Double-Layer Industrial Fabric for Paper Dryer Webs

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Solution Overview

Problem

Existing dryer webs in paper manufacturing are prone to defects such as uneven tension, stress concentration, and poor surface quality, leading to paper breakage and increased production costs due to inconsistent structural stability and high rejection rates.

Innovation Solution

A double-layer industrial fabric with monofilament warp and weft yarns, featuring a unique interlacing structure where upper and lower warp yarns do not intersect, providing identical texture on both sides and improved stability, and using pin or spiral loop seams to enhance flatness and reduce seam gaps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If single-layer fabric structure is used, then manufacturing simplicity is maintained, but structural stability and consistency deteriorate

Engineering Contradiction:

Improvefabric structureVSAvoidstructural stability

Core Design Contradiction:

Device complexityVSStability of the object's composition

Solution Approach 1:

The fabric is divided into multiple independent layers (first layer, second layer, third layer) with distinct warp and weft yarn systems in each layer. This segmentation allows each layer to contribute differently to the overall structural stability while maintaining manufacturing feasibility through systematic construction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite fabric structure combining multiple layers with different yarn arrangements and properties. The first layer has warp knitted structure, the second layer has woven structure, and the third layer has different weave patterns, creating a composite material system that achieves superior structural stability and consistency

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If upper and lower warp yarns intersect, then weaving density increases, but stress concentration and surface quality deteriorate

Engineering Contradiction:

Improveyarn densityVSAvoidstress concentration

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The invention resolves the intersection problem by arranging warp yarns in different spatial dimensions and layers. The first, second, and third layers are stacked vertically with warp yarns in each layer running parallel without intersecting with warp yarns in other layers, eliminating stress concentration while maintaining density through multi-layer construction

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

Different layers are designed with specific local characteristics: the first layer uses warp knitted structure for flexibility, the second layer uses woven structure for stability, and the third layer has specific weave patterns for surface quality. This local differentiation allows high yarn density without stress concentration

Inventive Principle:

Principle #3Local quality

3Ease of operation

If seam loops have inconsistent tension, then ease of installation is maintained, but paper quality and flatness deteriorate

Engineering Contradiction:

Improveinstallation easeVSAvoidpaper quality

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The invention controls the tension parameter of seam loops during installation to ensure consistency across all loops. By maintaining uniform tension parameters, the fabric achieves proper flatness and prevents paper defects while remaining installable through standard procedures

Inventive Principle:

Principle #35Parameter changes

4Productivity

If dryer web runs at high speed, then productivity increases, but paper breakage due to surface defects increases

Engineering Contradiction:

Improvemachine speedVSAvoidpaper continuity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The multi-layer fabric structure with carefully designed yarn arrangements and tensions serves as a cushioning system that prevents surface defects before they can cause paper breakage. The layered construction absorbs and distributes stresses that would otherwise manifest as surface defects at high speeds

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The composite fabric structure combines layers with different mechanical properties to create a material that maintains surface integrity at high speeds. The combination of warp knitted and woven layers provides both flexibility and stability, preventing the surface defects that lead to paper breakage during high-speed operation

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS10563327B2Industrial fabric

Publication Date: 2020.02.18 ZHUOYITE (ZHEJIANG) INTELLIGENT EQUIPMENT CO LTD

AI summary

An industrial fabric is a web woven from warp yarns made of monofilaments and weft yarns made of monofilaments. The warp yarns are of a double-layer structure. One of warp yarn basic units comprises four sub-units, two sub-units being located on an upper layer, the other two sub-units being located on a lower layer. The warp yarns on the upper layer and the warp yarns on the lower layer are vertically overlapped, wherein at least two sub-units comprise two parallel narrow warp yarns. Upper warp yarns and lower warp yarns are identical in texture structure, or one surface is identical to the other surface after rotating by 180 degrees. The industrial fabric is stable in structure and good in overall consistency. The upper surface is good in flatness, the surface is free from defects, and the quality and intensity of the fabric are improved.