Woven Fabric With Balanced Diagonal Twill Lines
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Solution Overview
Problem
Existing woven fabrics with strong diagonal twill lines are conducive to sheet building but difficult to guide on paper machines, lacking control over the pattern imparted to the fiber web.
Innovation Solution
A woven fabric with a balanced sum of CD vector components in first and second diagonal twill lines, where weft yarns in the middle of flotations have smaller cross sections, allowing for easier guidance and controlled pattern formation, achieved by interweaving warp and weft yarns with specific vector components and varying yarn diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If strong diagonal twill lines are used in the woven fabric, then sheet building is improved, but the fabric becomes difficult to guide on paper machines
Solution Approach 1:
The patent applies asymmetry by creating twill lines with different orientations - first diagonal twill lines extending in one diagonal direction and second diagonal twill lines extending in the opposite diagonal direction. This asymmetric arrangement with balanced CD vector components creates a fabric structure that maintains sheet building capability while improving guidability on paper machines.
Solution Approach 2:
The patent changes the parameter of CD vector component balance by ensuring that the sum of all CD vector components of first diagonal twill lines is substantially balanced with the sum of all CD vector components of second diagonal twill lines. This parameter adjustment resolves the contradiction between strong diagonal patterns for sheet building and balanced guidability on paper machines.
2Shape
If weft yarns with smaller cross sections are used in the middle of flotations, then knuckle height is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by varying the cross section of weft yarns based on their position - weft yarns in the middle of flotations have smaller cross sections while other weft yarns have larger cross sections. This localized differentiation reduces knuckle height at critical locations without requiring all yarns to be uniformly small, thereby managing manufacturing complexity.
Data Source
AI summary
A woven fabric for use in a machine to produce a fiber web, such as a tissue fiber web, has a paper side formed by interwoven warp yarns and weft yarns. The paper side has a plurality of twill lines formed by neighboring flotations of warp yarns. The twill lines have an MD vector component in a machine direction and a CD vector component in a cross machine direction. At least some twill lines are diagonal, with a CD vector component being unequal to zero. The diagonal twill lines include first diagonal twill lines with CD vector components that have an opposite sign to the CD vector components of second diagonal twill lines. A sum of all CD vector components of the first diagonal twill lines is substantially balanced with a sum of all CD vector components of the second diagonal twill lines.