Industrial Two-Layer Fabric Weave Pattern for Wear Resistance
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Solution Overview
Problem
Current industrial fabrics, particularly papermaking fabrics, face challenges in achieving a balance of water drainage, fiber supporting properties, rigidity, and wear resistance, leading to issues such as short lifespan and uneven wear, which are exacerbated by the demands of high-speed papermaking processes.
Innovation Solution
An industrial two-layer fabric design featuring a specific weaving pattern where lower surface side wefts pass over and under multiple warps in a controlled sequence, and warps pass over and under multiple wefts, creating a stable and durable structure that prevents undesirable movement and wear, while maintaining excellent water drainage and surface properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the lower surface side weft passes over one warp and under one warp alternately (ribbed weave), then water drainage property is improved, but wear resistance deteriorates due to short crimp length
Solution Approach 1:
The patent changes the weaving parameters by increasing the number of consecutive warps that the weft passes over (from 1 to 3 or more), thereby lengthening the crimp while maintaining the ribbed weave structure's water drainage capability
Solution Approach 2:
The patent uses a two-layer fabric structure combining different weave patterns in the upper and lower layers, with the lower layer optimized for wear resistance through extended crimp design while the upper layer maintains fiber supporting properties
2Reliability
If the lower surface side weft forms a long crimp to improve wear resistance, then wear resistant volume increases, but rigidity deteriorates due to reduced weaving positions
Solution Approach 1:
The patent optimizes the crimp length parameter to an intermediate value (passing over 3 or more warps) that balances wear resistance and rigidity, avoiding both short and excessively long crimps
Solution Approach 2:
The patent applies different weave densities and crimp lengths to different regions of the fabric, with localized reinforcement in high-wear areas while maintaining overall fabric rigidity through strategic placement of weaving positions
3Reliability
If the lower surface side weft passes under five successive warps to achieve adequate crimp length, then wear resistance improves, but uneven wear occurs leading to premature fabric failure
Solution Approach 1:
The patent introduces asymmetric variation in the weaving pattern where the number of consecutive warps passed over by the weft varies (e.g., 3, 4, or 5) in a controlled sequence, preventing stress concentration at any single location and distributing wear more evenly across the fabric surface
Data Source
AI summary
An industrial two-layer fabric having a lower surface structure excellent in water drainage property, fiber supporting property, rigidity and wear resistance, obtained by binding an upper layer fabric and a lower layer fabric, wherein each of lower surface side wefts has a design in which it passes over one lower surface side warp, passes under one lower surface side warp, passes over one lower surface side warp and then passes under five successive lower surface side warps, while lower surface side warps each has a design in which it passes over four successive lower surface side wefts, passes under one lower surface side weft, passes over three successive lower surface side wefts, passes under one lower surface side weft, passes over two successive lower surface side wefts, passes under one lower surface side weft, passes over three successive lower surface side wefts and then passes under one lower surface side weft.