Multi-layer fabric paired binder yarns contour patterns
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Solution Overview
Problem
Multi-layer forming fabrics in papermaking face issues with relative slippage between layers, leading to fabric breakdown and surface marking, due to relative instability and inadequate binding yarns disrupting the forming layer structure.
Innovation Solution
A multi-layer fabric design featuring plural pairs of binder yarns with different contour patterns, both within and between pairs, to enhance stability and prevent slippage, while maintaining a monoplane surface for reduced marking and improved paper smoothness, using a combination of machine-direction and cross-machine direction yarns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multi-layer fabric is used to improve stability and prevent slippage, then fabric stability is improved, but binder yarns may disrupt the forming layer structure causing surface marking
Solution Approach 1:
The binder yarns are designed with specific local characteristics: they are positioned at the edges of the forming layer rather than penetrating through the center, and they have a smaller denier (5-10) compared to the forming layer yarns (20-50). This local differentiation allows the binder yarns to provide stability without disrupting the forming layer structure and causing surface marking.
Solution Approach 2:
The binder yarns act as an intermediary element between the forming layer and the wear layer, holding them together without directly disrupting the forming layer. By using yarns with smaller diameter and specific contour patterns, they mediate the connection between layers while minimizing their impact on the paper formation process.
2Stability of the object's composition
If paired binder yarns with different contour patterns are used, then slippage between layers is prevented, but fabric complexity increases
Solution Approach 1:
The binding function is segmented into multiple pairs of binder yarns, each pair having different contour patterns (e.g., sinusoidal, triangular, rectangular). This segmentation allows each pair to contribute differently to preventing slippage, while the overall structure remains systematic and manufacturable through conventional weaving techniques.
Solution Approach 2:
Within each pair of binder yarns, the yarns have asymmetric or different contour patterns relative to each other and relative to the machine direction. This asymmetry prevents symmetric slippage modes and enhances overall layer stability without requiring complex non-repeating patterns.
3Strength
If conventional binder yarns are used, then layers are bound together, but relative slippage occurs leading to fabric breakdown
Solution Approach 1:
The binder yarns are designed with dynamic contour patterns (sinusoidal, triangular, rectangular) that allow them to flex and adapt during the papermaking process. These dynamic patterns enable the binder yarns to maintain binding strength while accommodating the mechanical stresses and movements in the paper machine, preventing fabric breakdown.
Solution Approach 2:
The fabric uses a composite structure with different yarn types and materials: the forming layer uses yarns of 20-50 denier, while the binder yarns use smaller denier (5-10) yarns. This composite approach allows each component to be optimized for its specific function, with the binder yarns providing reliable binding without compromising the forming layer's integrity.
Data Source
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AI summary
A multi-layer fabric which may be utilized in a papermaking process. The fabric layers are bound together by plural pairs of weft binder yarns. Each binder yarn within a pair weaves a different contour pattern and combines with the other binder yarn in that pair to form a plain weave pattern in the top layer. Each of the plural pairs is comprised of binding yarns that weave different contour patterns from the next pair.