Industrial textile

An industrial textile has a double warp. Yarns (111, 112) of a first warp and yarns (131, 132, 133, 134) of a weft are bonded to each other according to a first predetermined pattern, and yarns (121, 122) of a second warp and the yarns (131, 132, 133, 134) of the weft are bonded to each other according to a second predetermined pattern. The first predetermined pattern and the second predetermined pattern form a textile structure, which includes the yarns (131, 132) of the weft on a first level (L1) and the yarns (133, 134) of the weft on a second level (L2). The yarns of the weft having smaller diameter are configured to alternate with yarns of the weft having a larger diameter on the first level (L1).

CROSS REFERENCES TO RELATED APPLICATIONS

This application claims priority on Finnish Application No. 20216031, filed Oct. 6, 2021, the disclosure of which is incorporated by reference herein.

Not applicable.

BACKGROUND OF THE INVENTION

The present invention relates to industrial textiles, particularly industrial textiles used as conveyor fabrics, dryer fabrics or filter fabrics.

A conveyor fabric can be used to transport paper mass, paper web or board web to a pulper or cake to a cellulose dryer. The conveyor fabric has a first surface and a second surface. The first surface is in contact with paper mass or cake, when the conveyor fabric is assembled to a conveyor. The second surface is in contact with a conveyor equipment when the conveyor fabric is assembled to the conveyor. The first side should have a coarse surface texture to provide high friction and grip for carrying paper mass or cake also upward. The second side should have a relative smooth surface to provide good wear resistance and performance. When extra grip is needed, the conveyor fabric can be equipped with silicon stripes. The silicon stripes are formed in a cross-machine direction of the conveyor fabric.

However, the silicon stripe treatment is very time consuming. First, it bonds the labor force for hours for making silicon stripes. Secondly, drying of the silicon stripes takes several hours. In addition, when the fabric is drying, it takes up a lot of floor space for several hours.

EP3601665 B1 discloses an industrial textile having a granular texture on the first surface. However, the industrial textile has a substantially even surface topography with relatively small waviness. The industrial textile has relatively high contact surface area. Thus, material, such as dirt, on the first surface does not easily stick to the surface.

Therefore, there is need for improving industrial textiles, particularly developing alternatives to the silicone stripes.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention, there is provided an industrial textile having a machine direction and a cross-machine direction, and a first surface and a second surface, the industrial textile comprising a double warp comprising a first warp comprising first machine direction yarns, and a second warp comprising second machine direction yarns, the yarns of the first warp being arranged above the yarns of the second warp, a weft comprising cross-machine direction yarns, the yarns of the first warp and the yarns of the weft being bonded to each other according to a first predetermined pattern, the yarns of the second warp and the yarns of the weft being bonded to each other according to a second predetermined pattern, and the first predetermined pattern and the second predetermined pattern forming a textile structure, which comprises the yarns of the weft on a first level and the yarns of the weft on a second level in a thickness direction of the industrial textile, wherein yarns of the weft having smaller diameter are configured to alternate with yarns of the weft having larger diameter on the first level.

According to an embodiment, every second, third or fourth yarn of the weft on the first level has a larger diameter than the other yarns of the weft on the first level.

According to an embodiment, the yarns of the weft having a smaller diameter are configured to alternate with the yarns of the weft having a larger diameter on the second level.

According to an embodiment, the industrial textile has one yarn of the weft having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the first level, and one yarn of the weft having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the second level, one yarn of the weft having a smaller diameter and one yarn of the weft having a larger diameter in a pattern repeat on the second level, or every yarn of the weft on the second level has the same diameter, which diameter is smaller than the diameter of the larger yarns of the wefts on the first level.

According to an embodiment, the industrial textile has one yarn of the weft having a larger diameter and two yarns of the weft having a smaller diameter in a pattern repeat on the first level, and one yarn of the weft having a smaller diameter, one yarn of the weft having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the second level, or one yarn of the weft having a larger diameter and two yarns of the wefts having a smaller diameter in a pattern repeat on the second level.

