Industrial fabric

Abstract

The object of the present invention is to provide an industrial fabric which exhibits an excellent surface smoothness and an excellent filtering ability, while at the same time reduces the generation of the hydration mark. The industrial fabric of the present invention including at least one upper surface side fabric constituted by upper surface side warps and upper surface side wefts and at least one lower surface side fabric constituted by lower surface side warps and lower surface side wefts, said at least one upper surface side fabric comprising at least one concave binding yarn for pulling down including a portion where a single knuckle is formed and at least one convex binding yarn for pushing up located to be adjacent to said at least one concave binding yarn for pulling down, and said at least one convex binding yarn for pushing up passes under at least one or more said upper surface side warps or said upper surface side wefts woven with a portion where a single knuckle of said at least one concave binding yarn for pulling down is formed and includes at least two or more knuckles which are formed by passing over another upper surface side warp or another upper surface side weft located adjacent to said upper surface side warps or said upper surface side wefts.

Claims

1. An industrial fabric comprising: an upper surface side fabric constituted by upper surface side warps and upper surface side wefts, wherein the upper surface side warps or the upper surface side wefts include a first upper surface side warp or weft, a second upper surface side warp or weft that is located adjacent to the first upper surface side warp or weft, and a third upper surface side warp or weft that is located adjacent to the second upper surface side warp or weft; and a lower surface side fabric constituted by lower surface side warps and lower surface side wefts; said upper surface side fabric comprising: a first binding yarn including a single knuckle in a repeating unit that is formed on an upper surface of the upper surface side fabric by passing over the second upper surface side warp or weft, passing under the first upper surface side warp or weft, and passing under the third upper surface side warp or weft, the first binding yarn passes under one of the lower surface side warps or the lower surface side warps or wefts; a second binding yarn located adjacent to said first binding yarn, the second binding yarn passes under said second upper surface side warp or weft, passes over the first upper surface side warp or weft, passes over the third upper surface side warp or weft and passes under one of the lower surface side warps or wefts.

2. The industrial two-layer fabric according to claim 1, wherein said first binding yarn forms the knuckle by passing over the second upper surface side weft.

Description

BRIEF EXPLANATION OF DRAWINGS

(1) FIG. 1 is a conceptual view showing an effect of the industrial fabric according to the present invention.

(2) FIG. 2 is a design view of the industrial fabric according to the first embodiment of the present invention.

(3) FIG. 3 is a longitudinal cross section view showing a structure of the yarns with respect to the industrial fabric according to the first embodiment of the present invention.

(4) FIG. 4 is a design view of the industrial fabric according to the second embodiment of the present invention.

(5) FIG. 5 is a longitudinal cross section view showing a structure of the yarns with respect to the industrial fabric according to the second embodiment of the present invention.

(6) FIG. 6 is a photograph showing drawing patterns with respect to the industrial fabric according to the first embodiment of the present invention.

(7) FIG. 7 is a photograph showing drawing patterns with respect to the conventional industrial fabric.

DETAILED DESCRIPTION OF THE INVENTION

(8) Now, the structure and the effect of the fabric of the present invention will be described below. Embodiments of the fabric of the present invention will be described thereafter with reference to the drawings. In this connection, since the embodiment is just an example of the present invention, the embodiment which is not described hereinafter can be encompassed by the scope of the present invention.

(9) The industrial fabric of this embodiment includes at least one upper surface side fabric constituted by upper surface side warps and upper surface side wefts and at least one lower surface side fabric constituted by lower surface side warps and lower surface side wefts, said at least one upper surface side fabric comprises at least one concave binding yarn for pulling down including a portion where a single knuckle is formed.

