Abstract
Provided is an industrial two-layer fabric satisfying basic characteristics of a fabric. The industrial two-layer fabric pertaining to the present invention has at least a first structure and a second structure in the weave repeat thereof, the first structure being formed by a combination of two upper-surface-side warps and a single lower-surface-side warp, the second structure being formed by a single upper-surface-side warp and a single lower-surface-side warp, the first structure and the second structure being disposed adjacent to each other, the upper-surface-side warps in the first structure being formed by a warp binding yarn having the function of binding an upper-surface-side fabric and a lower-surface-side fabric, the combination of two upper-surface-side warps forming the first structure being disposed adjacent to each other and constituting a partial rib weave at the surface of the upper-surface-side fabric.
Claims
1. An industrial two-layer fabric comprising an upper-surface-side fabric formed from upper-surface-side warps and upper-surface-side wefts, lower-surface-side warps, and lower-surface-side wefts, wherein the industrial two-layer fabric has at least a first structure and a second structure in a weave repeat thereof, the first structure being formed by a combination of two upper-surface-side warps and a single lower-surface-side warp, the second structure being formed by a single upper-surface-side warp and a single lower-surface-side warp, the first structure and the second structure being disposed adjacent to each other, the upper-surface-side warps in the first structure being formed by a warp binding yarn having the function of binding an upper-surface-side fabric and a lower-surface-side fabric, the combination of two upper-surface-side warps forming the first structure being disposed adjacent to each other and constituting a partial rib weave at the surface of the upper-surface-side fabric, the diameter of the lower-surface-side warp being larger than the diameter of the upper-surface-side warp forming the first structure, and the upper-surface-side warp in the second structure being formed by a flat warp.
2. The industrial two-layer fabric according to claim 1, wherein the diameter of the lower-surface-side warp forming the first structure is 130% to 300% of the diameter of the upper-surface-side warp forming the first structure.
3. The industrial two-layer fabric according to claim 1, wherein the aspect ratio of the flat warp is 1.1 to 2.0 in the second structure.
4. The industrial two-layer fabric according to claim 2, wherein the aspect ratio of the flat warp is 1.1 to 2.0 in the second structure.
5. The industrial two-layer fabric according to claim 1, wherein the first structure and the second structure are formed being arranged alternately.
6. The industrial two-layer fabric according to claim 2, wherein the first structure and the second structure are formed being arranged alternately.
7. The industrial two-layer fabric according to claim 3, wherein the first structure and the second structure are formed being arranged alternately.
8. The industrial two-layer fabric according to claim 4, wherein the first structure and the second structure are formed being arranged alternately.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Embodiments will now be described, by way of example only, with reference to the accompanying drawings that are meant to be exemplary, not limiting, and wherein like elements are numbered alike in several figures, in which:
[0018] FIGS. 1A-1C are conceptual diagrams for explaining the operation and effect of a fabric having the knuckle shapes and heights of a warp and a weft that form the present invention. FIG. 1A is a conceptual diagram of a conventional warp and weft. FIGS. 1B and 1C are conceptual diagrams of the warp and the weft that form the present invention.
[0019] FIG. 2 is a design diagram showing a weave repeat according to the first embodiment of the present invention;
[0020] FIG. 3 is a partial side layout view showing a state of warps as viewed from the side according to the first embodiment of the present invention;
[0021] FIG. 4 is a design diagram showing a weave repeat according to the second embodiment of the present invention;
[0022] FIG. 5 is a partial side layout view showing a state of warps as viewed from the side according to the second embodiment of the present invention;
[0023] FIG. 6 is a design diagram showing a weave repeat according to the third embodiment of the present invention;
[0024] FIG. 7 is a partial side layout view showing a state of warps as viewed from the side according to the third embodiment of the present invention;
[0025] FIG. 8 is a design diagram showing a weave repeat according to the fourth embodiment of the present invention; and
[0026] FIG. 9 is a partial side layout view showing a state of warps as viewed from the side according to the fourth embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Hereinafter, embodiments of an industrial two-layer fabric according to the present invention will be described. The embodiments shown below are examples of the present invention and do not limit the present invention. The industrial two-layer fabric according to the present invention includes an upper-surface-side fabric formed from upper-surface-side warps and upper-surface-side wefts, lower-surface-side warps, and lower-surface-side wefts, and the industrial two-layer fabric has at least a first structure and a second structure in a weave repeat thereof, the first structure being formed by a combination of two upper-surface-side warps and a single lower-surface-side warp, the second structure being formed by a single upper-surface-side warp and a single lower-surface-side warp, the first structure and the second structure being disposed adjacent to each other, the upper-surface-side warps in the first structure being formed by a warp binding yarn having the function of binding an upper-surface-side fabric and a lower-surface-side fabric, the combination of two upper-surface-side warps forming the first structure being disposed adjacent to each other and constituting a partial rib weave at the surface of the upper-surface-side fabric, the diameter of the lower-surface-side warp being larger than the diameter of the upper-surface-side warp forming the first structure, and the upper-surface-side warp in the second structure being formed by a flat warp.
