic waste and supports the circular economy by promoting the use of renewable resources for sustainable development. That is, the fabric 1 is made of a mixture of polyketone (PK) and “bio-based or recycled PET”. Bio-based or recycled PET has lower negative impact on the environment than traditional fossil-based PET.

[0054] The “peel force test” shows that due to the polyketone (PK) contained in the warp yarns 130 of the first surface 110 of the fabric 1 of the present utility model, the fabric 1 has excellent anti-sticking performance, thereby being easy to keep clean and having good wear resistance. That is, compared with fabrics made of traditional polymers, the warp yarns 130 of the first surface 110 of the fabric 1 of the present utility model reduce its friction and make it anti-sticking, thereby improving wear resistance.

[0055] Compared with traditional fabrics made of “fossil-based PET”, the polyketone (PK) used in the present utility model reduces greenhouse gas (CO2) emissions and improves washability and hydrolysis resistance, thereby increasing the service life of the fabric 1 by about 25%.

[0056] Figure 3 andFigure 4 A polygonal cross-section of the warp yarn 130 is shown. It is noted that the polygonal cross-section does not limit each side to be a straight line shape, but each side can be a curved shape, and can be a combination of straight lines and / or curves. At least the warp yarn 130 forming the first surface 110 has a polygonal cross-section. Of course, it is also possible that both the warp yarn 130 forming the first surface 110 and the warp yarn 130 forming the second surface 120 have a polygonal cross-section. The polygonal cross-section has a width and a height, the width being greater than the height, and four corners 11, 12, 13, 14. The first pair of opposite corners 11, 13 has an angle of more than 90 degrees, and the second pair of opposite corners 12, 14 has an angle of less than 90 degrees. That is, the warp yarn 130 is a substantially flat yarn. The four corners 11, 12, 13, 14 are rounded. When the corners 11, 12, 13, 14 are rounded corners, there are no sharp corners that would cause, for example, the produced web to be imprinted. Furthermore, the shape of the yarn allows the stitching yarn to pass smoothly through the endless path, since there are no sharp yarn corner obstructions. The four sides 15 connecting the four corners 11, 12, 13, 14 are concave towards the center C of the polygonal cross-section. Figure 3 、 Figure 4 、 Figure 10 The concave structure is exaggerated for a clearer illustration of the concave structure. By "concave" is meant in this application that as long as any two adjacent corner connecting lines are at least partially not convex with respect to a straight line connecting form towards the side away from the center of the yarn. The two sides of the warp yarn 130 adjacent to the first pair of opposite corners 11, 13 form the two opposite first surface 110 and second surface 120 of the fabric 1. That is, the substantially flat face (the face in the width direction) of the warp yarn 130 forms the two opposite first surface 110 and second surface 120 of the fabric 1.

[0057] The fabric needs to be cleaned regularly to ensure its working performance, and a high power shower is a cleaning means of the fabric by the fiber web machine. The water flow of the high power shower can have a pressure of, for example, 400 bar to 600 bar. The high power shower is water sprayed through a nozzle having a diameter of, for example, 0.2 mm to 0.5 mm. When a conventional fabric is cleaned by such a fine and strong spray, the flat rectangular yarn has a tendency to crack because of its poor resistance to the high power shower. In addition, the conventional fabric also has a tendency for water to splash randomly from the flat surface of the yarn.

[0058] Figure 10A schematic of the water flow when the fabric 1 is washed with high pressure spray is shown. The water flow S is divided into two branches S1, S2 after it encounters the corner 11. Then, the two branches S1, S2 flow along the concave edges 15 towards the center C of the polygonal cross-section, respectively. That is, the corner 11 first weakens the water flow S into two branches S1, S2, and then the two concave edges 15 further slow down the flow rate of the two branches S1, S2, respectively, and weaken their impact. Thus, compared to the cross-section of the warp yarns of a conventional fabric (e.g. rectangular or circular), the shape of the polygonal cross-section of the warp yarns 130 of the first surface 110 of the fabric 1 of the present application has improved resistance to high pressure washing against the spray impact, can properly direct the spray flow into the fabric structure, and can achieve better cleaning effect.

[0059] Compared to the cross-section of the warp yarns of a conventional fabric (e.g. rectangular or circular), the polygonal cross-section of the warp yarns 130 of the present application reduces the weight of the warp yarns by about 10%, and improves the resistance to high pressure spray.

