Industrial two-layer fabric

Abstract

The object of the present invention is to provide an industrial two-layered fabric including binding wefts which is capable of improving a high adhesivity of the fabric on the front and back surface sides and the supportability of the warps, without deteriorating the surface smoothness, the abrasion resistance on the back surface side, the extension resistance in the longitudinal direction and the hydration property, which have been conventionally desired. The industrial two-layered fabric includes a first pair of warps consisting of a warp on the front surface side that weaves only a weft on the front surface side and a warp on the back surface side that weaves only the back surface side, and a second pair of warps consisting of a binding warp on the front surface side and a binding warp on the back surface side which functions to bind the fabric on the front surface side and the fabric on the back surface side, the one of the binding warp constituting the second pair of the warps consecutively forms a plurality of knuckles on the fabric on the front surface side, while the other of the binding warps does not emerge on the front surface side at a portion where a plurality of knuckles are formed by the one of the binding warp, and the other binding warp consecutively forms a plurality of knuckles on the fabric on the front surface side, while the one binding warp does not emerge on the front surface side, whereby a complementary structure is formed, the diameter of the warp on the front surface side is set to be substantially the same as the diameter of the binding warp, and the diameter of the warp on the back surface side is set to be larger than the diameter of the binding warp on the front surface side.

Claims

1. An industrial two-layered fabric comprising: a fabric on a front surface side comprising a weft on the front surface side and a warp on the front surface side; and a fabric on a back surface side comprising a weft on the back surface side and a warp on the back surface side; the fabric on the front surface side and the fabric on the back surface side are bound by a binding warp; the fabric on the front surface side consists, in a minimum unit, of 18 wefts on the front surface side; the industrial two-layered fabric includes: a first pair of warps consisting of a warp on the front surface side that weaves only a weft on the front surface side and a warp on the back surface side that weaves only the back surface side; and a second pair of warps consisting of a binding warp on the front surface side and a binding warp on the back surface side, which bind the fabric on the front surface side and the fabric on the back surface side; wherein, in the minimum unit: the binding warp on the front surface side consists of five knuckles consecutively formed on the fabric on the front surface side, while the binding warp on the back surface side does not emerge on the front surface side at a portion where the five knuckles are formed by the binding warp on the front surface side; and the binding warp on the back surface side consists of four knuckles consecutively formed on the fabric on the front surface side adjacent to the five knuckles, while the binding warp on the front surface side does not emerge on the front surface side.

2. The industrial two-layered fabric according to claim 1, the second pair of warps is arranged between said first pairs of warps.

3. The industrial two-layered fabric according to claim 1, a ratio of the warps on the front surface side to the warps on the back surface side is 1:1.

4. The industrial two-layered fabric according to claim 2, two of the second pairs of the warps are arranged to be adjacent to each other, and the first pair of warps is arranged on each side of the two of the second pairs of the warps, and such an arrangement is repeated.

5. The industrial two-layered fabric according to claim 1, a cross sectional shape of the warp on the front surface side, the weft on the front surface side, the weft on the back surface side, the warp on the back surface side, or the binding warp is one selected from the group consisting of a circle, a star, a quadrangle and an ellipse.

6. The industrial two-layered fabric according to claim 1, wherein: a diameter of the warp on the front surface side is set to be substantially the same as a diameter of the binding warp, and a diameter of the warp on the back surface side is set to be larger than the diameter of the binding warp on the front surface side.

7. The industrial two-layered fabric according to claim 1, wherein: the warp on the back surface side of said first pair of warps forms four knuckles on the back side.

Description

BRIEF EXPLANATION OF DRAWINGS

(1) FIG. 1 is a design view showing a complete structure of the first embodiment according to the industrial two-layered fabric of the present invention.

(2) FIG. 2 is a view showing a cross section in the warp direction of the pairs 1 to 4 of the warps of the first embodiment illustrated in FIG. 1.

(3) FIG. 3 is a design view showing a complete structure of the second embodiment according to the industrial two-layered fabric of present invention.

(4) FIG. 4 is a view showing a cross section in the warp direction of the pairs 1 to 4 of the warps of the second embodiment illustrated in FIG. 3.

(5) FIG. 5 is a design view showing a complete structure of the third embodiment according to the industrial two-layered fabric of present invention.

(6) FIG. 6 is a view showing a cross section in the warp direction of the pairs 1 to 4 of the warps of the third embodiment illustrated in FIG. 5.