According to an embodiment, the industrial textile has one yarn of the weft having a larger diameter and three yarns of the weft having a smaller diameter in a pattern repeat on the first level, and one yarn of the weft having a smaller diameter, two yarns of the wefts having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the second level.

According to an embodiment, the industrial textile has one yarn of the weft having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the first level, and one yarn of the weft having a smaller diameter, one yarn of the weft having a larger diameter and two yarns of the weft having smaller diameters in a pattern repeat on the second level.

According to an embodiment, the diameters of the yarns of the weft having a larger diameter are 0.2 mm greater than the diameters of the yarns of the weft having smaller diameters.

According to an embodiment, in the first predetermined pattern, the yarns of the first warp are configured to bind the yarns of the weft under two and over two yarns of the weft.

According to an embodiment, in the second predetermined pattern, the yarns of the second warp are configured to bond the yarns of the weft under three yarns and over one yarn of the weft.

According to an embodiment, the yarns of the first warp next to each other are arranged in such a manner that when a coincidentally selected warp yarn is under the weft yarns, the warp yarn next to the coincidentally selected warp yarn is above the weft yarn.

According to an embodiment, the yarns of the second warp next to each other are arranged in such a manner that when a coincidentally selected warp yarn is under the weft yarn, the warp yarn next to the coincidentally selected warp yarn is above the weft yarn.

According to an embodiment, a coincidentally selected yarn of the first warp and the yarn of the second warp are arranged in such a manner that when the yarn of the first warp binds the yarns of the weft under two, the yarn of the second warp binds the yarns of the weft under two, and a yarn of the first warp next to the coincidentally selected warp yarn of the first warp and a yarn of the second warp next to the coincidentally selected warp yarn are arranged in such manner that when the yarn of the first warp binds the yarns of the weft over two, the yarn of the second warp binds the yarns of the weft over one and under one.

According to an embodiment, the industrial textile has a contact area under 20%.

According to an embodiment, said contact area being measured by a method comprising providing a sample of the industrial textile having a length of 130 mm in the machine direction and a width of 20 mm in the cross-machine direction, polishing the paper-side of the sample by removing 0.12 mm in a thickness direction of the sample, photographing the sample by a microscope camera, calibrating magnification by a calibration ruler, imaging the calibration ruler and the polished surface of the sample with the calibrated magnification, and measuring the percentage of the contact area by an image processing software.

According to an embodiment, the industrial textile comprises a first edge and a second edge, which first edge and second edge are configured to be connected together by a seam element, which comprises a first part connected to the first edge and a second part connected to the second edge.

According to an embodiment, inner surfaces of the first part and inner surfaces of the second part of the seam element are shaped to correspond to a surface texture of the industrial textile.

According to an embodiment, the inner surfaces of the first part and the inner surfaces of the second part of the seam element comprise teeth configured to be attached to the industrial textile.

According to a second aspect of the present invention, there is provided use of an industrial textile as a conveyor fabric, a dryer fabric or a filter fabric.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the present context, the term “first side” refers to a side of an industrial textile, which side is in contact with a paper mass or cake, when the industrial fabric is assembled to a conveyor.

In the present context, the term “second side” refers to a side of an industrial textile, which side is in contact with a conveyor equipment, when the industrial fabric is assembled to the conveyor.

In the present context, the term “machine direction” refers to a moving direction or a first direction of the industrial textile in the paper, board or tissue machine when the textile is assembled to the paper, board or tissue machine.

In the present context, the term “cross-machine direction” refers to a direction which is perpendicular to the moving direction or the first direction of the industrial textile in the paper, board or tissue machine when the textile is assembled to the paper, board or tissue machine.

When extra grip is needed, the conveyor fabric can be equipped with silicon stripes. The silicon stripe treatment is very time consuming and binds labor force. At least some of the present embodiments solve the abovementioned problems.