[0060] Figure 11 A high pressure spray experiment (water flow speed: 1000 m / min, nozzle diameter: 0.25 mm, angle between nozzle and surface of fabric: 90°, water pressure: 450 bar, spray time: 30 min) is shown. It shows that, compared to the warp yarn materials of a conventional fabric, i.e. the standard PET of sample 1, and the two PPS (polyphenylene sulfide) of samples 3 and 4, the warp yarns 130 of the first surface 110 of the fabric 1 of the present application contain polyketone (PK), so that the warp yarns 130 have high impact resistance, and the fabric 1 is very clean after high pressure spray washing.

[0061] Due to both the shape of the polygonal cross-section of the warp yarns 130 of the fabric 1 of the present application and the polyketone (PK) contained therein, the warp yarns 130 are also prevented from breaking when they undergo high pressure spray. That is, the shape of the polygonal cross-section of the warp yarns 130 of the fabric 1 improves the resistance to high pressure spray, and the polyketone (PK) contained therein makes the fabric 1 have excellent anti-sticking property (easy to keep clean) and thus easy to be washed clean. The polyketone (PK) contained in the warp yarns 130 of the fabric 1 reduces the friction (makes it anti-sticking) and thus improves the wear resistance, and further relieves the impact force when high pressure spray (reduces the resistance to water flow).

[0062] Compared to a conventional yarn (e.g. rectangular or circular cross-section), the polygonal cross-section of the warp yarns 130 of the fabric 1 of the present application reduces the weight of the yarn by 15% because it saves material.

[0063] According to ISO14040 and ISO14044 standards, compared with traditional polymer materials, the polyketone (PK) material of the present invention significantly reduces greenhouse gas (CO2) emissions and is easy to recycle (because it does not contain additives that make it non-recyclable).

[0064] In one embodiment, the cross-section of the weft yarn 140 is circular to ensure the strength of the weft yarn 140 and thus ensure high stability in the second direction D2.

[0065] In one embodiment, the fabric 1 is a papermaking fabric or a filter fabric. Due to the polygonal cross-section of the warp yarn 130 of the present invention, the overall fabric 1 has uniform air permeability and a smooth surface, thereby being able to dry efficiently.

[0066] like Figure 5 As shown, in one embodiment, the fabric 1 preferably has a double warp weave structure. The warp yarns 130 of the fabric 1 with a double warp weave structure include a first upper warp yarn U1 and a first lower warp yarn L1, as well as a second upper warp yarn U2 and a second lower warp yarn L2. The first upper warp yarn U1 and the first lower warp yarn L1 are substantially arranged one above the other. The warp yarns U1, U2, L1, and L2 have a polygonal cross-section as described herein.

[0067] like Figures 5-9 As shown, the first upper warp yarn U1 and the first lower warp yarn L1 and the weft yarn 140 are combined with each other according to a first predetermined pattern; the second upper warp yarn U2 and the second lower warp yarn L2 and the weft yarn 140 are combined with each other according to a second predetermined pattern;

[0068] The weft yarns 140 include at least a first weft yarn W1, a second weft yarn W2, a third weft yarn W3, and a fourth weft yarn W4 that are adjacent to each other;

[0069] The first upper warp yarn U1 and the weft yarn 140 are combined with each other according to a first predetermined pattern so that the first upper warp yarn U1 repeatedly passes over the third weft yarn W3 and the fourth weft yarn W4 and under the first weft yarn W1 and the second weft yarn W2;

[0070] The second upper warp yarn U2, which is adjacent to the first upper warp yarn U1, repeatedly passes under the third weft yarn W3 and the fourth weft yarn W4 and over the first weft yarn W1 and the second weft yarn W2;

[0071] The first lower warp yarn L1 and the weft yarn 140 are combined with each other according to a second predetermined pattern so that the first lower warp yarn L1 repeatedly passes over the fourth weft yarn W4 and under the first weft yarn W1, the second weft yarn W2, and the third weft yarn W3;

[0072] The second lower warp yarn L2 next to the first lower warp yarn L1 repeatedly passes over the second weft yarn W2 and under the first weft yarn W1, the third weft yarn W3, and the fourth weft yarn W4.

[0073] The double warp structure of the present application makes the structure of the fabric 1 stable and durable.

[0074] In one embodiment, a seam is formed between the warp yarns 130 at the two ends of the first direction D1 of the fabric 1 to join the two ends of the first direction D1 of the fabric 1 together (to form a fabric loop).

[0075] In one embodiment, the fabric 1 is a drying fabric or a forming fabric of a fiber web machine.