(7) FIG. 7 is a design view showing a complete structure of the fourth embodiment according to the industrial two-layered fabric of present invention.

(8) FIG. 8 is a view showing a cross section in the warp direction of the pairs 1 to 4 of the warps of the fourth embodiment illustrated in FIG. 7.

DETAILED DESCRIPTION OF THE INVENTION

(9) Now, the structure and the effect of the two-layered fabric of the present invention will be described below. Embodiments of the two-layered fabric of the present invention will be described thereafter with reference to the drawings.

(10) In the industrial two-layered fabric with a complete structure of the present invention, a fabric on a front surface side consisting of a weft on the front surface side and a warp on the front surface side and a fabric on a back surface side consisting of a weft on the back surface side and a warp on the back surface side are bound by a binding warp. In the industrial two-layered fabric includes a first pair of warps consisting of a warp on the front surface side and a warp on the back surface side, and a second pair of warps which two binding warps are arranged to be adjacent to each other so as to function to bind the fabric on the front surface side and the fabric on the back surface side.

(11) The one of the binding warp constituting the second pair of the warps consecutively forms a plurality of knuckles on the fabric on the front surface side, while the other of the binding warps does not emerge on the front surface side at a portion where a plurality of knuckles are formed, and the other binding warp consecutively forms a plurality of knuckles on the fabric on the front surface side, while the one binding warp does not emerge on the front surface side, whereby a complementary structure is formed. That is to say, the second pair of warps forms one structure on the fabric on the front surface side by the complementing of two binding warps. Further, the binding warps can be defined to be the binding warps which functions as the binding yarn with mainly being woven with the front surface side, or the binding warps which functions as the binding yarn with mainly being woven with the back surface side.

(12) In addition, the diameter of the warp on the front surface side is set to be substantially the same as that of the binding warp, and the diameter of the warp on the back surface side is set to be larger than that of the binding warp on the front surface side. The complete structure of the present invention in the industrial two-layered fabric includes eight or more shafts.

(13) In the complete structure of the present invention in the industrial two-layered fabric, the first pair of warps and the second pair of warps are alternatively arranged. Still further, two sets of the second pair of the warps may be arranged to be adjacent to each other, and the first pair of warps may be arranged on each side of the second pair of the warps, and such an arrangement is repeated.

(14) In the complete structure of the present invention in the industrial two-layered fabric, the ratio of the warps on the front surface side to the wefts on the back surface side may be 1:1.

(15) 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.

(16) As the upper surface side warps, lower surface side warps, and upper surface side wefts, use of a polyester monofilament having rigidity and excellent dimensional stability is usually preferred. When lower surface side wefts which need wear resistance are obtained by interweaving of polyester monofilaments and polyamide monofilaments while arranging them alternately, they are able to have wear resistance without losing rigidity.

(17) It is also possible to place a plurality of yarns with the same design at a position where one yarn is normally placed from the standpoint of design. Design of a plurality of yarns having a thin diameter brings about improvement in surface property and thinning of the fabric.

(18) Now, the embodiments of the present invention will be described below. Each of the embodiments described below is an example of the present invention which does not limit the scope of the present invention.

(19) The embodiments of the present invention will be described below with reference to the drawings. Each of FIGS. 1 to 8 is a design view showing a complete structure of embodiments 1 to 4 of the present invention. Here, the design view corresponds to the complete structure of the fabric defining the minimum unit to be repeated of the fabric structure. The final product is completed by combining any number of such complete structures in the longitudinal direction and the direction perpendicular to the longitudinal direction.

(20) In each of the design views, the warp is indicated by a reference number such as 1, 2, 3 . . . . In the embodiments, a first pair of warps consisting of a warp on the front surface side and a warp on the back surface side, and a second pair of warps in which two sets of two biding warps are arranged to be adjacent to each other are shown. The weft is indicated by a reference number such as 1′,2′, 3′ . . . .

(21) In addition, in each of the design views, a symbol “×” indicates that the warp on the front surface side is arranged above the weft on the front surface side. A symbol “∘” indicates that the warp on the back surface side is arranged below the weft on the back surface side. A symbol “□” indicates that the binding warp on the back surface side is arranged below the weft on the back surface side. A symbol “.box-tangle-solidup.” indicates that the binding warp on the back surface side is arranged above the weft on the front surface side. A symbol “Δ” indicates that the binding warp on the front surface side is arranged below the weft on the back surface side. A symbol “.square-solid.” indicates that the binding warp on the front surface side is arranged below the weft on the front surface side. The warps and the wefts on the upper surface side are arranged to be overlapped with the warps and the wefts on the lower surface side, respectively. In this connection, 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.

