Abstract:
An open ended papermaker&#39;s fabric of the type woven from longitudinal and transverse thread systems including a plurality of seam loops at each end of the fabric. A seam zone exists at each end of the fabric between the respective seam loops and the last thread of the transverse thread system. At least one additional transverse thread is interwoven in at least one seam zone in a repeat pattern having a ratio of interlacings with longitudinal machine side threads to paper side longitudinal threads greater than zero and less than or equal to 1 in 6.

Description:
This application claims the benefit of: U.S. Provisional Application Serial No. 60/098,547, filed Aug. 31, 1998; U.S. Provisional Application Serial No. 60/097,831, filed Aug. 31, 1998; U.S. Provisional Application Serial No.60/098,566, filed Aug. 31, 1998; U.S. Provisional Application Serial No.60/098,567, filed Aug. 31, 1998; and U.S. Provisional Application Serial No. 60/098,573, filed Aug. 31, 1998. 
    
    
     BACKGROUND 
     The present invention generally relates to an open ended, woven fabric which is designed for use in a papermaking, cellulose or board manufacturing machine. The fabric has a plurality of loops at each end to form a seam for rendering the fabric endless. 
     As will be known to those skilled in the art, papermaking machines generally include three sections commonly referred to as the forming, press and dryer sections. The present invention finds particular application in the press section of a papermaking machine. 
     Typically, press felts include a supporting base, such as a woven fabric, and a paper carrying or supporting layer. Frequently, the paper support layer is a homogeneous, non-woven batt that has been affixed to the base. Base fabrics are typically woven fabrics which are used as an endless loop. Such an endless loop fabric may be woven endless with no seam or the fabric may be woven with two ends which are joined by a seam. Typical seams include pin type seams which utilize a pintle inserted through intermeshed seam loops to close the fabric. 
     Some prior art seams have employed threads in the seam area to increase batt adhesion in this area. However, these efforts have not always produced the desired sheet contact or loop length in the seam area. Additionally, some of the prior art seams do not provide the desired interconnection between paper and machine side machine direction threads. See U.S. Pat. Nos. 5,476,123 and 5,531,251. FIG. 1 shows a prior art seam area with a pair of additional threads A and B in complementary plain weave patterns interwoven in the fabric seam zone  40 . Thread A weaves over and under paired MD threads and thread B weaves oppositely with the same pairs. In addition to not always providing the desired contact area, this seam has a loop length L which is larger than desired. 
     There exists a need to provide increased sheet contact in the seam zone through better batt anchorage, and a shortened loop length which is balanced between the paper and machine sides. 
     SUMMARY 
     The present invention relates to an open ended papermaker&#39;s fabric of a type woven from a longitudinal thread system and a transverse thread system. A plurality of seam loops are formed at each end of the fabric by the threads of the longitudinal thread system. A seam zone exists at each end of the fabric between the respective seam loops and the last thread of the transverse thread system. At least one additional transverse thread is interwoven in at least one seam zone with the longitudinal thread system in a repeat pattern having a ratio of interlacings with longitudinal machine side threads to paper side longitudinal threads greater than zero and less than or equal to 1 in 6. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top plan view of a prior art fabric seam. 