[0076] In one embodiment, the first surface 110 of the fabric 1 is in contact with paper, paperboard or tissue produced by the fiber web machine, and the second surface 120 is in contact with the paper machine, the paperboard machine or the tissue machine.

[0077] In one embodiment, the fabric 1 is an industrial fabric used for pulp making, paper making or sewage treatment.

Claims

1. A fabric (1) having a first direction (D1) and a second direction (D2) and two opposite first surfaces (110) and second surfaces (120) in a thickness direction of the fabric (1), the fabric (1) extending from a first edge (E1) to a second edge (E2) in the second direction (D2), characterized in that The warp yarns (130) at least partially forming the first surface (110) have a polygonal cross section having: a width and a height, the width being greater than the height, and four corners (11, 12, 13, 14), wherein: A first pair of opposite corners (11, 13) has an angle greater than 90 degrees, and a second pair of opposite corners (12, 14) has an angle less than 90 degrees, wherein four sides (15) connecting the four corners (11, 12, 13, 14) are concave toward the center (C) of the polygonal cross section, and two sides of the warp yarn (130) adjacent to the first pair of opposite corners (11, 13) form two opposite first surfaces (110) and second surfaces (120) of the fabric (1).

2. The fabric (1) according to claim 1, characterized in that The fabric is a double warp woven structure, wherein the warp yarns (130) include a first upper warp yarn (U1) and a first lower warp yarn (L1), as well as a second upper warp yarn (U2) and a second lower warp yarn (L2), wherein the first upper warp yarn (U1) and the first lower warp yarn (L1) are substantially one above the other.

3. The fabric (1) according to claim 1, characterized in that At least some of the weft yarns (140) forming the fabric are circular in cross-section and are composed of bio-based polyethylene terephthalate (PET) or recycled polyethylene terephthalate (PET).

4. The fabric (1) according to claim 1, characterized in that At least one of the four corners (11, 12, 13, 14) is rounded, and the warp yarns forming the first surface (110) and / or the second surface (120) are made of a material with low surface tension.

5. The fabric (1) according to claim 4, characterized in that The four corners (11, 12, 13, 14) are all rounded, and the warp yarns forming the first surface (110) and / or the second surface (120) are made of polyketone or modified PET.

6. The fabric (1) according to claim 2, characterized in that A seam is formed between the warp yarns (130) at both ends of the fabric (1) in the first direction (D1) to connect the two ends of the fabric (1) in the first direction (D1) together.

7. The fabric (1) according to claim 1, characterized in that The warp yarns (130) at least partially forming the second surface (120) have the polygonal cross-section.

8. The fabric (1) according to claim 5, characterized in that 70% of the total matrix polymer mass of the warp yarns (130) of the first surface (110) is composed of thermoplastic aliphatic polyketone or modified PET.

9. The fabric (1) according to claim 2 or 6, characterized in that The first upper warp yarn (U1), the first lower warp yarn (L1), and the weft yarn (140) are self-bonded to each other according to a first predetermined pattern; the second upper warp yarn (U2), the second lower warp yarn (L2), and the weft yarn (140) are self-bonded to each other according to a second predetermined pattern; The weft yarn (140) includes at least a first weft yarn (W1), a second weft yarn (W2), a third weft yarn (W3), and a fourth weft yarn (W4) that are adjacent to each other; The first upper warp yarn (U1) and the weft yarn (140) are combined with each other according to the first predetermined pattern so that the first upper warp yarn (U1) repeatedly passes over the third weft yarn (W3) and the fourth weft yarn (W4) and under the first weft yarn (W1) and the second weft yarn (W2); The second upper warp yarn (U2) adjacent to the first upper warp yarn (U1) repeatedly passes under the third weft yarn (W3) and the fourth weft yarn (W4) and over the first weft yarn (W1) and the second weft yarn (W2); The first lower warp yarn (L1) and the weft yarn (140) are combined with each other according to the second predetermined pattern so that the first lower warp yarn (L1) repeatedly passes over the fourth weft yarn (W4) and under the first weft yarn (W1), the second weft yarn (W2), and the third weft yarn (W3); The second lower warp yarn (L2) immediately adjacent to the first lower warp yarn (L1) repeatedly passes over the second weft yarn (W2) and under the first weft yarn (W1), the third weft yarn (W3) and the fourth weft yarn (W4).

10. The fabric (1) according to any one of claims 1 to 8, characterized in that The fabric is an industrial fabric used for pulping, papermaking or sewage treatment.

Images