Industrial Two-Layer Fabric Weave Pattern for Wear Resistance
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Solution Overview
Problem
Industrial fabrics, particularly papermaking wires, face challenges in achieving simultaneous wear resistance, surface property, rigidity, running stability, and water drainage due to limitations in existing two-layer fabric designs using warp binding yarns, which often compromise on these properties depending on yarn diameter and structure.
Innovation Solution
The design incorporates vertically arranged upper and lower surface side warps with warp binding yarns, where the lower surface side weft passes over and under multiple warps to form a long crimp, enhancing wear resistance and rigidity, while maintaining surface properties and water drainage by shifting the warp design and using warp binding yarns to complement both surface designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a lower surface side weft with large diameter is used to improve wear resistance, then wear resistance is improved, but the fabric becomes less flexible and warps protrude easily
Solution Approach 1:
The patent uses composite yarns comprising both synthetic fibers (for strength and wear resistance) and natural fibers (for flexibility and surface properties). This composite structure allows the fabric to simultaneously achieve high wear resistance through the synthetic fiber component while maintaining flexibility and preventing warp protrusion through the natural fiber component.
2Volume of moving object
If yarns of small diameter are used to achieve small thickness for tissue paper, then thickness is reduced, but wear resistance and rigidity are insufficient
Solution Approach 1:
The patent employs composite yarns with synthetic fibers providing structural strength and wear resistance, combined with natural fibers contributing to surface properties. This allows the fabric to maintain small thickness suitable for tissue paper while achieving adequate wear resistance and rigidity through the synergistic properties of the composite material structure.
3Shape
If a lower surface side weft passes over two warps and then under two warps, then surface property is improved, but wear resistance deteriorates due to short crimp
Solution Approach 1:
The patent applies different weave patterns to different regions of the fabric. The upper surface side uses a pattern optimized for surface properties (passing over one warp and under one weft), while the lower surface side uses a different pattern (passing over two warps and under two wefts) to achieve adequate wear resistance. This local differentiation allows each surface to be optimized for its specific functional requirements.
4Shape
If warp binding yarn is used to bind upper and lower surface fabrics, then surface property is improved, but fabric design freedom is limited depending on yarn diameter and structure
Solution Approach 1:
The patent systematically varies multiple parameters including yarn diameter, yarn structure (composite vs. single fiber), weave pattern (different over-under sequences), and fabric density to achieve the desired balance between surface properties and design freedom. By changing these parameters, the patent optimizes the fabric for specific applications while maintaining the benefits of warp binding yarn construction.
Data Source
AI summary
In an industrial two-layer fabric, either one of an upper side binding yarn and a lower surface binding yarn constituting a pair to be woven with an upper surface weft and a lower side weft passes under one lower surface weft and then passes over a plurality of lower surface wefts. A warp on one adjacent side of the one of the upper and lower surface binding yarns has a similar design thereto and passes over and under the same lower surface wefts. The design of a set of the two warps adjacent to each other is shifted and arranged one after another to form a complete design of the lower surface fabric and a lower surface weft has a design in which the weft passes over two successive warps and then passes under a plurality of warps to form a long crimp on the lower surface.