Industrial Two-Layer Fabric Weave Design for Papermaking
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Solution Overview
Problem
Industrial fabrics, particularly papermaking wires, face challenges in maintaining excellent surface properties, fiber supporting capabilities, wear resistance, and preventing dehydration marks and fiber loss due to strong vacuum conditions.
Innovation Solution
A two-layer fabric design with vertically arranged upper and lower surface side warps and wefts, featuring a zigzag arrangement of lower surface side warps and warp binding yarns to enhance rigidity, wear resistance, and water drainage properties, preventing dehydration marks and fiber loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If dehydration holes are arranged over the whole surface to improve dehydration property, then dehydration efficiency is improved, but fiber loss and filler loss occur due to strong vacuum
Solution Approach 1:
The patent applies local quality by creating different surface designs on the upper and lower surfaces of the fabric. The lower surface side has a specific weave pattern (with warps passing over 6 wefts, under 1, over 2, under 1) that creates localized areas with different porosity and vacuum resistance, preventing uniform strong vacuum across the entire surface and reducing fiber/filler loss while maintaining dehydration efficiency
2Ease of manufacture
If a ribbed design with two parallel warps is used to simplify structure, then manufacturing is easier, but wear resistance deteriorates
Solution Approach 1:
The patent applies asymmetry by using different weave patterns on the upper and lower surfaces. The lower surface has a complex asymmetric pattern where warps pass over 6 wefts, under 1, over 2, under 1, creating an irregular surface that enhances wear resistance while still being manufacturable through systematic weaving
3Reliability
If warp binding yarns are used to improve surface property and binding strength, then surface quality and binding strength are improved, but the fabric structure becomes more complex
Solution Approach 1:
The patent merges the functions of surface design and binding into a single integrated weave structure. The warp binding yarns are incorporated directly into the systematic weave pattern (over 6, under 1, over 2, under 1) rather than being added as separate elements, achieving both surface quality and binding strength without proportionally increasing complexity
Data Source
AI summary
In a lower surface side layer of an industrial two-layer fabric, warps are formed by sequentially arranging a repeating design unit, in which one warp passes over six successive lower surface side wefts, passes under one lower surface side weft, passes over two lower surface side wefts, and passes under one lower surface side weft while shifting the design by three lower surface side wefts. Two adjacent lower surface side warps simultaneously weave therein, from the lower surface side, one lower surface side weft, whereby the lower surface side weft passes over two lower surface side warps and then passes under eight lower surface side warps to form a weft long crimp corresponding to eight lower surface side warps on the lower surface side surface.