(10) In this connection, the concave binding yarn for pulling down is defined to be a binding yarn which binds the upper surface side fabric and the lower surface side fabric and includes a portion where a single knuckle is formed by passing over one or two upper surface side warps or upper surface side wefts. Such a concave binding yarn for pulling down possesses a force for drawing the upper surface side warps or the upper surface side wefts inside the fabric at the portion where the single knuckle is formed, since it is hooked by the lower surface side fabric. In addition, since the concave binding yarn for pulling down forms the single knuckle, an effect in which such a force for drawing the upper surface side warps or the upper surface side wefts inside the fabric is focused on the portion where the single knuckle is formed is caused.

(11) Still further, a single knuckle represents a situation in which the concave binding yarn for pulling down forms a knuckle at a single location in a complete structure of the fabric. In other words, the concave binding yarn for pulling down can be defined to be a binding yarn which includes a single knuckle in the complete structure of the fabric. In a case where the concave binding yarn for pulling down is the warp, it is woven with the upper surface side weft at only one location in the complete structure of the fabric. On the other hand, In a case where the concave binding yarn for pulling down is the weft, it is woven with the upper surface side warp at only one location in the complete structure of the fabric.

(12) In addition, in the industrial fabric of the present invention, at least one convex binding yarn for pushing up is located to be adjacent to the at least one concave binding yarn for pulling down, and the at least one convex binding yarn for pushing up includes at least two knuckles which are formed by passing under at least one or more said upper surface side warps or said upper surface side wefts woven with said knuckle forming portion of said at least one concave binding yarn for pulling down and passing over another upper surface side warp or another upper surface side weft located adjacent to said at least one or more said upper surface side warps or said upper surface side wefts.

(13) In this connection, the convex binding yarn for pushing up is defined to be a binding yarn which binds the upper surface side fabric and the lower surface side fabric and is located adjacent to the concave binding yarn for pulling down. In addition, the convex binding yarn for pushing up scoops the upper surface side warps of the upper surface side wefts between at least two single knuckles from below which at least two single knuckles are formed by the convex binding yarn for pushing up at the both sides in the direction in which the yarns of the portion where the single knuckle is formed extend. In this connection, the both sides in the direction in which the yarns extend is defined to be two upper surface side wefts arranged upper and lower, respectively, in the direction in which the warps of the fabric extend, in a case where the concave binding yarn for pulling down is the warp. On the other hand, the both sides in the direction in which the yarns extend is defined to be two upper surface side warps arranged right and left, respectively, in the direction in which the wefts of the fabric extend, in a case where the concave binding yarn for pulling down is the weft. In this connection, the convex binding yarn for pushing up may include knuckles in the complete structure of the fabric other than the above-described two knuckles. For instance, the industrial fabric including three or more knuckles is encompassed by the technical scope of the present invention.

(14) By adopting such a structure, the convex binding yarn for pushing up possesses a force for pushing up the upper surface side warps or the upper surface side wefts which is drawn inside the fabric of the convex binding yarn for pushing up toward the upper surface side, at the portion where the convex binding yarn for pushing up forms the single knuckle.

(15) FIG. 1 is a conceptual view showing the effect of the above-described concave binding yarn for pulling down and the convex binding yarn for pushing up.

(16) In FIG. 1, a yarn 1 is the concave binding yarn for pulling down. In addition, a yarn 2 is the convex binding yarn for pushing up. Three yarns 3,4,5 are arranged in the direction perpendicular to the direction in which the binding yarns extend. The concave binding yarn for pulling down and the convex binding yarn for pushing up in this embodiment may be either the weft or the warp. Here, in this embodiment, the concave binding yarn for pulling down and the convex binding yarn for pushing up are presumed to be the warps, in view of the convenience of the explanation of the embodiment.

(17) In the industrial fabric of this embodiment, the concave binding yarn 1 for pulling down functions to bind the upper surface side fabric and the lower surface side fabric. Accordingly, it is known that a force for drawing the upper surface side weft woven at the upper surface side is stronger than that caused by the yarns other than the binding yarns. In particular, in the present invention, the upper surface side weft 4 is adapted to be drawn inside by the stronger force by making a knuckle N1 of the concave binding yarn 1 for pulling down single. In other words, as shown in FIG. 1, in the concave binding yarn 1 for pulling down in the present invention, a force for strongly drawing the upper surface side weft 4 inside in the direction in which the fabric extends inside is generated by an arrow.