[0028] The yarn used in the present invention may be selected depending on the intended use. For example, in addition to monofilaments, multifilaments, spun yarn, processed yarn generally referred to as textured yarn, bulky yarn, stretch yarn, etc., on which crimping, bulk processing, or the like has been performed, or yarn into which these yarns are combined by, e.g., twisting can be used. Further, regarding the cross-sectional shape of yarn other than a flat warp, not only those of a circular shape but also a star-shaped, rectangular, or polygonal yarn or an elliptical yarn, a hollow yarn, or the like can be used. Also, the material of the yarn can be freely selected, and polyester, polyamide, polyphenylene sulfide, polyvinylidene fluoride, polypro, aramid, polyetheretherketone, polyethylene naphthalate, polytetrafluoroethylene, cotton, wool, metal, etc., can be used. Needless to say, a yarn may be used that is obtained by blending or including various substances in a copolymer or in these materials depending on the purpose. In general, for an industrial fabric, a polyester monofilament is preferably used that allows the upper-surface-side warps, the lower-surface-side warps, the lower warp binding yarns, and the upper-surface-side wefts to have rigidity and is excellent in dimensional stability. Further, for the lower-surface-side wefts, which are required to have rigidity and wear resistance, polyester monofilaments and polyamide monofilaments can be mixed-woven by, e.g., alternately arranging the polyester monofilaments and the polyamide monofilaments.
[0029] Further, in the present invention, the combination of two warps in the first structure is rib woven in cooperation by arranging the warps in parallel. FIGS. 1A-1C are conceptual diagrams for explaining the knuckle shape and height of a warp that forms the present invention. FIG. 1A is a conceptual diagram showing a conventional interwoven portion of a warp and a weft. Also, FIG. 1A is a conceptual diagram that shows a knuckle shape and a height using a warp and a weft having diameters in a fabric. Further, FIG. 1B is a diagram in which a combination of two upper-surface-side warps 1t and 2t in the first structure is arranged under an upper-surface-side weft 1′u. Also, FIG. 1C is a diagram in which a flat warp 3h in the second structure is arranged under the upper-surface-side weft 1′u. The warps used for the first structure in the present invention is characterized in that the upper-surface-side warp has a smaller diameter than the lower-surface-side warp. Therefore, as shown in FIGS. 1A-1C, the vertical lengths L2 and L3 of respective knuckle shapes formed by the upper-surface-side warps 1t and 2t and by the flat warp 3h are found to be smaller than the vertical length L1 of a knuckle shape formed by a yarn of a conventional diameter. Therefore, since the industrial two-layer fabric according to the present invention can form a flat knuckle shape on the upper surface structure side as compared with conventional industrial two-layer fabrics, a fabric having a reduced net thickness can be obtained. Further, since the knuckle shape of a weft woven into the combination of two warps or the flat warp becomes flattened, surface smoothness and fiber supportability can be improved. Further, since the mesh can be adjusted to be small without increasing the thickness, unprecedented dewatering characteristics can be provided. The present invention has a structure in which a weave structure is formed by two warps and is bound. Therefore, for a binding yarn, one of the two warps in a set has both a structure arrangement and a binding structure arrangement, and the other yarn forming the upper surface side allows the collapse of the weave structure at the binding part to be minimized.