According to an embodiment, the industrial textile100has a machine direction (MD) and a cross-machine direction (CMD), and a first surface101and a second surface102. The industrial textile comprises a double warp comprising a first warp comprising first machine direction yarns111,112, and a second warp comprising second machine direction yarns121,122. The yarns111,112of the first warp are arranged above the yarns121,122of the second warp. The industrial textile further comprises a weft comprising cross-machine direction yarns131,132,133,134. The double warp comprising the overlapping warp yarns makes the textile strong and resistant against wear. The yarns111,112of the first warp and the yarns131,132,133,134of the weft are bonded to each other according to a first predetermined pattern. The yarns121,122of the second warp and the yarns131,132,133,134of the weft are bonded to each other according to a second predetermined pattern. The first predetermined pattern and the second predetermined pattern form a textile structure, which comprises the cross-machine direction yarns on a first level and the cross-machine direction yarns on a second level in a thickness direction of the industrial textile100. Yarns of the weft having a smaller diameter are configured to alternate with yarns of the weft having a larger diameter on the first level. This enables a coarse textured structure on the first side of the industrial textile. Higher peaks and lower valleys are formed in the industrial textile in a thickness direction of the industrial textile. The coarse structure provides more friction and grip to carry paper mass or cake. Thanks to the coarse structure, paper mass or cake can be also carried upwards. In addition, a time-consuming silicon stripe treatment can be avoided.

The industrial textile100comprises a first edge103and a second edge104. The first edge103and the second edge104can be connected together to form a loop.

According to an embodiment, in the first predetermined pattern, the yarns111,112of the first warp are configured to bind the yarns131,132,133,134of the weft under two131,132and over two yarns133,134of the weft.

According to an embodiment, in the second predetermined pattern, the yarns121,122of the second warp are configured to bond the yarns131,132,133,134of the weft under three yarns131,132,134and over one yarn133of the weft.

FIG.1Aillustrates a cross section of an industrial textile100in a machine direction in accordance with at least some embodiments. The industrial textile100comprises the yarns111,112of the first warp, the yarns121,122of the second warp and the yarns131,132,133,134of the weft. The yarns111,112of the first warp are arranged above the yarns121,122of the second warp. The yarn111of the first warp and the yarn121of the second warp are configured to form a first row of the industrial textile100, and the yarn112of the first warp and the yarn122of the second warp are configured to form a second row of the industrial textile100.

FIG.1Billustrates a cross section of the yarns131,132,133,134of the weft and the yarn112of the first warp in a machine direction in accordance with at least some embodiments. The yarn112of the first warp forming the second row of the industrial textile100is configured to bind the yarns131,132,133,134of the weft under two131,132and over two yarns133,134of the weft.

FIG.1Cillustrates a cross section of the yarns131,132,133,134of the weft and the yarn122of the second warp in a machine direction in accordance with at least some embodiments. The yarn122of the second warp forming the second row of the industrial textile100is configured to bind the yarns131,132,133,134of the weft under three131,132,133and over one yarn134of the weft.

FIG.1Dillustrates a cross section of yarns of a weft and a yarn of a first warp in a machine direction in accordance with at least some embodiments. The yarn111of the first warp forming the first row of the industrial textile100is configured to bind the yarns131,132,133,134of the weft over two131,132and under two yarns133,134of the weft.

FIG.1Eillustrates a cross section of yarns of a weft and a yarn of a second warp in a machine direction in accordance with at least some embodiments. The yarn121of the second warp forming the first row of the industrial textile100is configured to bind the yarns131,132,133,134of the weft over one yarn and under three yarns of the weft.

FIG.2Aillustrates a cross section of an industrial textile in a machine direction. The industrial textile100comprises the yarns111,112of the first warp, the yarns121,122of the second warp and the yarns131,132,133,134of the weft. The yarns111,112of the first warp are arranged above the yarns121,122of the second warp. The yarn111of the first warp and the yarn121of the second warp are configured to form a first row of the industrial textile100, and the yarn112of the first warp and the yarn122of the second warp are configured to form a second row of the industrial textile100.