DETAILED DESCRIPTION OF THE INVENTION

Embodiment 1

(22) FIG. 1 is a design view showing a complete structure of the first embodiment according to the industrial two-layered fabric of the present invention. A complete structure of the industrial two-layered fabric according to the embodiment 1 includes a first pair of warps consisting of warps (1,4,5,8,9,12) on the front surface side and warps (1,4,5,8,9,12) on the back surface side which does not include the binding warps and a second pair of warps consisting of binding warps (2,3,6,7,10,11) on the front surface side and binding warps (2,3,6,7,10,11) on the back surface side which includes a binding functions.

(23) The first pair 1 of warps are alternately woven with the wefts on the front surface side in such a way that the warp on the front surface side forms a plain weaving on the fabric on the front surface side, while the warps on the back surface side are woven with the wefts on the back surface side, as shown in the warps 1 on the back surface side in FIG. 2, and as a result, a ¼-⅓ structure is formed on the fabric on the back surface side.

(24) In addition, a second pair of warps never fails to be arranged at a position adjacent to each of the first pair of warps. For instance, two sets 2,3 of a second pair of warps are arranged at a position adjacent to each of the first pair 1 of warps. More specifically, as shown in FIG. 2, the binding warp 2 among the second pair 2,3 of warps passes below the weft 1′ on the front surface side, above the wefts 2′,4′ on the front surface side, below the wefts 7′,11′ on the back surface side, and above the wefts 14′,16′,18′ on the front surface side to form a knuckle, while the binding warp 2 on the back surfaces side among the second pair 2,3 of warps passes above the weft 1′ on the back surface side, below the weft 2′ on the back surface side, above the wefts 6′,8′, 10′,12′ on the front surface side, and below the weft 16′ on the back surface side to bind the fabric on the front surface side with the fabric on the back surface side.

(25) In addition, the second pair 2,3 of warps are arranged to be adjacent to the first pair 4 of warps. The warp 4 in the first pair of warps forms a plain weaving on the fabric on the front surface side. The binding warp 3 on the front surface side among the second pair 2,3 of warps passes above the wefts 1′, 3′, 5′, 7′ on the front surface side, below the wefts 10′,14′ on the back surface side, and above the weft 17′ on the front surface side to form a knuckle, while the binding warp 3 on the back surfaces side among the second pair 2,3 of warps passes below the wefts 1′,5′ on the back surface side, and above the wefts 9′, 11′, 13′, 15′ on the back surface side to bind the fabric on the front surface side with the fabric on the back surface side.

(26) Further, the second pair 6,7 of warps are arranged to be adjacent to the first pair 5 of warps. The second pair 6,7 of warps are also arranged to be adjacent to the first pair 8 of warps. The second pair 10,11 of warps are arranged to be adjacent to the first pair 9 of warps, while the second pair 10,11 of warps are also arranged to be adjacent to the first pair 12 of warps.

(27) By adopting such a structure, since the binding warps with small diameters never fails to be arranged to be adjacent to the warps on the back surface side with large dimeters, the uniform hydration speed can be secured, so that the generation of the hydration marks can be decreased. In addition, the abrasion resistance on the back surface side and the extension resistance in the longitudinal direction can be improved, so that the adhesive property between the fabric on the front surface side and the fabric on the back surface side can be enhanced.

Embodiment 2

(28) FIG. 2 is a design view showing a complete structure of the second embodiment according to the industrial two-layered fabric of the present invention. A complete structure of the industrial two-layered fabric according to the embodiment 2 includes a first pair of warps consisting of warps (1,4,5,8,9,12) on the front surface side and warps (1,4,5,8,9,12) on the back surface side which does not include the binding warps and a second pair of warps consisting of binding warps (2,3,6,7,10,11) on the front surface side and binding warps (2,3,6,7,10,11) on the back surface side which includes binding functions.