[0030] Further, in the industrial two-layer fabric according to the present invention, the respective diameters of the upper-surface-side warps can be all set to be the same. Also, the respective diameters of the lower-surface-side warps may be all set to be the same. Further, the diameter of the lower-surface-side warps may be set to be 130 to 300% of the diameter of the upper-surface-side warps. With this configuration, in a rib weave formed by two relatively thin warps, the upper-surface-side fabric and the lower-surface-side fabric can be bound by one of the yarns. Therefore, regarding the diameter of the binding yarn going up and down inside the fabric, the binding yarn can be formed from a yarn that is thinner than a warp binding yarn in an industrial two-layer fabric using a conventional warp binding yarn. Therefore, the occurrence of partial dewatering unevenness can be minimized. Further, the diameter of the yarns forming a fabric is conventionally controlled to suppress the net thickness. However, in the case of an industrial two-layer fabric having different diameters at the top and bottom, the warp space on the upper surface side is larger than that on the lower surface side. Therefore, it is difficult to suppress dewatering and reduce net thickness at the same time. In the present invention, the dewatering speed can be adjusted while maintaining the net thickness by combining two thin warps and a flat warp.
[0031] Further, in the present invention, the respective diameters of the two upper-surface-side warps forming the first structure may be smaller than the diameter of the single upper-surface-side warp forming the second structure. By reducing the respective diameters of the two upper-surface-side warp forming the first structure, the force applied to the weft when forming a knuckle can be made to be about the same as that in the case of a single upper-surface-side warp, and the surface smoothness, fiber supportability, etc., can thus be improved. Further, since the diameter can be adjusted by selecting the diameter in accordance with the wire, the diameter and the wire can be appropriately selected. Also, in the present invention, an on-stack arrangement may be employed. By using the on-stack arrangement, high dewaterability can be obtained, and an excessive difference in opening between the upper surface side and the lower surface side can be suppressed by appropriately closing a vertical opening with two yarns since the surface structure is a rib weave. Therefore, the dewatering speed can be controlled.
[0032] Next, embodiments pertaining to the industrial two-layer fabric of the present invention will be described with reference to the drawings. FIGS. 2 to 9 are design diagrams and partial side layout views showing examples pertaining to the industrial two-layer fabric of the present invention. A design drawing shows the smallest repeating unit of a fabric structure, and this weave repeat is connected vertically and horizontally to form the structure of the entire fabric. In the design drawings, warps are indicated by Arabic numerals, for example, 1, 2, 3 . . . . Wefts are indicated by Arabic numerals with dashes, for example, 1′, 2′, 3′ . . . . A binding yarn is an upper-surface-side warp that constitutes the first structure. Further, a cross mark indicates that one upper-surface-side warp that constitutes the first structure is located above an upper-surface-side weft, a triangle mark indicates that an upper-surface-side warp is located under a lower-surface-side weft, and a circle mark indicates that a lower-surface-side warp is located under a lower-surface-side weft. An upper-surface-side warp and a lower-surface-side warp, and an upper-surface-side weft and a lower-surface-side weft with the same number are arranged vertically. In the design drawings, yarns are arranged so as to be exactly overlapped vertically, or a lower-surface-side warp is arranged at the midpoint between two upper-surface-side warps. This is for the convenience of the drawings, and the yarns may be arranged with a slight deviation in the actual fabric.
First Embodiment
[0033] FIG. 2 is a design diagram of the first embodiment pertaining to the industrial two-layer fabric of the present invention. FIG. 3 is a partial side layout view of the first embodiment pertaining to the industrial two-layer fabric of the present invention. The first structure according to the first embodiment is composed of a combination of two upper-surface-side warps and a single lower-surface-side warp. The upper-surface-side warps in the first structure are formed by warp binding yarns having a function of binding the upper-surface-side fabric and the lower-surface-side fabric. Further, the combination of two upper-surface-side warps forming the first structure are disposed adjacent to each other and forms a partial rib weave on the surface of the upper-surface-side fabric. Also, the second structure is composed of a single upper-surface-side warp and a single lower-surface-side warp. The upper-surface-side warp in the second structure is formed by a flat warp. Further, as shown in FIG. 2, the first structures 1, 3, and 5 and the second structures 2, 4, and 6 are formed being adjacent to one another and arranged alternately. Further, the diameter of the lower-surface-side warp is formed to be larger than the diameter of the upper-surface-side warp forming the first structure.