FIG.2Billustrates a cross section of the yarns131,132,133,134of the weft and the yarn112of a first warp in a machine direction in accordance with at least some embodiments. The yarn112of the first warp forming the second row of the industrial textile100is configured to bind the yarns131,132,133,134of the weft over two131,132and under two yarns133,134of the weft.

FIG.2Cillustrates a cross section of the yarns131,132,133,134of the weft and the yarn122of the second warp in a machine direction in accordance with at least some embodiments. The yarn122of the second warp forming the second row of the industrial textile100is configured to bind the yarns131,132,133,134of the weft over one131and under three yarns132,133,134of the weft.

FIG.2Dillustrates a cross section of the yarns of the weft131,132,133,134and the yarn of the first warp in a machine direction in accordance with at least some embodiments. The yarn111of the first warp forming the first row of the industrial textile100is configured to bind the yarns131,132,133,134of the weft under two131,132and over two yarns133,134of the weft.

FIG.2Eillustrates a cross section of the yarns of the weft131,132,133,134and the yarn121of the second warp in a machine direction in accordance with at least some embodiments. The yarn121of the second warp forming the first row of the industrial textile100is configured to bind the yarns131,132,133,134of the weft under three yarns and over one yarn of the weft.

The industrial textile can comprise the yarns of the weft having two to four different diameters. Preferably, there are the yarns of the weft having two different diameters.

According to an embodiment, every second, third or fourth yarn of the weft on the first level L1has a larger diameter than the other yarns of the weft on the first level L1. This enables a coarse structure on the first side of the industrial textile.

According to an embodiment, the yarns of the weft having smaller diameter are configured to alternate with the yarns of the weft having larger diameter on the second level L2.

According to an embodiment, the industrial textile100has one yarn of the weft having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the first level. In addition, the industrial textile100has one yarn of the weft having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the second level, one yarn of the weft having a smaller diameter and one yarn of the weft having a larger diameter in a pattern repeat on the second level, or every yarn of the weft on the second level has the same diameter, which diameter is smaller than the diameter of the larger yarns of the wefts on the first level. This enables a coarse structure on the first side and a relative smooth structure on the second side of the industrial textile.

According to an embodiment, the industrial textile100has one yarn of the weft having a larger diameter and two yarns of the weft having a smaller diameter in a pattern repeat on the first level. In addition, the industrial textile has one yarn of the weft having a smaller diameter, one yarn of the weft having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the second level, or one yarn of the weft having a larger diameter and two yarns of the wefts having a smaller diameter in a pattern repeat on the second level. This enables a coarse structure on the first side and a relative smooth structure on the second side of the industrial textile.

According to an embodiment, the industrial textile100has one yarn of the weft having a larger diameter and three yarns of the weft having a smaller diameter in a pattern repeat on the first level. In addition, the industrial textile has one yarn of the weft having a smaller diameter, two yarns of the wefts having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the second level. This enables a coarse structure on the first side and a relative smooth structure on the second side of the industrial textile.

According to an embodiment, the industrial textile100has one yarn of the weft having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the first level. In addition, the industrial textile has one yarn of the weft having a smaller diameter, one yarn of the weft having a larger diameter and two yarns of the weft having smaller diameters in a pattern repeat on the second level. This enables a coarse structure on the first side and a relative smooth structure on the second side of the industrial textile.

FIGS.3A to3Gillustrate sizes of yarns of a weft on a first level and a second level of an industrial textile in accordance with at least some embodiments. The yarns of the weft with a larger diameter alternate with the yarns of the weft with a smaller diameter in a pattern repeat.