(18) The technical feature of the present invention lies in the fact that one convex binding yarn 2 for pushing up is arranged at a location adjacent to the concave binding yarn 1 for pulling down. Such a convex binding yarn 2 for pushing up is woven with the upper surface side wefts 3, 5 arranged on the both sides of the upper surface side weft 4 woven at the portion N1 forming the single knuckle of the concave binding yarn 1 for pulling down. In other words, the convex binding yarn 2 for pushing up forms the knuckles N2, N3 at two locations. The convex binding yarn 2 for pushing up is adapted to be woven with the upper surface side weft 4 so as to scoop the upper surface side weft 4 from below, between the knuckles N2, N3. Such being the case, a stress is generated so as to push up the upper surface side weft 4 in the direction indicated by an arrow, between the two knuckles N2, N3 of the convex binding yarn 2 for pushing up.

(19) Accordingly, an effect in which a force for drawing the upper surface side weft 4 generated at a location of the single knuckle N1 of the concave binding yarn 1 for pulling down is cancelled by a force for pushing up the upper surface side weft 4 generated between the two knuckles N2, N3 of the convex binding yarn 2 for pushing up adjacent to the concave binding yarn 1 for pulling down is caused.

(20) No particular limitation is imposed on a yarn to be used in the present invention and it can be selected freely depending on the properties which an industrial fabric is desired to have. Examples of it include, in addition to monofilaments, multifilaments, spun yarns, finished yarns subjected to crimping or bulking such as so-called textured yarn, bulky yarn and stretch yarn, and yarns obtained by intertwining them. As the cross-section of the yarn, not only circular form but also square or short form such as stellar form, or elliptical or hollow form can be used. The material of the yarn can be selected freely and usable examples of it include polyester, polyamide, polyphenylene sulfide, polyvinylidene fluoride, polypropylene, aramid, polyether ketone, polyethylene naphthalate, polytetrafluoroethylene, cotton, wool and metal. Of course, yarns obtained using copolymers or incorporating or mixing the above-described material with a substance selected depending on the intended purpose may be used.

(21) As to the diameter of the yarn constituting the fabric, it is preferable that the diameter of the upper surface side weft be smaller than that of the lower surface side weft, in view of the surface smoothness, the fiber supportability, etc., and any diameter of the warp may be appropriately selected, the diameter of all the warps may be the same, or the diameter of the lower surface side warp may be larger than that of other warps, for instance.

(22) Now, the embodiments of the present invention will be described below with reference to the drawings. FIG. 2 is a design view of the industrial fabric according to the first embodiment of the present invention. FIG. 3 is a longitudinal cross section view showing a structure of the yarns with respect to the industrial fabric according to the first embodiment of the present invention. FIG. 4 is a design view of the industrial fabric according to the second embodiment of the present invention. FIG. 5 is a longitudinal cross section view showing a structure of the yarns with respect to the industrial fabric according to the second embodiment of the present invention.

(23) Here, the design view corresponds to the complete structure of the fabric defining the minimum unit to be repeated of the fabric structure. A structure of the whole fabric is formed by the complete structures woven with each other in the upper and lower directions, and in the left and right directions. In addition, the longitudinal cross sectional view is the one showing a situation in which the warps are woven with each other in the complete structure. In each of the design views, the warp is indicated by a reference number such as 1,2,3 . . . . The warp binding yarn weaving the upper and lower wefts is indicated by the reference number to which b is attached. The upper and lower warps are indicated by the reference number to which U and L are attached, respectively. In each of the design views, the warps with the same reference numbers indicate to form a set, so that, in FIG. 2, the upper surface side warp U and the lower surface side warp L, the upper surface side warp U and the binding yarn b, and the upper surface side binding yarn Ub and the lower surface side binding yarn Lb form a set, respectively, for instance.