[0034] More specifically, as shown in FIGS. 2 and 3, a structure is formed where one upper-surface-side warp 1 in the first structure passes under a lower-surface-side weft 1′ and passes above upper-surface-side wefts 5′, 7′, 9′, 11′, 13′, 15′, 17′, 19′, and 21′. Then, a structure is formed where the other upper-surface-side warp 1 in the first structure passes above upper-surface-side wefts 1′, 3′, 5′, 7′, and 9′, passes under a lower-surface-side weft 13′, and further pass above upper-surface-side wefts 17′, 19′, 21′, and 23′. The lower-surface-side warp 1 passes under the lower-surface-side wefts 1′ and 13′. Therefore, as is clear from FIG. 3, the combination of two upper-surface-side warps 1 in the first structure forms a partial rib weave at the upper-surface-side wefts 5′, 7′, 9′, 17′, 19′, and 21′ on the surface of the upper-surface-side fabric. Next, an upper-surface-side warp 2 serving as a flat warp in the second structure passes above upper-surface-side wefts 2′, 4′, 6′, 8′, 10′, 12′, 14′, 16′, 18′, 20′, 22′, and 24′ so as to form a plain weave. A lower-surface-side warp 2 in the second structure passes under lower-surface-side wefts 3′ and 15′.
[0035] The first structure in the industrial two-layer fabric according to the first embodiment can form a pseudo-flat yarn by forming a rib weave by arranging two thin upper-surface-side warps in parallel on a part of the surface of the upper-surface-side fabric. Furthermore, by arranging the flat warp in the second structure adjacent to the first structure, suitable rigidity and elongation resistance can be ensured while suppressing the thickness, and a fabric excellent in wear resistance, suitable dewaterability, low water retention, and surface smoothness can be provided, in the same way as in a fabric in which only flat yarns are used to form a surface structure. Further, by employing the fabric structure according to the first embodiment, it is possible to reduce the mesh size while suppressing the thickness of the fabric. Therefore, the dewaterability and the water retention property can be adjusted by selecting the diameter of the yarn. Furthermore, since the knuckle shape of the weft can be flattened by two rib weave structures, the surface smoothness and the fiber supportability can be improved.
Second Embodiment
[0036] FIG. 4 is a design diagram of the first embodiment pertaining to the industrial two-layer fabric of the present invention. FIG. 5 is a partial side layout view of the second embodiment pertaining to the industrial two-layer fabric of the present invention. The first structure according to the second embodiment is composed of a combination of two upper-surface-side warps and a single lower-surface-side warp. The upper-surface-side warps in the first structure are formed by warp binding yarns having a function of binding the upper-surface-side fabric and the lower-surface-side fabric. Further, the combination of two upper-surface-side warps forming the first structure are disposed adjacent to each other and forms a partial rib weave on the surface of the upper-surface-side fabric. Also, the second structure is composed of a single upper-surface-side warp and a single lower-surface-side warp. The upper-surface-side warp in the second structure is formed by a flat warp. Further, as shown in FIG. 4, the first structures 1, 3, and 5 and the second structures 2, 4, and 6 are formed being adjacent to one another and arranged alternately. Further, the diameter of the lower-surface-side warp is formed to be larger than the diameter of the upper-surface-side warp forming the first structure.
[0037] More specifically, as shown in FIGS. 4 and 5, a structure is formed where one upper-surface-side warp 1 in the first structure passes above upper-surface-side wefts 1′, 3′, 5′, and 7′, passes under a lower-surface-side weft 10′, and further pass above upper-surface-side wefts 13′, 15′, and 17′. Further, a structure is formed where the other upper-surface-side warp 1 in the first structure passes under a lower-surface-side weft 1′ and passes above upper-surface-side wefts 3′, 5′, 7′, 9′, 11′, 13′, 15′, and 17′. The lower-surface-side warp 1 passes under the lower-surface-side wefts 1′ and 10′. Therefore, as is clear from FIG. 5, the combination of two upper-surface-side warps 1 in the first structure forms a partial rib weave at the upper-surface-side wefts 3′, 5′, 7′, 13′, 15′, and 17′ on the surface of the upper-surface-side fabric. Next, an upper-surface-side warp 2 serving as a flat warp in the second structure passes above upper-surface-side wefts 2′, 4′, 6′, 8′, 10′, 12′, 14′, 16′, and 18′ so as to form a plain weave. A lower-surface-side warp 2 in the second structure passes under lower-surface-side wefts 2′ and 11′.