(29) The first pair 1 of warps are alternately woven with the wefts on the front surface side in such a way that the warp on the front surface side forms a plain weaving on the fabric on the front surface side, while the warps on the back surface side are woven with the wefts on the back surface side, as shown in the warps 1 on the back surface side in FIG. 4, and as a result, a ¼-⅓ structure is formed on the fabric on the back surface side.

(30) In addition, a second pair of warps never fails to be arranged at a position adjacent to each of the first pair of warps. For instance, two sets 2,3 of a second pair of warps are arranged at a position adjacent to each of the first pair 1 of warps. More specifically, as shown in FIG. 4, the binding warp 2 among the second pair 2,3 of warps passes below the weft 1′ on the front surface side, above the weft 2′,4′ on the front surface side, below the weft 7′ on the back surface side, and above the weft 10′,12′,14′, 16′,18′ on the front surface side to form a knuckle, while the binding warp 2 on the back surfaces side among the second pair 2,3 of warps passes above the weft 1′ on the back surface side, below the weft 2′ on the back surface side, above the wefts 6′,8′ on the front surface side, and below the wefts 11′,16′ on the back surface side to bind the fabric on the front surface side with the fabric on the back surface side.

(31) In addition, the second pair 2,3 of warps are arranged to be adjacent to the first pair 4 of warps. The warp 4 in the first pair of warps forms a plain weaving on the fabric on the front surface side. The binding warp 3 on the front surface side among the second pair 2,3 of warps passes above the wefts 1′, 3′, 5′, 7′, 9′, 11′ on the front surface side, below the weft 14′ on the back surface side, and above the weft 17′ on the front surface side to form a knuckle, while the binding warp 3 on the back surfaces side among the second pair 2,3 of warps passes below the wefts 1′,5′,10′ on the back surface side, and above the wefts 13′, 15′ on the back surface side to bind the fabric on the front surface side with the fabric on the back surface side.

(32) Further, the second pair 6,7 of warps are arranged to be adjacent to the first pair 5 of warps. The second pair 6,7 of warps are also arranged to be adjacent to the first pair 8 of warps. The second pair 10,11 of warps are arranged to be adjacent to the first pair 9 of warps, while the second pair 10,11 of warps are also arranged to be adjacent to the first pair 12 of warps.

(33) By adopting such a structure, since the binding warps with small diameters never fails to be arranged to be adjacent to the warps on the back surface side with large dimeters, the uniform hydration speed can be secured, so that the generation of the hydration marks can be decreased. In addition, the abrasion resistance on the back surface side and the extension resistance in the longitudinal direction can be improved, so that the adhesive property between the fabric on the front surface side and the fabric on the back surface side can be enhanced.

Embodiment 3

(34) FIG. 5 is a design view showing a complete structure of the third embodiment according to the industrial two-layered fabric of the present invention. A complete structure of the industrial two-layered fabric according to the embodiment 3 includes a first pair of warps consisting of warps (1,4,5,8) on the front surface side and warps (1,4,5,8) on the back surface side which does not include the binding warps and a second pair of warps consisting of binding warps (2,3,6,7) on the front surface side and binding warps (2,3,6,7) on the back surface side which includes a binding functions.

(35) The first pair 1 of warps are alternately woven with the wefts on the front surface side in such a way that the warp on the front surface side forms a plain weaving on the fabric on the front surface side, while the warps on the back surface side are woven with the wefts on the back surface side, as shown in the warps 1 on the back surface side in FIG. 6, and as a result, a ¼-¼-⅕ structure is formed on the fabric on the back surface side.

(36) In addition, a second pair of warps never fails to be arranged at a position adjacent to each of the first pair of warps. For instance, two sets (2,3) of a second pair of warps are arranged at a position adjacent to each of the first pair 1 of warps. More specifically, as shown in FIG. 5, the binding warp 2 among the second pair 2,3 of warps passes above the wefts 2′,4′,6′,8′ on the front surface side, below the weft 11′ on the back surface side, and above the weft 16′ on the front surface side, while the binding warp 2 on the back surfaces side among the second pair 2,3 of warps passes below the wefts 1′, 6′ on the back surface side, and above the wefts 10′,12′,14′ on the front surface side to bind the fabric on the front surface side with the fabric on the back surface side.

