Two-Layer Fabric Binding Yarn Alignment for Dehydration Marks
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Solution Overview
Problem
Conventional two-layer fabrics used in papermaking suffer from misalignment of binding yarns, leading to dehydration marks, surface roughness, and inadequate water drainability, which compromises their rigidity, wear resistance, and fiber supporting properties.
Innovation Solution
The industrial two-layer fabric design places a binding yarn between two adjacent upper side warps of a first warp set, ensuring that the binding yarn does not misalign and forms a stable surface design, with the warp binding yarn positioned between the upper side warps to maintain dehydration routes and prevent wire marks, using a combination of upper and lower side wefts to enhance rigidity and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a binding yarn is used to weave upper and lower side layers in conventional two-layer fabrics, then the fabric achieves binding strength and surface design, but the binding yarn misaligns at interwoven positions causing dehydration marks and surface roughness
Solution Approach 1:
The fabric is divided into first and second warp sets with distinct functions. The first warp set contains binding yarns that bind upper and lower side layers, while the second warp set forms the surface design. This segmentation allows each set to perform its specific function without interference, preventing misalignment of binding yarns at interwoven positions.
Solution Approach 2:
The binding function is extracted from the surface-forming warps and assigned to a dedicated first warp set. The binding yarns in the first warp set are positioned between adjacent warps of the second warp set, separating the binding action from the surface design formation and eliminating misalignment issues.
2Productivity
If dehydration holes completely penetrate from upper to lower side layers, then water drainability is improved, but surface smoothness deteriorates due to wire marks and dehydration marks
Solution Approach 1:
Different regions of the fabric are designed with different properties. The first warp set with binding yarns provides localized binding strength without affecting surface smoothness. The second warp set is optimized for surface design and smoothness. This local differentiation allows the fabric to achieve both good water drainability and surface smoothness simultaneously.
3Strength
If fabric thickness is increased to improve rigidity and wear resistance, then mechanical strength is improved, but dehydration performance deteriorates due to blocked dehydration routes
Solution Approach 1:
The fabric structure is made asymmetric with the first warp set (binding yarns) and second warp set (surface warps) having different arrangements and functions. The binding yarns are positioned between adjacent warps of the second set, creating an asymmetric structure that provides rigidity and wear resistance while maintaining open dehydration routes on the surface.
Data Source
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AI summary
An industrial two-layer fabric includes an upper side fabric and a lower side fabric. The upper side warps of the upper side fabric comprise a first warp set and a second warp set.. The first warp set contains two upper side warps and a warp binding yarn that binds the upper side fabric and the lower side fabric. The two upper side warps are woven with the same upper side wefts The second warp set contains one upper side warp. At a position where the warp binding yarn passes above one of the upper side wefts, the warp binding yarn is placed between the two upper side warps of the first warp set and pass below the same one of the upper side wefts, whereby the two upper side warps and the warp binding yarn of the first warp set form the upper side warp design