Astenjohnson, Inc.

Jwi Ltd.

Johnson, Dale B.

Stone, Richard

Dale B Johnson

Richard Stone

Roger Danby

Ronald H Seabrook

Rex Barrett

Girish M Bhatt

James D Harrison

Rick Stone

Derek G Chaplin

A flat woven industrial filtration fabric comprises three layers of weft yarns. A first set of warp yarns interweaves only with paper side layer weft yarns and intermediate weft yarns, and a second set of warp yarns interweaves only with machine side layer weft yarns and the intermediate yarns, the first warp yarns and the second warp yarns interweaving with the same intermediate weft yarns at common turning points. The first warp yarns comprise groups of intrinsic binder yarns forming a single combined path on the paper side surface, and the second warp yarns are woven as individual yarns or in groups, such as pairs or triplets. The distinct nature of the paper side and machine side layers increases the available combinations of weave patterns to optimize the characteristics for each layer, and the distinct centre planes between the three layers provide improved drainage control.

Industrial filtration fabric with high center plane resistance

A triple layer woven industrial fabric, particularly suitable for through-air drying applications, has a paper side (PS) layer and a machine side (MS) layer of polymeric warp and weft yarns woven to a repeat pattern wherein all the warp yarns are arranged as vertically stacked pairs, all the weft yarns comprise pairs of intrinsic weft binder yarns, and each pair of weft yarns forms an unbroken weft path in both the PS layer and the MS layer whereby when either the first or second member of the pair passes from the PS layer to the MS layer, the other member of the pair passes from the MS layer to the PS layer at an exchange point located between at least one common pair of warp yarns.

Triple layer industrial fabric for through-air drying process

Double layer forming fabrics, woven to an overall repeating weave pattern requiring at least 8 sheds in the loom, provide a low drainage area in a notional center plane between the paper and machine side layers, to resist and retard initial impingement drainage. Transverse binder yarn pairs follow a single combined path interweaving with paper side layer and machine side layer yarns, with long internal floats under at least four paper side layer yarns between exchange points and interlacing points in the machine side layer. The members of the pairs are laterally displaced in relation to each other along the single combined path. The fabric has a total warp fill after heatsetting of at least 100%. The drainage areas of the paper side layer and the machine side layers are between 25% and 50%, and the center plane drainage area is between 8% and 20%.

Double layer forming fabric with high center plane resistance

A multilayer through-air dryer (TAD) fabric architecture having a single warp yarn system with a maximum warp fill and a weft yarn system comprised of two sets of weft yarns selected to set the warp yarn height above the weft yarns without embedment into the fabric plane, the warp and weft yarns interlacing to form diagonal apertures within the fabric to produce a high fabric air permeability for providing increased paper sheet bulk without compromising paper machine running parameters. A method of using the TAD fabric of the present invention for forming a paper sheet having increased bulk and a predetermined embossed pattern. Also, a method for manufacturing a TAD fabric to provide increased bulk and a predetermined embossed pattern of the paper sheet.

Multilayer through-air dryer fabric

A double layer forming fabric for a paper making machine is woven to an overall repeating pattern, which comprises in combination paper side layer weft yarns, machine side layer weft yarns, and warp yarns. The paper side layer weft yarns interweave with the warp yarns in a first repeating weave pattern, the machine side layer weft yarns interlace with the warp yarns in a second repeating weave pattern, and the fabric is woven in an overall repeating pattern requiring 3N sheds, in which N is an integer and is at least 2. For each warp yarn, the first repeating weave pattern includes interweaving locations comprising a first and a second interweaving point, each of the interweaving points being separated by an internal warp float of at least two paper side layer weft yarns. For each warp yarn, the second repeating weave pattern includes a series of interlacing points in which each interlaced machine side layer weft yarn also passes substantially below an interweaving location of paper side layer weft yarns and each adjacent warp yarn. In addition, for each warp yarn, each of the first and second interweaving points with a paper side layer weft yarn is separated from an adjacent machine side layer interlacing point by at least two machine side layer weft yarns. The machine side face of the machine side layer includes exposed machine side layer weft yarn floats having a float length L defined as L=3N&#x2212;M, wherein M is an integer and is at least 1.