(37) In addition, the second pair 2,3 of warps are arranged to be adjacent to the first pair 4 of warps. The binding warp 3 on the front surface side among the second pair 2,3 of warps passes above the wefts 1′, 3′ on the front surface side, below the weft 7′ on the back surface side, and above the wefts 13′, 15′ on the front surface side, while the binding warp 3 on the back surfaces side among the second pair 2,3 of warps passes below the weft 2′ on the back surface side, above the wefts 5′, 7′, 9′, 11′ on the back surface side, and below the weft 13′ on the back surface side to bind the fabric on the front surface side with the fabric on the back surface side.

(38) Further, the second pair 6,7 of warps are arranged to be adjacent to the first pair 5 of warps. The second pair 6,7 of warps are also arranged to be adjacent to the first pair 8 of warps.

(39) By adopting such a structure, since the binding warps with small diameters never fails to be arranged to be adjacent to the warps on the back surface side with large dimeters, the uniform hydration speed can be secured, so that the generation of the hydration marks can be decreased. In addition, the abrasion resistance on the back surface side and the extension resistance in the longitudinal direction can be improved, so that the adhesive property between the fabric on the front surface side and the fabric on the back surface side can be enhanced.

Embodiment 4

(40) FIG. 1 is a design view showing a complete structure of the first embodiment according to the industrial two-layered fabric of the present invention. A complete structure of the industrial two-layered fabric according to the embodiment 1 includes a first pair of warps consisting of warps (1,4,5,8,9,12) on the front surface side and warps (1,4,5,8,9,12) on the back surface side which does not include the binding warps and a second pair of warps consisting of binding warps (2,3,6,7,10,11) on the front surface side and binding warps (2,3,6,7,10,11) on the back surface side which includes a binding functions.

(41) The first pair 1 of the warps are woven with the wefts on the front surface side ins such a way that the warps on the front surface side form a 2/2 structure on the fabric on the front surface side, while the warps on the back surface side are woven with the wefts on the back surface side, as shown in FIG. 8, to form a ¼-¼-⅕ structure. The first pair 5 of the warps also includes the same structure. In addition, the first pair 4 of the warps are alternately woven with the wefts on the front surface side in such a way that the warp on the front surface side forms a plain weaving on the fabric on the front surface side, while the warps on the back surface side are woven with the wefts on the back surface side, as shown in the warps 4 on the back surface side in FIG. 8, and as a result, a ¼-¼-⅕ structure is formed on the fabric on the back surface side. The first pair 8 of the warps also includes the same structure.

(42) In addition, a second pair of warps never fails to be arranged at a position adjacent to each of the first pair of warps. For instance, two sets (2,3) of a second pair of warps are arranged at a position adjacent to each of the first pair 1 of warps. More specifically, as shown in FIG. 8, the binding warp 2 among the second pair 2,3 of warps passes above the wefts 2′,4′,6′,8′ on the front surface side, below the weft 11′ on the back surface side, and above the weft 16′ on the front surface side, while the binding warp 2 on the back surfaces side among the second pair 2,3 of warps passes below the wefts 1′, 6′ on the back surface side, and above the wefts 10′,12′,14′ on the front surface side, to bind the fabric on the front surface side with the fabric on the back surface side.

(43) In addition, the second pair 2,3 of warps are arranged to be adjacent to the first pair 4 of warps. The binding warp 3 on the front surface side among the second pair 2,3 of warps passes above the wefts 1′, 2′ on the front surface side, below the wefts 5′,10′ on the back surface side, and above the wefts 13′,14′ on the front surface side, while the binding warp 3 on the back surfaces side among the second pair 2,3 of warps passes above the wefts 5′,6′ on the back surface side, below the wefts 7′, 8′ on the back surface side, the wefts 9′,10′ on the front surface side, and below the weft 15′,6′ on the back surface side to bind the fabric on the front surface side with the fabric on the back surface side.

(44) Further, the second pair 6,7 of warps are arranged to be adjacent to the first pair 5 of warps. The second pair 6,7 of warps are also arranged to be adjacent to the first pair 8 of warps.

(45) By adopting such a structure, since the binding warps with small diameters never fails to be arranged to be adjacent to the warps on the back surface side with large dimeters, the uniform hydration speed can be secured, so that the generation of the hydration marks can be decreased. In addition, the abrasion resistance on the back surface side and the extension resistance in the longitudinal direction can be improved, so that the adhesive property between the fabric on the front surface side and the fabric on the back surface side can be enhanced.

EXPLANATION OF SYMBOLS

(46) 1˜12: warp

(47) 1′˜18′: weft