(24) The weft is indicated by a reference number such as 1, 2, 3 . . . . There is a case in which the upper surface side wefts and the lower surface side wefts are arranged upper and lower, respectively, and there is another case in which the only upper surface side wefts are arranged upper. The upper surface side weft and the lower surface side weft are indicated by the reference number to which U and L are attached, respectively, such as 1U, 2 L, etc.

(25) In each of the design views, a symbol indicates that the lower surface side warp is arranged under the lower surface side weft to form a knuckle, and a symbol X indicates that the upper surface side warp (U) is arranged above the upper surface side weft to form a knuckle, and a symbol indicates that the warp binding yarn (b) is arranged under the lower surface side weft to form a knuckle, and a symbol .square-solid. indicates that the yarn functioning as the concave binding yarn among the warp binding yarns (b) is arranged above the upper surface side weft to form a single knuckle, and a solid triangle symbol .box-tangle-solidup. indicates that the yarn functioning as the convex binding yarn for pushing up among the warp binding yarns (b) is arranged above the upper surface side weft to form a knuckle.

(26) In the design view, the warps and the wefts on the upper surface side are depicted to be precisely arranged over the warps and the wefts on the upper surface side, because of the clarity of the drawing. In the real fabric, it does not matter if they are arranged to be offset.

(27) In particular, FIGS. 2 and 4 show that the concave portions are regularly separated from each other by using the symbols .square-solid. and .box-tangle-solidup..

First Embodiment

(28) FIGS. 2 to 3 are a design view and a cross section view showing an industrial fabric according to the first embodiment, respectively.

(29) As shown in FIG. 2, the fabric of the first embodiment includes upper surface side warps (1U8U), lower surface side warps (1L,2L,5L,6L), and lower surface side warps 3Lb, 4Lb,7Lb, 8Lb each serving as a binding weft yarn. In addition, the fabric of the first embodiment includes upper surface side wefts (1U16U), and lower surface side wefts (2L, 4L, 6L,8L,10L, 12L, 14L,16L) to form sixteen shafts.

(30) An arranging ratio of the upper surface side wefts (1U16U) to the lower surface side wefts (2L, 4L . . . ) is two.

(31) In this embodiment, as shown in FIG. 3, the upper surface side warps 1U, 2U, 5U, 6U are woven with the upper surface side wefts in an alternate manner. In addition, the lower surface side warps 1L, 2L, 5L, 6L pass under the two lower surface side wefts.

(32) Among the lower surface side wefts each serving as a binding weft yarn, the lower surface side wefts 3Lb, 7Lb are the concave binding yarns for pulling down. As shown in FIG. 3(c), the concave binding yarn 3Lb for pulling down passes under the lower surface side weft 2L and passes over the upper surface side weft 5U to pass under the lower surface side weft 12L to bind the upper surface side fabric and the lower surface side fabric. In addition, as shown in FIG. 3(g), the concave binding yarn 7Lb for pulling down passes under the lower surface side weft 4L and passes under the lower surface side weft 10L to pass over the upper surface side weft 13U to bind the upper surface side fabric and the lower surface side fabric. The technical feature of the lower surface side wefts 3Lb, 7Lb lies in the fact that they form a single knuckle at the upper surface side fabric. A location where the single knuckle is formed is a portion .square-solid.(N1) where the lower surface side wefts 3Lb, 7Lb pass over the upper surface side wefts 5U,13U. At the portion .square-solid.(N1), a force by which the binding yarn draws the upper surface side wefts woven therewith inside is stronger than that at other locations. In particular, in the industrial fabric according to the first embodiment, the upper surface side wefts 5U,13U are adapted to be drawn inside by the stronger force by making the portion .square-solid.(N1) where the knuckle of the concave binding yarns 3Lb, 7Lb for pulling down is formed single

