Industrial Two-Layered Fabric Warp Binding for Curl Resistance
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Solution Overview
Problem
Industrial two-layered fabrics face issues with fiber sticking, low lateral and diagonal rigidity, surface density, and curling in the widthwise direction, which affect their permeability and sheet supportability during use.
Innovation Solution
The industrial two-layered fabric structure includes an upper and lower surface side fabric bound by binding yarns, with specific arrangements of warps and wefts, incorporating an auxiliary weft not exposed on the surface, and using a plain weaving structure with varying weft diameters to enhance surface density and prevent curling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the permeability of the industrial fabric is increased to improve fiber flow, then the fabric becomes more permeable, but fibers get stuck into the fabric with repeated use due to the sticking phenomenon
Solution Approach 1:
The patent applies different surface treatments to different regions of the wire intersections. Specifically, the knuckle surfaces are treated with fluorocarbon resin or silicone resin to reduce friction and prevent fiber sticking, while maintaining the overall porous structure for permeability. This local quality modification allows the fabric to maintain both high permeability and resistance to fiber sticking.
2Strength
If the diameter of the wefts is enlarged to improve lateral rigidity, then the lateral rigidity increases, but the surface density decreases
Solution Approach 1:
The patent modifies the physical and chemical parameters of the yarns, particularly the surface properties through coating treatments. By applying fluorocarbon or silicone resin coatings to the yarn surfaces, the fabric achieves improved lateral rigidity without needing to increase yarn diameter, thereby maintaining surface density. The coating layer provides additional structural support while the base yarn structure maintains the required density.
3Strength
If the fabric structure is changed to plain weaving to maximize intersection supporting force, then the intersection supporting force is strongest, but it is technically difficult to produce due to conversion issues between lateral density and surface density
Solution Approach 1:
The patent segments the fabric structure into distinct functional layers and components. The weaving structure is divided into specific patterns with controlled intersection points, and the surface treatment is applied selectively to knuckle regions. This segmentation allows the fabric to achieve strong intersection support where needed while maintaining manufacturability through standardized production processes for the non-treated regions.
4Stability of the object's composition
If thermal processing is applied to the fabric to set the shape, then the fabric shape is stabilized, but the woven yarns deform largely in the weft direction causing curling in the widthwise direction
Solution Approach 1:
The patent applies preliminary anti-action by treating the yarn surfaces with fluorocarbon or silicone resin coatings before thermal processing. This pre-treatment creates a protective layer that restricts yarn deformation during subsequent thermal processing, preventing the lateral contraction that would otherwise cause fabric curling. The coating acts as a constraint that counteracts the natural tendency of yarns to deform under thermal stress.
Data Source
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AI summary
An object of the present invention is to provide an industrial two-layered fabric is capable of restricting the sticking of fibers to improve a lateral rigidity, a diagonal rigidity, a sheet-supportability, while at the same time of maintain a good permeability and a good surface density on the upper surface side fabric so as to attain an excellent permeability and improve a rigidity to restrict a curl of the fabric in its widthwise direction. The present invention includes an industrial two-layered fabric comprising an upper surface side fabric comprising at least an upper surface side warp and at least an upper surface side weft, and a lower surface side fabric comprising at least a lower surface side warp and at least a lower surface side weft bound by at least an upper surface side biding yarn and at least a lower surface side biding yarn, said industrial two-layered fabric is constituted by at least first pair of warps in which the upper surface side warp and the lower surface side warp are vertically arranged, at least second pair of warps in which the upper surface side binding yarn functioning as a binding yarn and the lower surface side binding yarn functioning as a binding yarn are vertically arranged, and at least third pair of warps in which two upper surface side warps are adjacently arranged, said industrial two-layered fabric further comprises at least an auxiliary weft which is not exposed to a surface of the fabric without being woven with any warp.