[0038] The first structure in the industrial two-layer fabric according to the second embodiment can form a pseudo-flat yarn by forming a rib weave by arranging two thin upper-surface-side warps in parallel on a part of the surface of the upper-surface-side fabric. Furthermore, by arranging the flat warp in the second structure adjacent to the first structure, suitable rigidity and elongation resistance can be ensured while suppressing the thickness, and a fabric excellent in wear resistance, suitable dewaterability, and surface smoothness can be provided, in the same way as in a fabric in which only flat yarns are used to form a surface structure. Further, by employing the fabric structure according to the second embodiment, it is possible to reduce the mesh size while suppressing the thickness of the fabric. Therefore, the dewatering characteristics can be adjusted by selecting the diameter of the yarn. Furthermore, since the knuckle shape of the weft can be flattened by two rib weave structures, the surface smoothness and the fiber supportability can be improved.
Third Embodiment
[0039] FIG. 6 is a design diagram of the third embodiment pertaining to the industrial two-layer fabric of the present invention. FIG. 7 is a partial side layout view of the third embodiment pertaining to the industrial two-layer fabric of the present invention. The first structure according to the third embodiment is composed of a combination of two upper-surface-side warps and a single lower-surface-side warp. The upper-surface-side warps in the first structure are formed by warp binding yarns having a function of binding the upper-surface-side fabric and the lower-surface-side fabric. Further, the combination of two upper-surface-side warps forming the first structure are disposed adjacent to each other and forms a partial rib weave on the surface of the upper-surface-side fabric. Also, the second structure is composed of a single upper-surface-side warp and a single lower-surface-side warp. The upper-surface-side warp in the second structure is formed by a flat warp. Further, as shown in FIG. 6, the first structures 1, 3, and 5 and the second structures 2, 4, and 6 are formed being disposed adjacent to one another. Further, the diameter of the lower-surface-side warp is formed to be larger than the diameter of the upper-surface-side warp forming the first structure.
[0040] More specifically, as shown in FIGS. 6 and 7, a structure is formed where one upper-surface-side warp 1 in the first structure passes above upper-surface-side wefts 1′, 3′, 5′, and 7′, passes under a lower-surface-side weft 10′, and further pass above upper-surface-side wefts 13′, 15′, and 17′. The lower-surface-side warp 1 passes under the lower-surface-side wefts 1′ and 10′. A structure is formed where the other upper-surface-side warp 1 in the first structure passes under a lower-surface-side weft 1′ and passes above upper-surface-side wefts 5′, 7′, 9′, 11′, 13′, and 15′. Therefore, as is clear from FIG. 7, the combination of two upper-surface-side warps 1 in the first structure forms a partial rib weave at the upper-surface-side wefts 5′, 7′, 13′, and 15′ on the surface of the upper-surface-side fabric. Next, an upper-surface-side warp 2 serving as a flat warp in the second structure passes above upper-surface-side wefts 2′, 4′, 6′, 8′, 10′, 12′, 14′, 16′, and 18′ so as to form a plain weave. A lower-surface-side warp 2 in the second structure passes under lower-surface-side wefts 2′ and 11′.
[0041] The first structure in the industrial two-layer fabric according to the third embodiment can form a pseudo-flat yarn by forming a rib weave by arranging two thin upper-surface-side warps in parallel on a part of the surface of the upper-surface-side fabric. Furthermore, by arranging the flat warp in the second structure adjacent to the first structure, suitable rigidity and elongation resistance can be ensured while suppressing the thickness, and a fabric excellent in wear resistance, suitable dewaterability, and surface smoothness can be provided, in the same way as in a fabric in which only flat yarns are used to form a surface structure. Further, by employing the fabric structure according to the third embodiment, it is possible to reduce the mesh size while suppressing the thickness of the fabric. Therefore, the dewatering characteristics can be adjusted by selecting the diameter of the yarn. Furthermore, since the knuckle shape of the weft can be flattened by two rib weave structures, the surface smoothness and the fiber supportability can be improved.