(33) Among the lower surface side warps each serving as a binding weft yarn, the lower surface side warps 4Lb, 8Lb are the concave binding yarns for pulling down. As shown in FIG. 2, the lower surface side warps 4Lb, 8Lb are arranged adjacent to the above-described concave binding yarns 3Lb, 7Lb for pulling down. In addition, the above-described concave binding yarns 4Lb, 8Lb for pulling down pass under the upper surface side wefts 5U,13U woven at the portion N1 where the single knuckle of the above-described concave binding yarns 3Lb, 7Lb is formed and passes over the upper surface side wefts 4U,6U or the upper surface side wefts 12U,14U adjacent to the upper surface side wefts 5U,13U to form two knuckles .box-tangle-solidup.(N2,N3). By adopting such a structure, the above-described concave binding yarns 4Lb, 8Lb for pulling down are woven so as to scoop the upper surface side wefts 5U,13U from below, between the two knuckles A (N2,N3). Such being the case, a stress for pushing up the upper surface side wefts 5U,13U is generated between the two knuckles .box-tangle-solidup.(N2,N3) of the concave binding yarns 4Lb, 8Lb for pulling down. Accordingly, a force for drawing the upper surface side wefts 5U,13U generated at the location of the single knuckle N1 of the concave binding yarns 3Lb, 7Lb for pulling down is cancelled by a stress for pushing up the upper surface side weft 5U generated on the two knuckles .box-tangle-solidup.(N2,N3) of the concave binding yarns 4Lb, 8Lb for pulling down adjacent to the concave binding yarns 3Lb, 7Lb.

(34) Therefore, the formation of the concave portions consecutively generated can be controlled in order to prevent the marking from diagonally generating on the produced object. In addition, by adopting the industrial fabric according to the first embodiment, the marking can be prevented from diagonally generating on the surface of the produced object by regularly dividing the concave portions generated on the upper surface of the fabric.

Second Embodiment

(35) FIGS. 4 to 5 are a design view and a cross section view showing an industrial fabric according to the second embodiment, respectively.

(36) As shown in FIG. 4, the fabric of the second embodiment includes upper surface side warps (1U,2U,5U,6U), lower surface side warps (1L,2L,5L,6L), lower surface side warps (3Lb, 4Lb,7Lb, 8Lb) each serving as a binding weft yarn, and upper surface side warps (3Ub, 4Ub,7Ub, 8Ub) each serving as a binding weft yarn. In addition, the fabric of the second embodiment includes upper surface side wefts (1U16U), and lower surface side wefts (1L, 3L, 5L,7L,9L, 11L, 13L,15L) to form sixteen shafts.

(37) An arranging ratio of the upper surface side wefts (1U, 2U . . . ) to the lower surface side wefts (2L, 4L . . . ) is two.

(38) In this embodiment, as shown in FIG. 5, the upper surface side warps 1U, 5U are woven with the upper surface side wefts in an alternate manner. In addition, the upper surface side warps 2U, 6U are woven with two upper surface side wefts in an alternate manner. In addition, the lower surface side warps 1L, 2L, 5L, 6L pass under the two lower surface side wefts.

(39) Among the lower surface side warps each serving as a binding weft yarn, the lower surface side warps 4Lb, 8Lb are the concave binding yarns for pulling down. As shown in FIG. 5(d), the concave binding yarn 4Lb for pulling down passes under the lower surface side weft 3L and passes over the upper surface side wefts 9U, 10U to bind the upper surface side fabric and the lower surface side fabric. The technical feature of the concave binding yarn 4Lb for pulling down lies in the fact that it forms a single knuckle at the upper surface side wefts 9U, 10U. In addition, as shown in FIG. 5(h), the concave binding yarn 8Lb for pulling down passes under the lower surface side weft 11L and passes over the upper surface side wefts 1U, 2U to bind the upper surface side fabric and the lower surface side fabric. The technical feature of the concave binding yarn 7Lb for pulling down lies in the fact that it forms a single knuckle at the upper surface side wefts 1U, 2U. A location where the single knuckle is formed is a portion .square-solid. (N1) where the concave binding yarns 4Lb, 8Lb pass over the upper surface side wefts 1U,2U and the upper surface side wefts 9U, 10U. At the portion .square-solid. (N1), a force by which the binding yarn draws the upper surface side wefts woven therewith inside is stronger than that at other locations. In particular, in the industrial fabric according to the second embodiment, the upper surface side wefts 1U,2U, 9U,10U are adapted to be drawn inside by the stronger force by making the portion .square-solid. (N1) where the knuckle of the concave binding yarns 1U,2U for pulling down and the concave binding yarns 9U,10U for pulling down is formed single