FIG.3Aillustrates that every second yarn of the weft on the first level has a larger diameter than the other yarns of the weft on the first level. Thus, there is one yarn of the weft having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the first level. Every second yarn of the weft on the second level has a larger diameter than the other yarns of the weft on the second level. Thus, there is one yarn of the weft having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the second level.

FIG.3Billustrates that every second yarn of the weft on the first level has a larger diameter than the other yarns of the wefts on the first level. Thus, there is one yarn of the weft having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the first level. Every second yarn of the weft on the second level has a larger diameter than the other yarn of the wefts on the second level. Thus, there is one yarn of the weft having a smaller diameter and one yarn of the weft having a larger diameter in a pattern repeat on the second level.

FIG.3Cillustrates that every second yarn of the weft on the first level has a larger diameter than the other yarns of the weft on the first level. Thus, there is one yarn of the weft having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the first level. Every yarn of the weft on the second level has the same diameter, which diameter is smaller than the diameter of the larger yarn of the wefts on the first level.

FIG.3Dillustrates that every third yarn of the weft on the first level has a larger diameter than the other yarns of the weft on the first level. Thus, there is one yarn of the weft having a larger diameter and two yarns of the wefts having smaller diameter in a pattern repeat on the first level. Every third yarn of the weft on the second level has a larger diameter than the other yarn of the wefts on the second level. Thus, there is one yarn of the weft having a smaller diameter, one yarn of the weft having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the second level.

FIG.3Eillustrates that every third yarn of the weft on the first level has a larger diameter than the other yarns of the weft on the first level. Thus, there is one yarn of the weft having a larger diameter and two yarns of the wefts having a smaller diameter in a pattern repeat on the first level. Every third yarn of the weft on the second level has a larger diameter than the other yarn of the wefts on the second level. Thus, there is one yarn of the weft having a larger diameter and two yarns of the wefts having a smaller diameter in a pattern repeat on the second level.

FIG.3Fillustrates that every fourth yarn of the weft on the first level has a larger diameter than the other yarns of the weft on the first level. Thus, there is one yarn of the weft having a larger diameter and three yarns of the weft having a smaller diameter in a pattern repeat on the first level. There is one yarn of the weft having a smaller diameter, two yarns of the wefts having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the second level.

FIG.3Gillustrates that every second yarn of the weft on the first level has a larger diameter than the other yarns of the weft on the first level. Thus, there is one yarn of the weft having a larger diameter and one yarn of the weft having a smaller diameter in a pattern repeat on the first level. Every fourth yarn of the weft on the second level has a larger diameter than the other yarn of the wefts on the second level. Thus, there is one yarn of the weft having a smaller diameter, one yarn of the weft having a larger diameter and two yarns of the weft having smaller diameters in a pattern repeat on the second level.

The diameters of the yarns of the weft having the larger diameter are 0.2 mm greater than the diameters of the yarns of the weft having the smaller diameter. Thus, the diameters of the yarns of the weft differ from each other to form a textured textile surface.

The diameters of the yarns of the weft having smaller diameters can be for example, under 0.6 mm, preferably 0.4-0.6 mm, more preferably 0.5 mm.

The diameters of the yarns of the weft having larger diameters can be for example, over 0.6 mm, preferably 0.6-0.9 mm, more preferably 0.7 mm.

FIG.4illustrates a surface view of an industrial textile in accordance with at least some embodiments. The yarns111,112of the first warp next to each other are arranged in such a manner that when a coincidentally selected warp yarn111is under the weft yarns, the warp yarn112next to the coincidentally selected warp111yarn is above the weft yarns. Furthermore, the yarns121,122of the second warp next to each other are arranged in such a manner that when a coincidentally selected warp yarn121is under the weft yarn, the warp yarn122next to the coincidentally selected warp121yarn is above the weft yarn.