Fourth Embodiment
[0042] FIG. 8 is a design diagram of the fourth embodiment pertaining to the industrial two-layer fabric of the present invention. FIG. 9 is a partial side layout view of the fourth embodiment pertaining to the industrial two-layer fabric of the present invention. The first structure according to the fourth embodiment is composed of a combination of two upper-surface-side warps and a single lower-surface-side warp. The upper-surface-side warps in the first structure are formed by warp binding yarns having a function of binding the upper-surface-side fabric and the lower-surface-side fabric. Further, the combination of two upper-surface-side warps forming the first structure are disposed adjacent to each other and forms a partial rib weave on the surface of the upper-surface-side fabric. Also, the second structure is composed of a single upper-surface-side warp and a single lower-surface-side warp. The upper-surface-side warp in the second structure is formed by a flat warp. Further, as shown in FIG. 8, the first structure 1 and the second structures 2 and 8 are formed being disposed adjacent to each other, and the first structure 5 and the second structures 4 and 6 are formed being disposed adjacent to each other. Further, the diameter of the lower-surface-side warp is formed to be larger than the diameter of the upper-surface-side warp forming the first structure.
[0043] More specifically, as shown in FIGS. 8 and 9, a structure is formed where one upper-surface-side warp 1 in the first structure passes above upper-surface-side wefts 1′, 3′, 5′, 7′, 9′, and 11′, passes under a lower-surface-side weft 13′, and further pass above upper-surface-side wefts 15′, and 17′. The lower-surface-side warp 1 passes under the lower-surface-side wefts 1′, 7′, and 13′. A structure is formed where the other upper-surface-side warp 1 in the first structure passes under a lower-surface-side weft 1′ and passes above upper-surface-side wefts 3′, 5′, 7′, 9′, 11′, 13′, 15′, and 17′. Therefore, as is clear from FIG. 9, the combination of two upper-surface-side warps 1 in the first structure forms a partial rib weave at the upper-surface-side wefts 3′, 5′, 7′, 9′, 11′, 15′, and 17′ on the surface of the upper-surface-side fabric. Next, an upper-surface-side warp 2 serving as a flat warp in the second structure passes above upper-surface-side wefts 2′, 4′, 6′, 8′, 10′, 12′, 14′, 16′, and 18′ so as to form a plain weave. A lower-surface-side warp 2 in the second structure passes under lower-surface-side wefts 2′, 8′, and 14′. Next, an upper-surface-side warp 3 serving as a flat warp in the second structure passes above upper-surface-side wefts 1′, 3′, 5′, 7′, 9′, 11′, 13′, 15′, and 17′ so as to form a plain weave. A lower-surface-side warp 3 in the second structure passes under lower-surface-side wefts 4′, 10′, and 16′. Next, an upper-surface-side warp 4 serving as a flat warp in the second structure passes above upper-surface-side wefts 2′, 4′, 6′, 8′, 10′, 12′, 14′, 16′, and 18′ so as to form a plain weave. A lower-surface-side warp 4 in the second structure passes under lower-surface-side wefts 5′, 11′, and 17′.
[0044] The first structure in an industrial two-layer fabric according to the fourth embodiment can form a pseudo-flat yarn by forming a rib weave by arranging two thin upper-surface-side warps in parallel on a part of the surface of the upper-surface-side fabric. Furthermore, by arranging the flat warp in the second structure adjacent to the first structure, suitable rigidity and elongation resistance can be ensured while suppressing the thickness, and a fabric excellent in wear resistance, suitable dewaterability, and surface smoothness can be provided, in the same way as in a fabric in which only flat yarns are used to form a surface structure. Further, by employing the fabric structure according to the fourth embodiment, it is possible to reduce the mesh size while suppressing the thickness of the fabric. Therefore, the dewatering characteristics can be adjusted by selecting the diameter of the yarn. Furthermore, since the knuckle shape of the weft can be flattened by two rib weave structures, the surface smoothness and the fiber supportability can be improved.