     FIG. 2 is a schematic perspective view of a portion of one end of the base fabric of a first embodiment of the present invention. 
     FIG. 3 illustrates one weave repeat pattern for one of the additional threads of the fabric of FIG.  2 . 
     FIG. 4 illustrates one weave repeat pattern for a second a second additional thread of FIG.  2 . 
     FIG. 5 is an elevation view of the fabric taken along line  5 — 5  in FIG.  2 . 
     FIG. 6 is a top plan view of the two ends of the fabric of FIG. 2 prior to joining together thereof. 
     FIG. 7 is a top plan view of the two ends of the fabric of FIG. 2 joined together. 
     FIG. 8 is a photomicrograph top plan view of the fabric of the first embodiment adjacent to the fabric of FIG. 1, both fabrics with their additional threads removed. 
     FIG. 9 illustrates the weave repeat for one additional thread in accordance with a second embodiment. 
     FIG. 10 illustrates the weave repeat for a second additional thread in accordance with the second embodiment. 
     FIG. 11 shows the weave repeats of FIGS. 9 and 10 in combination. 
     FIG. 12 illustrates the weave repeat for one additional thread in accordance with a third embodiment. 
     FIG. 13 illustrates the weave repeat for a second additional thread in accordance with the third embodiment. 
     FIG. 14 shows the weave repeats of FIGS. 12 and 13 in combination. 
     FIG. 15 is a top plan view of the combined weave patterns as illustrated in FIGS. 12-14. 
     FIG. 16 illustrates the weave repeat for the additional threads in accordance with a fourth embodiment. 
     FIG. 17 is a top plan view of the combined weave patterns as illustrated in FIG.  16 . 
     FIG. 18 illustrates the weave repeat for one additional thread in accordance with a fifth embodiment. 
     FIG. 19 illustrates the weave repeat for a second additional thread in accordance with the fifth embodiment. 
     FIG. 20 shows the weave repeats of FIGS. 18 and 19 in combination. 
     FIG. 21 illustrates the weave repeat for one additional thread in accordance with a sixth embodiment. 
     FIG. 22 illustrates the weave repeat for a second additional thread in accordance with the sixth embodiment. 
     FIG. 23 shows the weave repeats of FIGS. 21 and 22 in combination. 
     FIG. 24 illustrates the weave repeat for one additional thread in accordance with a seventh embodiment. 
     FIG. 25 illustrates the weave repeat for a second additional thread in accordance with the seventh embodiment. 
     FIG. 26 shows the weave repeats of FIGS. 24 and 25 in combination. 
     FIG. 27 illustrates the weave repeat for one additional thread in accordance with an eighth embodiment. 
     FIG. 28 illustrates the weave repeat for a second additional thread in accordance with the eighth embodiment. 
     FIG. 29 shows the weave repeats of FIGS. 27 and 28 in combination. 
     FIG. 30 illustrates the weave repeat for one additional thread in accordance with a ninth embodiment. 
     FIG. 31 illustrates the weave repeat for a second additional thread in accordance with the ninth embodiment. 
     FIG. 32 shows the weave repeats of FIGS. 30 and 31 in combination. 
     FIG. 33 illustrates the weave repeat for one additional thread in accordance with a tenth embodiment. 
     FIG. 34 illustrates the weave repeat for a second additional thread in accordance with the tenth embodiment. 
     FIG. 35 shows the weave repeats of FIGS. 33 and 34 in combination. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The preferred embodiments will be described with reference to the drawing figures where like numerals represent like elements throughout. 
