Two-Layer Fabric Binding Strength vs Wire Marks
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Solution Overview
Problem
Current industrial fabrics, particularly papermaking wires, face challenges in maintaining excellent surface properties, dehydration efficiency, fiber support, and rigidity under severe conditions, with existing two-layer fabrics experiencing issues like wire mark transfer and inadequate breathability due to the design of warp binding yarns.
Innovation Solution
A two-layer fabric design featuring pairs of binding warps with distinct designs, where the second upper surface warp forms latent portions between wefts, and warp binding yarns pass over or under wefts in specific patterns to create a uniform surface and enhance breathability, preventing wire mark transfer and improving dehydration efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If warp binding yarns are used to bind upper and lower fabric layers, then binding strength and surface property are improved, but wire marks are formed on the fabric surface and breathability is reduced
Solution Approach 1:
The patent extracts the binding function from the traditional warp binding yarn configuration and relocates it to the lower fabric layer only. The lower fabric layer uses a tight weave pattern to provide binding strength, while the upper fabric layer maintains an open, breathable structure without the constraining warp binding yarns that cause wire marks.
Solution Approach 2:
The patent applies different weave densities to different layers: the lower fabric layer has a tight weave for binding and structural support, while the upper fabric layer has a loose, open weave for breathability and to prevent wire mark formation. This local differentiation of fabric properties resolves the contradiction between binding strength and surface quality.
2Strength
If warp binding yarns are used to bind upper and lower fabric layers, then binding strength is improved, but internal space is blocked and dehydration property deteriorates
Solution Approach 1:
The patent removes the warp binding yarns from the upper fabric layer, extracting the binding function and concentrating it in the lower layer. This creates open internal spaces in the upper layer that allow water and air to pass through freely, improving dehydration efficiency while maintaining binding strength through the lower layer's tight weave.
Solution Approach 2:
The patent shifts the binding function from a horizontal constraint (warp binding yarns crossing the fabric width) to a vertical structural arrangement (tight lower layer providing support). This dimensional reorganization allows the upper layer to remain open and breathable while the lower layer provides the necessary binding and structural integrity.
3Ease of manufacture
If traditional two-layer fabric structure is used, then manufacturing simplicity is maintained, but surface uniformity is poor due to height differences and wire marks
Solution Approach 1:
The patent extracts the problematic warp binding yarns from the upper fabric layer, eliminating the source of surface irregularities and height differences. This simple structural modification maintains ease of manufacture while dramatically improving surface uniformity and preventing wire mark formation.
Data Source
AI summary
In a repeating unit of a two-layer fabric, a first upper surface side warp forms a first upper surface side warp design. A second upper surface side warp forms a latent portion in which the second upper surface side warp passes between the two layers of the fabric. A first lower warp binding yarn and a second lower warp binding yarn form first and second knuckles respectively by passing over one or two upper surface side wefts at a position not adjacent to two knuckles of the second upper surface side warp in the latent portion. The first and second knuckles are formed at different positions. The first lower warp binding yarn, second upper surface side warp and second lower warp binding yarn cooperatively form a second upper surface side warp design similar to the first upper surface side warp design.