Two-Layer Industrial Fabric Weave Pattern for Stability
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Solution Overview
Problem
Conventional papermaking wires face challenges such as wire marks on paper, reduced rigidity, and instability due to twilled weave patterns, which affect surface properties and running stability, especially under high-speed papermaking conditions.
Innovation Solution
A two-layer industrial fabric design using warp binding yarns with a specific weaving pattern where upper side warps pass over and under multiple wefts to create a weft long crimp, combined with broken twill weave to prevent diagonal marks and enhance rigidity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If twilled weave is adopted to improve surface property and binding strength, then the fabric has excellent surface property and binding strength, but marks in diagonal direction stand out causing wire marks on paper and the wire is stretched inevitably resulting in deterioration in running stability
Solution Approach 1:
The fabric structure is segmented into eight pairs of warps (upper side and lower side) with specific binding yarn arrangements. The binding yarns are distributed at intervals rather than continuous, segmenting the twill pattern to prevent continuous diagonal lines that cause stretching and instability.
Solution Approach 2:
The fabric employs asymmetric weave patterns where upper side warps and lower side warps have different configurations. The binding yarns are arranged with specific asymmetry in their passing sequences (over and under patterns) to balance surface properties while preventing diagonal mark formation.
2Shape
If twilled weave is adopted to improve surface property, then the fabric has excellent surface property, but marks in diagonal direction stand out causing wire marks on paper
Solution Approach 1:
The continuous twill pattern is segmented by strategically placing binding yarns at specific intervals among the eight pairs of warps. This segmentation breaks the continuous diagonal lines that cause visible marks on paper while preserving the surface design properties.
Solution Approach 2:
Different regions of the fabric have different weave characteristics. The binding yarns create localized areas with enhanced binding strength and surface design, while other regions maintain openness for drainage. This local variation prevents uniform diagonal marking across the entire fabric surface.
3Strength
If continuous twill lines are formed to improve binding strength, then the fabric has good binding strength, but the wire is stretched inevitably causing deformation and meandering
Solution Approach 1:
The binding function is achieved through segmented binding yarns distributed at specific intervals rather than continuous twill lines. This segmentation allows the fabric to maintain binding strength at critical points while preventing continuous stretching that would cause deformation and meandering.
Solution Approach 2:
The binding yarns are arranged in periodic patterns with specific intervals between them. This periodic arrangement provides regular binding points that maintain dimensional stability while allowing the fabric to flex and conform without continuous stretching, preventing meandering during operation.
Data Source
AI summary
An industrial two-layer fabric having eight upper side warps and eight lower warps are stacked vertically forming upper and lower layers which are bound by a warp binding yarn of these warps. In a repeating unit of the upper layer, one of the warps has repetition of a design in which it passes over one upper side weft, passes under four successive upper side wefts, passes over one upper side weft, and passes under two upper side wefts, and an upper side weft has a design in which it passes over three upper side warps and then passes under one upper side warp to form, on the upper side, a weft long crimp corresponding to three warps, whereby forming an industrial fabric excellent in running stability, surface property and wear resistance.