     Referring to FIG. 2, it shows a portion of one end of the base fabric seam loops with additional threads woven in accordance with a first embodiment of the present invention. The base fabric  1  comprises a top layer of MD threads,  10 ,  12 ,  14 ,  16 ,  18 ,  20 ,  22 , and  24 , and a bottom layer of MD threads,  11 ,  13 ,  15 ,  17 ,  19 ,  21 ,  23  and  25 . It will be understood that the top and bottom layers are essentially continuous threads which form the seam loops  35 - 1  to  35 - 8  between the top and bottom layers. 
     Typically, the body CMD threads  2 - 5 , shown in phantom, are interwoven with the top and bottom MD thread layers in a given repeat pattern to form the body of the fabric. A seam zone  40  exists between the end CMD thread  2  and the seam loops  35 - 1  to  35 - 8 . The weave pattern of the body CMD threads  2 - 5  can be varied to provide the desired characteristics of the fabric  1 . 
     Reference is now made to FIGS. 3-5. Although some benefits will be obtained with a single thread, in the preferred embodiments, two additional threads are preferred for increased uniformity in the paper side surface. Although, the fabric will be described with the preferred two additional threads in each end of the fabric, the additional threads may be provided along only one end of the fabric. 
     The two additional CMD threads  50  and  51  are interwoven in the seam zone  40  with both layers of MD threads  10  through  25 . As shown in FIG. 3, additional CMD thread  50  weaves in a repeat that passes over MD threads  10 - 17 , between threads  18 - 19 , under threads  20 - 21 , between threads  22 - 23  and over threads  24 - 25 . With reference to FIG. 4, the second additional thread  51  is woven in a repeat pattern which is shifted four MD thread pairs compared to that of thread  50 . Thus, CMD thread  51  weaves in a repeat that passes between the paired threads  10 - 11 , beneath the paired threads  12 - 13 , between the paired threads  14 - 15 , and over threads  16 - 25 . 
     As can be seen from FIG. 5, two threads  50 ,  51  woven in accordance with FIGS. 3 and 4 produce a weave repeat structure wherein each machine side interlacing  52  and  53 , respectively, is aligned with the paper side float  54  and  55  of the other additional thread  50 ,  51  respectively. The repeat pattern extends over eight pairs of MD threads with minimal interlacing in the machine side MD layer. As a result of the long floats  54 , 55  and the single machine side interlacings, the threads  50  and  51  migrate relative to each other and the seam zone  40  has effectively one long float across the width of the fabric. This result is illustrated in FIGS. 6 and 7. This effect may be further enhanced by selecting the additional threads  50 ,  51  from materials with no or low twist which allow them to flatten and cover more of the seam zone  40 . 
     The invention results in a loop length L, the distance between the end CMD thread  2  and the end of the seam loops, which is shortened over the prior art. Referring to FIG. 8, a photomicrograph of the seam area of the fabric of the present embodiment between each of the pairs of paper side and machine side longitudinal thread  1  is shown adjacent to the seam area of the fabric woven in accordance with FIG.  1 . The additional threads have been removed from each fabric. As shown in the photographs, the loop length L of the present embodiment 1 is shorter than the loop length L of the prior art fabric. 
     Table 1 below provides a comparison of the loop lengths at each end of the fabrics between the prior art fabric of FIG.  1  and embodiments of the present invention. The comparisons are based on identical body fabric weaves and thread material and sizes. The fabrics are identical except for the weave patterns of the additional threads. The loop lengths are measured in pixels with a Photovolt, Microwatcher, microscope, Model VS-35H, at a magnification of 50X wherein 458 pixels are equal to 0.100″. 
     