FIG.5illustrates a weaving pattern of an industrial textile in accordance with at least some embodiments. FW refers to a first warp of the industrial textile and SW refers to a second warp of the industrial textile. X denotes that the yarn of the first warp of the second warp is over a yarn of a weft. Numbers 1 to 8 refers to the warps 1 to 8. A coincidentally selected yarn of the first warp and the yarn of the second warp are arranged in such a manner that when the yarn of the first warp binds the yarns of the weft under two, the yarn of the second warp binds the yarns of the weft under two. In addition, a yarn of the first warp next to the coincidentally selected warp yarn of the first warp and a yarn of the second warp next to the coincidentally selected warp yarn are arranged in such manner that when the yarn of the first warp binds the yarns of the weft over two, the yarn of the second warp binds the yarns of the weft over one and under one.

Referring toFIG.5, diameters of the yarns of the weft which the warp number 1 binds can be for example, 0.50 mm. Diameters of the yarns of the weft which the warp number 2 binds can be for example, 0.50 mm, diameters of the yarns of the weft which the warp number 3 bind can be for example, 0.70 mm, diameters of the yarns of the weft which the warp number 4 bind can be for example, 0.50 mm, diameters of the yarns of the weft which the warp number 5 bind can be for example, 0.70 mm, diameters of the yarns of the weft which the warp number 6 bind can be for example, 0.50 mm, diameters of the yarns of the weft which the warp number 7 bind can be for example, 0.50 mm, and diameters of the yarns of the weft which the warp number 8 bind can be for example, 0.70 mm. This enables a coarse textured structure on the first side of the industrial textile.

FIG.6illustrates a contact area of an industrial textile in accordance with at least some embodiments. There is higher peaks (white areas) and lower valleys in a thickness direction of the industrial textile.

According to an embodiment, the contact area can be under 20%.

The contact area is measured by a method comprising providing a sample of the industrial textile having a length of 130 mm in the machine direction and a width of 20 mm in the cross-machine direction, polishing the paper-side of the sample by removing 0.12 mm in a thickness direction of the sample, photographing the sample by a microscope camera, calibrating magnification by a calibration ruler, imaging the calibration ruler and the polished surface of the sample with the calibrated magnification, and measuring percentage of the contact area by an image processing software. An image area is 12 mm in the cross-machine direction.

According to an embodiment, the first machine direction yarns111,112of the first warp are flat yarns.

According to an embodiment, the second machine direction yarns121,122of the second warp are flat yarns.

According to an embodiment, the cross-machine direction yarns131,132,133,134of the weft are round yarns. However, also oval yarns can be used.

FIG.7illustrates a seam element140in accordance with at least some embodiments. The industrial textile100comprises a first edge103and a second edge104, which the first edge103and the second edge104are configured to be connected together by the seam element140. The seam element comprises a first part141connected to the first edge103and a second part142connected to the second edge104. The granular surface of the industrial textile enables better grip of the seam element on the textile surface. Thus, strength of the seam is higher.

FIG.7illustrates that the first part141and the second part142of the seam element140have inner surfaces, which are arranged in the contact with the industrial textile100. The inner surface of the first part141and the inner surface of the second part142of the seam element140are shaped to correspond to a surface texture of the industrial textile100. The granular surface of the industrial textile with the shaped inner surface of the parts of the seam element enables better grip of the seam element on the textile surface. Thus, the strength of the seam is higher, because the seam element does not slide out of its place during the use of the industrial textile.

Alternatively, the inner surface of the first part141and the inner surface of the second part142of the seam element can comprise teeth configured to be attached to the industrial textile100. The teeth can be configured to be attached to the lower valleys of the industrial textile.

According to an embodiment, the industrial textile100is used as a conveyor fabric, a dryer fabric or a filter fabric.

Reference throughout this specification to “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrase “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment.

The verb “to comprise” is used in this document as open limitations that neither exclude nor require the existence of also un-recited features. The features recited in depending claims are mutually freely combinable unless otherwise explicitly stated. Furthermore, it is to be understood that the use of “a” or “an”, i.e., a singular form, throughout this document does not exclude a plurality.