Multi-layer Papermaking Fabric with Integrated Binding
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Solution Overview
Problem
Existing paper machine fabrics face challenges in achieving high fiber support, low marking tendency, mechanical stability, and stable layer connection, particularly in high-speed paper production, where traditional binding methods lead to wear and separation of fabric layers.
Innovation Solution
A multi-layer paper machine fabric is designed with an upper transverse thread system that connects and forms the upper fabric layer, using interwoven threads to create a stable and fine paper side while a coarser lower fabric ensures mechanical stability and open dewatering, eliminating the need for separate binding threads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If separate binding threads are used to connect fabric layers, then layer connection is achieved, but the fabric structure becomes more complex and binding threads wear and break quickly
Solution Approach 1:
The patent merges the binding function into the fabric structure itself by using transverse threads that serve dual purposes: forming the fabric pattern and binding layers together. This eliminates separate binding threads and simplifies the overall fabric structure while maintaining stable layer connection.
Solution Approach 2:
The transverse threads are designed to perform multiple functions simultaneously: they form the fabric weave pattern and also act as binding elements to connect the fabric layers. This multi-functionality reduces the number of separate components needed and simplifies the fabric construction.
2Manufacturing precision
If thin binding threads are used to connect layers, then fabric homogeneity is maintained, but binding threads wear and break quickly under abrasive conditions
Solution Approach 1:
The binding function is merged into the main fabric structure through transverse threads that are integral to the fabric weave. This eliminates the need for separate thin binding threads that would wear and break, while maintaining fabric homogeneity as the binding threads are indistinguishable from the fabric's own threads.
Solution Approach 2:
The fabric's own transverse threads serve the dual purpose of forming the fabric pattern and binding the layers together. The fabric binds itself without requiring separate binding threads, and the binding threads have the same durability characteristics as the rest of the fabric structure.
3Manufacturing precision
If plain weave is used on paper side, then fiber support and sheet formation are improved, but the weave has unfavorable conditions for stable layer connection
Solution Approach 1:
The patent merges the layer binding function into the plain weave structure by using the transverse threads of the plain weave to also bind the layers. This allows the plain weave to maintain its excellent sheet formation properties while simultaneously providing stable layer connection through the same transverse threads.
4Stability of the object's composition
If fabric layers are connected with separate binding threads, then layer connection is achieved, but running time is reduced due to thread breakage
Solution Approach 1:
The fabric uses its own transverse threads to bind the layers together, eliminating the need for separate binding threads. Since the binding threads are integral to the fabric structure and have the same durability characteristics as the rest of the fabric, the overall service life is extended without requiring separate binding components that would wear and break.
Solution Approach 2:
The binding function is merged into the fabric's own thread structure, eliminating separate binding threads that would have different wear characteristics. This integration ensures that the binding threads have the same durability as the rest of the fabric, extending the overall service life.
Data Source
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AI summary
The invention relates to a papermaking fabric which is designed as a multi-layer woven fabric having an upper fabric layer and a lower fabric layer. The upper fabric layer has a plurality of upper longitudinal threads which run solely in the upper fabric layer and a plurality of upper transverse threads which are interwoven with the upper longitudinal threads and each run at least primarily in the upper fabric layer. The lower fabric layer has a plurality of lower longitudinal threads which run solely in the lower fabric layer and a plurality of lower transverse threads which are interwoven with the lower longitudinal threads and run solely in the lower fabric layer. The upper fabric layer has a repeating upper weave pattern on the upper side thereof which is formed from nine upper longitudinal threads and three upper transverse threads. The three upper transverse threads of the upper weave pattern each have the following course in the upper weave pattern: under a upper longitudinal thread, over the next upper longitudinal thread, under the next upper longitudinal thread, over the next upper longitudinal thread, under the four next successive upper longitudinal threads and over the following upper longitudinal thread, wherein, in the upper weave pattern, the course of the respective upper transverse thread is arranged offset to the course of the adjacent upper transverse thread in the transverse direction by three upper longitudinal threads. At least some of the upper transverse threads in the woven fabric are designed as binding transverse threads which, in order to bind the upper fabric layer to the lower fabric layer, temporarily switch into the lower fabric layer during the course thereof under the four successive to longitudinal threads and there run under at least one lower longitudinal thread.