       
         
               
               
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                   
                 LOOP LENGTH 
                 % REDUCTION 
                 LOOP LENGTH 
                 % REDUCTION 
               
               
                 FABRIC 
                 AT FIRST END 
                 OVER PRIOR ART 
                 AT SECOND END 
                 OVER PRIOR ART 
               
               
                   
               
             
             
               
                 FIG. 1 - PRIOR ART 
                 478 
                 — 
                 470 
                 — 
               
               
                 FIGS 2-7 
                 412 
                 13.8 
                 389 
                 17.2 
               
               
                 FIGS 8-10 
                 412 
                 13.8 
                 389 
                 17.2 
               
               
                 FIGS 11-14 
                 385 
                 19.5 
                 364 
                 22.6 
               
               
                 FIGS 15-16 
                 415 
                 13.2 
                 405 
                 13.8 
               
               
                   
               
             
          
         
       
     
     As shown in Table  1 , the loop lengths L of the present embodiment, FIGS. 2-7, are reduced by between 13.8 and 17.2% 
     It may also be desirable, although not necessary, to weave the additional threads in what will be opposed seaming ends of the fabric in reverse positioning with respect to each other. As illustrated in FIG. 7, the additional thread  51  is adjacent the last CMD thread  2  in one end of the fabric  1 , and additional thread  50 ′ is adjacent to the last CMD thread  2  in the opposed end. This allows the two ends of the fabric  1  to complement each other when the fabric  1  is joined. 
     A second embodiment is disclosed with respect to FIGS. 9-11. Additional thread  60  is woven in the same manner as in FIG. 3 with respect to the first embodiment. The weave of additional CMD thread  61  is modified as depicted in FIG.  10 . Thread  61  weaves between paired MD threads  10 ,  11 , under MD threads  12  and  13 , between paired MD threads  14 , 15  and  16 , 17 , over MD threads  18 - 23  and between paired MD threads  24 ,  25 . As seen in FIG. 11, the effective long float across the width of the fabric is maintained with this pattern. As shown in Table  1 , threads  60 ,  61  tend to migrate towards the loops  35 - 1  to  35 - 8  and shorten the loop lengths L by between 13.8 and 17.2%. 
     Referring to FIGS. 12-15, a third embodiment of the present invention is shown. Each additional CMD thread  70  and  71  is interwoven in the seam zone  40  with both layers of MD threads  10  through  25 . Additional CMD thread  70  preferably weaves in a repeat that passes over MD threads  10 - 11 , between threads  12 - 13 , over threads  14 - 15 , between the thread pairs  16 , 17  and  18 , 19 , under threads  20 - 21  and between the paired threads  22 , 23  and  24 , 25 . 
     With reference to FIG. 13, the second thread  71  is woven in a mirror image to the thread  70 . Thus, CMD thread  71  weaves in a repeat that passes between the paired threads  10 - 11 , beneath the threads  12 - 13 , between the paired threads  14 , 15  and  16 , 17 , over the threads  18 - 19 , between paired threads  20 - 21 , over paired threads  22 - 23 , and between threads  24 - 25 . As can be seen from FIG. 14, threads woven in accordance with FIGS. 12 and 13 produce a weave repeat structure having crossover points  73  and  74  which are spaced apart by at least three MD threads. It will also be noted that MD thread  16  passes over both additional threads  70  and  71 . Since the repeat pattern extends over eight pairs of MD threads with only a single interlacing with the machine side MD layer, providing a ratio of interlacings with longitudianl machine side threads to paper side longitudinal threads of 1 in 8, the threads can shift beneath thread  16  and threads  70  and  71  tend to act as one. As a result of the long transition and the single interlacing with the machine side MD layer, the threads  70  and  71  can migrate relative to each other so that the resulting sheet side MD and CMD weave repeat appears to be a plain weave, as shown in FIG.  15 . With this embodiment, the loop lengths L are shortened by approximately 19.5 to 22.6%. 
     With reference to FIGS. 16 and 17, there is shown a fourth embodiment  150 . In this fourth embodiment, weave repeats of the CMD threads  80  and  81  result in floats over three MD threads  10 ,  12  and  14  and over three MD threads  18 ,  20 , and  22 . The long transition between pairs of machine direction threads and the interlacing with a single machine side MD thread per repeat is as previously described. Thus, the threads  80  and  81  will migrate relative to each other and produce relatively large, in-line sheet side floats and shortened loop lengths L. 
