Papermaking press felt

Abstract: A base fabric structure and a press felt incorporating that base fabric structure, having at least one set of plied monofilament twist yarns in the cross machine direction. The base fabric structure may be a single base fabric, or it may be a base fabric assembly of more than one separately woven fabric layers, of which one, more than one, or all, have plied monofilament twist yarns in the cross machine direction.

Description: This invention relates to papermakers' fabrics and especially to papermaking felts for the press section of a papermaking machine. In the conventional fourdrinier papermaking process, a water slurry or suspension of cellulose fibres, known as the paper "stock", is fed onto the top of the upper run of a travelling endless forming belt. The forming belt provides a papermaking surface and operates as a filter to separate the cellulosic fibres from the aqueous medium to form a wet paper web. In forming the paper web, the forming belt serves as a filter element to separate the aqueous medium from the cellulosic fibres by providing for the drainage of the aqueous medium through its mesh openings, also known as drainage holes, promoted by vacuum means or the like located on the drainage side of the belt. After leaving the forming medium, the somewhat self-supporting paper web is transferred to the press section of the machine and onto a press felt, where still more of its water content is removed by passing it through a series of pressure nips formed by cooperating press rolls, these press rolls serving to compact the web as well. A press felt, generally, is produced from one or more base fabrics to which is added one or more layers of batt material. Subsequently, the paper web is transferred to a dryer section where it is passed about and held in heat transfer relation with a series of heated, generally cylindrical rolls to remove still further amounts of water therefrom. In general, the press felts in the press section are used in papermaking machinery to support the moist, freshly formed paper web as it encounters a variety of rolls to extract water from the moist paper web. In addition to serving as a support for the moist paper web, the press felt serves as a receptacle for the water removed from the paper sheet. Preferably, the base fabrics for press felts are woven so as to have relatively large open areas or voids which will enhance their water-conveying capabilities. The press felt normally has a conveyer belt-like shape and, during the various operations previously mentioned, a large amount of water is built up in the press felt which is removed by suction or various other drainage devices, usually after the paper web and press felt are no longer in direct contact. In the press section of the machine, it is advantageous to remove as much water as possible from the paper web without causing any damage thereto, such as by crushing. Crushing occurs when an excessive amount of water is removed from the paper web, the excessive water then accumulating at the ingoing side of the nip, not carrying through the nip, and moving in a direction counter to that of the moving paper web. Accordingly, care should be taken to ensure that there is sufficient void volume present in the area of the press nip (either in the papermaking fabric or in the press rolls) such that, as the paper web undergoes compaction and compression, all of the water expressed therefrom will be carried through the nip. A press felt's performance with respect to drainage is affected by its contact area and caliper. The contact area represents the area of the felt that is in contact with the paper sheet in the microscale. In areas of contact between the press felt and paper sheet, mechanical pressure is higher, giving better drainage compared to areas without pressure. The higher the contact area becomes, the better the drainage, as long as the press felt provides enough permeability. Additionally, caliper affects drainage in that reducing the caliper of a fabric means shorter flow channels in the felt. Shorter flow channels will make dewatering performance more efficient. It is also important that the press felt provide a good papermaking surface. Standard in the industry today for production of a base fabric for a press felt is the use of cross machine direction yarns of coarse monofilament twists, for example polyamide (PA) 0.2 x 2 x 2 or PA 0.2 x 2 x 3, or single monofilaments, such as PA 0.2 to PA 0.5. US 4,503,113 discloses an example of cross machine direction yarns of coarse monofilament twists which consist of 0.2mm (0.008 inches) yarns twisted about each other in pairs wherein two of these pairs are then twisted together, i.e. 0.2 x 2x2 multiple plied yarns. It has been found that coarse monofilament twists do not form round-shaped, uniform twists. Accordingly, at the crossings of machine direction yarns and cross machine direction yarns in the fabric, hard knuckles are formed. These knuckles are responsible for non-uniform pressure transfer in the microscale between the felt and the paper sheet. Surface marking and shadow marks are caused by the non-uniform specific pressure in the press nip. On the other hand, it has been determined that single monofilaments are not suitable for use because they do not have flexibility. There are significant limitations on the single monofilament's ability to adapt to demanding press positions where resiliency is required. Other prior art fabrics are known which do not comprise monofilaments. GB Patent No 966741 describes a papermaker's dryer felt in which the yarns are not monofilaments but some of the yarns comprise spun synthetic yarns twisted together with one of more filamentous synthetic yarns. US 4,151,323 discloses a fabric not having monofilament yarns but having weft yarns comprising multiple fibres or filaments. US 3,049,153 discloses a weft yarn that included a nylon core spirally wound with a staple fibre blend. Therefore, one object of the present invention is to provide an improved papermaker's felt for use in the press section of the papermaking machine. Another object of the present invention is to provide an improved papermaker's felt