Industrial Fabric Binding Warp Structure for Surface Texture
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Solution Overview
Problem
The increase in the number of pairs of upper and lower surface side warps serving as binding yarns in industrial fabrics for paper machines reduces the surface properties of the upper surface side fabric, compromising its performance.
Innovation Solution
An industrial fabric design where upper and lower surface side fabrics are bound by first, second, and third binding warps, with upper surface side warps and third binding warps forming pairs that complement each other, and upper surface side collapsing yarns passing below wefts to maintain surface texture integrity, reducing the number of binding yarns and maintaining surface properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the number of pairs of upper surface side warps serving as binding yarns and lower surface side warps serving as binding yarns is increased to improve binding strength, then binding strength is improved, but surface properties of the upper surface side fabric decrease
Solution Approach 1:
The binding function is segmented into two distinct components: (1) binding warps that extend through both upper and lower surface side fabrics to provide binding strength, and (2) upper surface side warps that are interwoven only with upper surface side wefts to maintain surface properties. This segmentation allows each component to optimize its specific function without compromising the other.
Solution Approach 2:
The binding function is extracted from the upper surface side warps and assigned to dedicated binding warps. By taking out the binding function from the surface-side warps, the upper surface side warps are freed to focus solely on maintaining surface properties, while the binding warps assume the responsibility of providing binding strength through their extension through both fabrics.
2Strength
If the number of binding yarns is increased to ensure binding strength, then binding strength is improved, but air permeability and surface texture integrity deteriorate
Solution Approach 1:
Different regions of the fabric have different qualities: binding warps provide binding strength where needed at the interfaces between fabrics, while upper surface side warps maintain surface texture and air permeability in the upper fabric region. This local differentiation of function allows the fabric to simultaneously achieve binding strength and preserve surface properties.
Solution Approach 2:
The binding warps extend in the vertical dimension through both the upper and lower surface side fabrics, providing binding strength from a three-dimensional perspective. This vertical extension allows binding strength to be achieved without increasing the number of warps in the horizontal plane, thereby preserving surface properties and air permeability.
Data Source
AI summary
Binding warps have first and second binding warps arranged vertically in a pair and a third binding warp forming knuckles passing above upper surface side wefts. Upper surface side warps include an upper surface side collapsing yarn forming a pair with the third binding warp. The upper surface side collapsing yarn passes below the wefts and collapses a part of the upper surface side obverse surface texture at a position where the third binding warp forms knuckles on the wefts. The pair formed by the first and second binding warps complement each other while the pair formed by the third binding warp and the upper surface side collapsing yarn complement each other in a weave repeat.