     Although the remaining embodiments have not been tested to confirm such, it is believed that the fabrics will also experience shortened loops lengths do to their long transitions and minimal interlacings with the machine side MD threads. This is particularly true for the embodiments shown in FIGS. 18-29 which repeat on twelve MD pairs while interlacing with only a single machine side MD thread. 
     A fifth embodiment of the present invention is shown in FIGS. 18-20. The fabric of this embodiment repeats on twenty four MD threads  10 - 33 . The two additional threads  90  and  91  are interwoven in the seam zone  40  with both layers of longitudinal threads  10  through  33 . Additional CMD thread  90  weaves in a repeat pattern that passes between MD threads  10 - 11 , under MD threads  12 - 13 , between MD thread pairs  14 , 15  and  16 , 17 , and then weaves a continuous portion of plain weave with top layer MD threads  18 ,  20 ,  22 ,  24 ,  26 ,  28 , 30  before transitioning down between MD threads  32 - 33 . With reference to FIG. 19, the second additional thread  91  is woven in a complementary pattern to that of thread  90 . Additional thread  91  weaves a plain weave construction with top layer threads  10 ,  12 ,  14  before transitioning into a mid-plane float between MD thread pairs  16 - 17 ,  18 - 19 ,  20 - 21 ,  22 - 23 , weaving under MD threads  24 - 25  and transitioning back to a mid-plane float between thread pairs  26 - 27 ,  28 - 29 ,  30 - 31 ,  32 - 33 . 
     As can be seen from FIG. 20, two additional threads interwoven in accordance with FIGS. 18 and 19 produce a weave repeat structure having the appearance of a plain weave in the upper layer and two crossover points  93  and  94  which are spaced apart by at least three MD threads. This results from the additional longitudinal thread being in a continuous portion  95  of the weave repeat with seven adjacent MD threads between transitions from the machine or paper side longitudinal threads. Since the repeat pattern extends over twelve pairs of MD threads with only a single interlacing with the machine side MD layer, providing a ratio of interlacings with longitudinal machine side threads to paper side longitudinal threads of 1 in 12, and the additional threads can shift relative to each other, threads  90  and  91  tend to act as one thread in a continuous plain weave on the top layer. As a result of the long transitions and the interlacing patterns, the additional threads can migrate relative to each other to produce the desired sheet side weave pattern while also providing mid-plane floats and long transitions. 
     The second additional thread  101  weaves in the mirror image of thread  100 . As shown by FIG. 23, the threads  100  and  101  produce a plain weave pattern on the paper sheet side, relatively long transitions which combine to simulate a mid-plane float and cross over points  103 ,  104  which encourage migration of the threads relative to each other. As with the prior embodiment, this embodiment provides a continuous portion  105  of the weave repeat that extends for a length of at least five adjacent paper side longitudinal threads between transitions from the machine or paper side longitudinal threads. 
     Referring to FIGS. 24-26, a seventh embodiment is shown. Additional CMD thread  110  weaves in a repeat pattern that passes between MD threads  10 - 11 , under MD threads  12 - 13 , between MD thread pairs  14 - 15 ,  16 - 17 , floats over MD threads  18 - 23 , between MD threads  24 - 25 , floats over MD threads  26 - 31  and between MD threads  32 - 33 . With reference to FIG. 25, the second additional thread  111  is woven in a complementary weave pattern to that of thread  110 . Additional thread  111  weaves over MD threads  10 - 15 , between MD thread pairs  16 - 17 ,  18 - 19 ,  20 - 21 ,  22 - 23 , under MD threads  24 - 25  and between MD threads  26 - 27 ,  28 - 29 ,  30 - 31 ,  32 - 33 . It will be noted from FIG. 25 that additional thread  111  forms two mid-plane floats between four pairs of MD threads  16 - 17 ,  18 - 19 ,  20 - 21 ,  22 - 23  and  26 - 27 ,  28 - 29 ,  30 - 31 ,  32 - 33 . 
     As can be seen from FIG. 26, two additional threads  110 , 111  as interwoven in FIGS. 24 and 25 produce a weave repeat structure having the appearance of an over three, under one repeat in the upper layer. The two crossover points,  113 ,  114  are spaced apart by at least three MD threads. This creates a long continuous portion of the second additional thread  111  which generally forms mid-plane floats that complement the long transition of the first additional thread  100 . Since the repeat pattern extends over twelve pairs of MD threads with only a single interlacing with the machine side MD layer and the additional threads can shift relative to each other, threads  110  and  111  tend to act as one thread in a continuous over three, under one weave pattern on the top layer. With reference again to FIG.  24  and additional thread  110 , it can be seen that the weave repeat of thread  110  includes a subrepeat of three over, one under which repeats twice within the pattern. This weave repeat permits the relatively loose interlacing of the thread  111  but enables the pattern to be continued throughout the upper layer when the threads  110 ,  111  are combined in accordance with FIG.  26 . 