having increased contact area and improved resiliency. Another object of the present invention is to provide an improved dewatering arrangement in the press section of a papermaking machine wherein relatively large quantities of water may be removed from a paper web without crushing or marring the surface thereof, by offering shorter flow channels and low flow resistances. A further object of the present invention is to provide means for increasing the amount of water removed from a paper web in the press section of a papermaking machine. Still another object of the present invention is to provide an improved papermaking press felt which improved water flow and compaction resistance. Additional objects and advantages of this invention will be apparent from the description herein. The present invention provides a base fabric structure for press felts, and a press felt incorporating that base fabric structure for use in the press section of a papermaking machine, the base fabric structure comprising at least one base fabric produced from at least one set of machine direction yarns interwoven with at least one set of cross machine direction yarns characterised in that at least one set of said cross machine direction yarns is a single plied yarn of at least two twisted monofilaments. The base fabric may be a single base fabric or a base fabric assembly comprised of more than one separately woven fabric layers, of which one, more than one, or all, will have plied monofilament twist yarns in the cross machine direction. The weave of the base fabric may be any weave suitable for a base fabric for a press felt. The preferred weave for a base fabric according to the present invention will depend on the application of the finished press felt. It is envisioned that single layer, double layer and triple layer weaves can be used in a base fabric according to the present invention. One skilled in the relative art easily will be able to choose a weave depending on the application of the finished press felt within the concepts of the present invention. For example, to maximise the papermaking surface, weaves with long floats may be used near the papermaking surface of the press felt to improve surface uniformity. One such preferred weave is a 6 harness satin weave. A weave with short floats, like a broken twill, can be incorporated into a base fabric of the present invention to improve compaction resistance, and is especially preferred for fabric layers that will contact the papermaking machinery. When a base fabric according to the present invention comprises a base fabric assembly, in a preferred embodiment, the individual fabric layers of the base fabric layers of the base fabric assembly will be single layer weaves. Again, the selection of the individual fabric layers in a base fabric assembly according to the present invention dependent on the application of the finished press felt is within the skill of those knowledgeable in the relevant art. Base fabric stratification will be planned according to the demands in uniform pressure transfer, void volume and compaction resistance. Yarns selected for use in the base fabric of the present invention may be of materials commonly used in press felt base fabric layers. For example, the yarns could be of cotton, wool, polypropylenes, polyesters, aramides or polyamides. Again, one skilled in the relevant art will select a yarn material according to the particular application of the final composite press felt. The yarns utilised in the base fabric of the present invention may vary depending upon the desired properties of the final composite press felt. In accordance with the concepts of the present invention, at least one set of the cross machine direction yarns in the base fabric or in at least one base fabric of the base fabric assembly will be plied monofilament twists. As is well known to those skilled in the art, a plied yarn is one in which two or more single yarns are twisted together. The plied monofilament of the present invention will be more than one monofilament turned to a single twist. The plied monofilament twist yarns utilised in the cross machine direction for the base fabric according to the present invention will preferably have a single monofilament diameter ranging from approximately 0.1 mm to approximately 0.3 mm. The most preferred plied monofilament twist yarns for use in the cross machine direction of a base fabric according to the present invention are polyamide monofilament twists. The preferred polyamide monofilament twists are monofilament yarns, generally 0.1 mm or 0.2 mm in diameter, used two ply or three ply. The remaining yarns in the base fabric may be multifilament yarns, monofilament yarns, twisted multifilament and/or monofilament yarns, spun yarns or any combination of these yarns. It is within the skill of those practising in the relevant art to select a yarn type, depending on the purpose of the desired press felt, for utilisation with the concepts of the present invention. To form a press felt incorporating the base fabric structure of the present invention, typically one or more batt layers will be assembled with the one or more base fabrics and subsequently needled thereto. Usually, a layer of batt material will be positioned on the side of the to-be-formed press felt that will contact the paper web. Additionally, one or more layers of batt material may be inserted on the machine-contacting surface of the to-be-formed press felt. The batt material may be made up of fibres formed from any of the well known natural or synthetic fibres which are commonly used for this purpose, including animal fibres such as wool and synthetic fibres such as polyacrylics e.g. 'Orlon', polyesters e.g. 'Dacron', and polyamides e.g. 