(40) Among the lower surface side warps each serving as a binding weft yarn, the lower surface side warps 3Lb, 7Lb are the concave binding yarns for pushing up. As shown in FIGS. 5(c), 5(d), the concave binding yarns 3Lb, 7Lb for pushing up are arranged adjacent to the above-described concave binding yarns 4Lb, 8Lb for pulling down. In addition, the above-described concave binding yarns 3Lb, 7Lb for pushing up pass under the upper surface side wefts 9U, 1U woven at the portion N1 where the single knuckle of the above-described concave binding yarns 4Lb, 8Lb for pulling down is formed and passes over the upper surface side wefts 8U,10U or the upper surface side wefts 2U,16U adjacent to the upper surface side wefts 9U, 1U to form two knuckles .box-tangle-solidup.(I\12,N3). By adopting such a structure, the above-described concave binding yarns 3Lb, 7Lb for pushing up are woven so as to scoop the upper surface side wefts 9U, 1U from below, between the two knuckles .box-tangle-solidup.(N2,N3). Such being the case, a stress for pushing up the upper surface side wefts 9U, lU is generated between the two knuckles .box-tangle-solidup.(N2,N3) of the concave binding yarns 3Lb, 7Lb for pushing up. Accordingly, a force for drawing the upper surface side wefts 9U, 1U generated at the location of the single knuckle N1 of the concave binding yarns 4Lb, 8Lb for pulling down is cancelled by a stress for pushing up the upper surface side weft 9U or the upper surface side weft 1U generated on the two knuckles .box-tangle-solidup.(N2,N3) of the concave binding yarns 3Lb, 7Lb for pushing up adjacent to the concave binding yarns 4Lb, 8Lb for pulling down.

(41) Therefore, the formation of the concave portions consecutively generated can be controlled in order to prevent the marking from diagonally generating on the object to be produced. In addition, by adopting the industrial fabric according to the second embodiment, the marking can be prevented from diagonally generating on the surface of the object to be by regularly separating the concave portions generated on the upper surface of the fabric from each other.

Embodiment 1

(42) Drawing patterns are created by applying a thin paper on the upper surface of the fabric to trace them by means of a thick pencil, etc. so as to emerge on the thin paper. FIG. 6 is a photograph showing the drawing patterns of the industrial fabric according to the first embodiment.

(43) As clearly shown in FIG. 6, it is found that white rhombus patterns separated from each other on the surface of the industrial fabric according to the first embodiment. It is also found that the consecutive diagonal drawing patterns which were generated on the surface of the conventional industrial fabric are not formed. As described above, such consecutive diagonal drawing patterns are the cause for the marking diagonally generated on the produced object.

(44) In the industrial fabric according to the first embodiment, it was proved that an excellent technical effect that the marking can be prevented from consecutively diagonally generating on the surface of the produced object by controlling the formation of the concave portions can be caused. 1 concave binding yarn for pulling down 2 convex binding yarns for pushing up 3,4,5 upper surface side weft N1 single knuckle N2, N3 two or more single knuckles 3Lb, 4Lb (FIG. 2), 4Lb, 8Lb (FIG. 4) concave binding yarn for pulling down 4Lb, 8Lb (FIG. 2), 3Lb, 7Lb (FIG. 4) concave binding yarn for pushing up