     With reference to FIGS. 27-29, there is shown an eighth embodiment of the present invention. In this eighth embodiment, the first additional thread  120  weaves between MD thread pairs  10 - 11 ,  12 - 13 , beneath MD threads  14 - 15 , between MD threads  16 - 17 ,  18 - 19 ,  20 - 21 , and then in two repeats of the subrepeat pattern of over two, under one with upper MD threads  22 ,  24 ,  26 ,  28 ,  30 ,  32 . 
     The second additional thread  121  weaves in the mirror image of thread  120 . As shown by FIG. 29, the threads  120  and  121  produce an over two, under one weave pattern on the paper sheet side, relatively long transitions which combine to simulate continuous floats in the mid-plane and crossover points  123 , 124  which encourage migration of the threads relative to each other. As with the prior embodiment, this embodiment provides a weave repeat that includes two repeats of the subrepeat in adjacent paper side longitudinal threads between the transitions from the machine or paper side longitudinal threads. 
     Referring to FIGS. 30-32, a ninth embodiment is shown. The fabric repeats on sixteen MD threads  10 - 25 . Each additional CMD thread  130  and  131  is interwoven in the seam zone  40  with both layers of MD threads  10  through  25 . Additional CMD thread  130  weaves in a repeat pattern that passes over MD threads  10 - 11 , between MD threads  12 - 13 ,  14 - 15 ,  16 - 17 ,  18 - 19 ,  20 - 21 , over MD threads  22 - 23  and under MD threads  24 - 25 . With reference to FIG. 31, the second additional thread  131  is woven in a complementary pattern to that of thread  130 . Thus, CMD thread  131  weaves in a repeat that passes over threads  14 - 15 , under threads  16 - 17 , over threads  18 - 19  and between threads  20 - 21 ,  22 - 23 ,  24 - 25 ,  10 - 11 ,  12 - 13 . 
     The complementary pattern of the repeats can be seen from FIG.  32 . It will be noted from FIG. 32 that the weave repeats of threads  130  and  131  result in a transverse weave repeat that appears as a plain weave on the paper side surface of the fabric. Likewise, the mid-plane float repeat produces what is essentially a continuous float through the mid-plane of the fabric. This is particularly beneficial in two-layer fabric constructions. Finally, the weave repeats result in a single interlacing with the machine side of the fabric for each additional thread  130 ,  131 . 
     With reference to FIGS. 33-35, there is shown a tenth embodiment of the present invention. In this embodiment, the transverse additional thread  140  weaves between MD threads  10 - 11 , under MD threads  12 - 13 , between MD threads  14 - 15 , over MD threads  16 - 17 , between MD thread pairs  18 - 19 ,  20 - 21 ,  22 - 23  and over MD threads  24 - 25 . The additional transverse thread  141  weaves in a complementary pattern. Thread  141  weaves over MD threads  10 - 11 , between MD thread pairs  12 - 13 ,  14 - 15 ,  16 - 17 , over MD threads  18 - 19 , between MD threads  20 - 21 , under MD threads  22 - 23 , and between MD threads  24 - 25 . As can be seen from FIG. 35, these complementary weave patterns produce a sheet side weave pattern with adjacent pairs of plane weave knuckles alternating with pairs of MD threads that float over both of the additional transverse threads  140  and  141 . In additional to producing long continuous mid-plane floats, these complementary patterns also provide for an increase in the thread&#39;s transition length from layer to layer. Accordingly, the threads  140  and  141  will transition under three sheet side MD threads while passing under only one machine side MD thread. Accordingly, this embodiment provides for a single machine side interlacing and long transitions while preserving a virtually continuous mid-plane float. 
     It will be appreciated that batt adhesion will be most improved on the sheet side surface but that some improvement in machine side surface adhesion will result from the presence of the interlacings and relatively long transitions. 
     The additional CMD threads in all embodiments may be multifilament, spun, braided, knitted, or bicomponent. If the thread is of a bicomponent nature, the bicomponent material may have a core material with a higher melting point surrounded by a covering of a lower melting point material. This allows the covering to melt and adhere to the batt material during finishing without affecting the core structure of the thread. Threads may be made from polymeric resins selected from a group consisting of polyamide, polyurethanes, polyesters, polyaramids, polyimides, polyolefins, polyetherketones, polypropylenes, PET, PBT, PTT, phenolics, and copolymers thereof.