'Nylon'. The batt layer(s) may be needled to the base fabric(s) in a conventional manner. In the needling process, assembled base fabric layers are joined together as well. The invention will now be described, by way of example only, with reference to the accompanying drawings, in which Figure 1 to Figure 5 each shows a separate embodiment of a base fabric in accordance with the invention and Figure 6 shows an embodiment of a press felt in accordance with the invention, in diagrammatic cross-section. Figure 1 illustrates a base fabric 10 which is a single layer weave of interwoven cross machine direction yarns 12 and machine direction yarns 14 having long floats on the papermaking surface of the base fabric. In the cross machine direction, two monofilaments 11 of polyamide 0.2 are used, twisted together to produce each cross machine direction plied monofilament twist yarn 12. Figure 2 illustrates a base fabric 20 which is a dual layer weave, by which is meant a fabric having two sets of machine direction yarns 24,25 with one set of cross machine direction yarns 22 interweaving them. The cross machine direction yarns 22 are plied monofilament twist yarns produced from three monofilaments 21 of polyamide 0.2, twisted together. Figure 3 illustrates a preferred embodiment, in which a base fabric 30 is an assembly of two fabric layers 31,32. Each fabric layer 31,32 is a single layer weave and is made of interwoven cross machine direction yarns 35 and machine direction yarns 34. In each fabric layer 31,32, the cross machine direction plied monofilament twist yarns 35 are made from three individual monofilaments 36 twisted together. Figure 4 illustrates a further embodiment of a base fabric 40 produced from an assembly of two fabric layers 42,44. In this embodiment, however, one fabric layer 44 is a dual layer weave having two sets of machine direction yarns 47,48 while the other fabric layer 42 is a single layer weave incorporating machine direction yarns 43. In both fabric layers 42,44, the cross machine direction plied monofilament twist yarns 45,47 comprise three individual monofilaments 46,41 twisted together. Figure 5 illustrates another preferred embodiment, in which a base fabric 50 is an assembly of three fabric layers 52,54,56, each being a single layer weave. In each fabric layer, the cross machine direction plied monofilament twist yarns 51,53,55 comprise two individual monofilaments 51a,53a,55a twisted together. Figure 6 illustrates a press felt 60 wherein a base fabric 20 as shown in Figure 2 is assembled with a layer of batt material 61 on its papermaking surface and the assembled structure is needled together in one or more needling operations. It is within the knowledge of one skilled in the art to select the number of and weaves for the one or more base fabrics to be included in a press felt according to concepts of the present invention. An advantage of the press felt described herein is that the different yarn systems facing each other provide more equal pressure support in the press nip. In addition, a better balancing of water flow and compaction resistance is achieved because the fabrics adapt to pressure transfer and porosity more easily. The application of the concept of multiple base fabric layers offers the possibility to select fabric layers to optimise the performance characteristics for the different requirements needed of the felt. To ensure a uniform pressure transfer, high water-permeability and good compaction resistance, for example, a dense machine direction oriented top fabric layer with long machine direction floats will be chosen. In addition, a coarser cross machine direction oriented bottom fabric layer will ensure good abrasion resistance and wear resistance of the felt. Moreover, the fact that there can be at least two fabric layers ensures a good compaction resistance and increases the permeability of the felt. The use of long machine direction or cross machine direction floats on the top surface of the intermediate and bottom layers provides support and maintains the individual desired characteristics of the separate fabric layers. While preferred embodiments of the invention have been described and illustrated, it will be understood that modifications may be made in the invention.

Claims: A base fabric structure for a press felt for a papermaking machine, comprising at least one base fabric (10, 20, 30, 40, 50) produced from at least one set of machine direction yarns (14, 24, 25, 34, 47, 48, 43) interwoven with at least one set of cross machine direction yarns (12, 22, 35, 45, 47, 51, 53, 55) characterised in that at least one set of said cross machine direction yarns is a single plied yarn of at least two twisted monofilaments (11, 21, 36, 46, 41, 51a, 53a, 55a). A base fabric structure according to claim 1 wherein the plied yarn comprises two monofilaments (11, 21, 36, 46, 41, 51a, 53a, 55a)twisted together. A base fabric structure according to claim 1 wherein the plied yarn comprises three monofilaments (11, 21, 36, 46, 41, 51a, 53a, 55a) twisted together. A base fabric structure according to any preceding claim comprising at least one said base fabric which is a single layer weave (10). A base fabric structure according to any preceding claim comprising at least one said base fabric which is a dual layer weave (20). A base fabric structure according to any preceding claim comprising one said base fabric. A base fabric structure according to one of claims 1 to 5 comprising an assembly of two said base fabrics (31, 32) each of which is a single layer weave. A base fabric structure according to one of claims 1 to 5 comprising an assembly of two said base fabrics, being a single layer weave (42) positioned above and adjacent to a dual layer weave (44). A base fabric structure according to claim 7 or claim 8 wherein the plied yarns in each base fabric are three monofilaments (21, 36, 46, 41) twisted together. A base fabric structure according to any one of claims 1 to 5 comprising an assembly of three said base fabrics (52, 54, 56), each of which is a single layer weave. A base fabric structure according to claim 10 wherein the plied yarns in each base fabric are two monofilaments (51a, 52a, 53a) twisted together. A press felt (60) for a papermaking machine comprising a base fabric structure according to any preceding claim and at least one layer of batt material (61) positioned adjacent to said at least one base fabric and needled thereto.

Inventors: GSTREIN HIPPOLIT, GSTREIN, HIPPOLIT
Applicants: HUYCK LICENSCO INC, HUYCK LICENSCO, INC.
Application year: 1996
Main classification: D21F7
IPC codes: D21F7