High support double layer forming fabric

A composite forming fabric woven to a repeating pattern in at least 6 sheds; up to at least 36 sheds can be used. All of the paper side layer warp yarns are pairs of intrinsic warp binder yarns ( ) occupying an unbroken warp path in the paper side surface including three segments. The first and a second are occupied in turn by each intrinsic warp binder yarn ( ), and the third by both intrinsic warp binder yarns ( ) of a pair. The first, second and third segments are separated by at least one paper side layer weft, and a first or second segment is adjacent each end of the third segment. Within each first and second segment, each intrinsic warp binder yarn ( ) also interlaces once with a machine side layer weft ( &prime;), at the same point as a machine side layer warp ( ) interlaces with the same weft ( &prime;). The weave path occupied by each member of a pair of intrinsic warp binder yarns ( ) can be the same or different. The segment lengths can be the same or different, and the machine side layer interlacing points can be regularly or irregularly spaced. After heat setting, the fabrics typically have a warp fill from about 110% to about 140%, an open area of at least 35% in the paper side surface, and an air permeability typically from about 3,500 to about 8,200 m /m /hr. Paper products made using these fabrics have enhanced printability.

Warp-tied composite forming fabric

A flat woven papermaker's forming fabric having a paper side layer and a machine side layer interconnected by pairs of weft binder yarns. Each of the binder yarn pair members in sequence interweaves with a portion of the paper side layer warp yarns in segments of the weft yarn path so as to complete an unbroken weft path in the paper side layer weave pattern, and to provide an internal paper side layer float. Each of the binder yarn pair floats interlaces with a machine side layer warp yarn so as to bind the paper and machine side layers together. To recess the binder yarns from the plane of fabric wear the interlacing point is located at or near the midpoint of an internal float in the machine side layer warp yarn. The number of paper side layer weft yarns located between each of the pairs of intrinsic weft yarns is irregular within one repeat of the overall fabric weave pattern. The location of the paper side layer internal floats also determines the interlacing locations with the machine side layer. A wider choice of possible paper and machine side layer weave design combinations than was previously possible is thus made available in forming fabrics including weft binder yarn pairs, thereby allowing for a better match between the fabric and the paper maker's requirements.

Forming fabric

A forming fabric having a paper side layer and a machine side layer comprises at least two systems of weft yarns and a single set of warp yarn triplets. In the fabric weave pattern, each member of each triplet set of warp yarns interweaves with the paper side weft yarns to occupy in sequence segments of an unbroken warp path in the paper side surface, and the members of each triplet interlace in pairs with single machine side layer weft yarns. Each segment in the unbroken warp path is separated by at least one paper side layer weft yarn. The machine side layer interlacing points can be regularly or irregularly spaced. After heat setting, the fabrics typically have a warp fill from about 105% to about 140%, an open area of at least 35% in the paper side surface, and an air permeability typically from about 3,500 to about 8,200 m,/m,/hr. Paper products made using these fabrics have enhanced printability.

Forming fabric woven with warp triplets

A composite forming fabric, comprising in combination a paper side layer having a paper side surface, a machine side layer and paper side layer intrinsic warp binder yarns. Each of the paper side layer and the machine side layer are woven together in a repeating pattern, and the two layers together are woven in at least 6 sheds, and up to at least 36 sheds can be used. All of the paper side layer warp yarns are provided by pairs of intrinsic warp binder yarns. The paper side layer weave pattern provides an unbroken warp path in the paper side surface including at least two segments, occupied in turn by each intrinsic binder yarn; the segments are separated by at least one paper side layer weft. Within each segment, each intrinsic binder yarn also interlaces once with a machine side layer weft, at the same point as a machine side layer warp interlaces with the same weft. The weave path occupied by each member of a pair of intrinsic warp binder yarns can be the same or different. The segment lengths can be the same or different, and the machine side layer interlacing points can be regularly or irregularly spaced apart. The fabrics as woven and before heat setting conveniently have a warp fill of from about 100% to about 125%. After heat setting, the fabrics typically have a warp fill from about 110% to about 140%, an open area of about 35% or more in the paper side face of the paper side layer, and an air permeability that is typically from about 3,500 to about 8,200 m,/m,/hr. The fabrics are thus particularly suitable for the formation of paper products having very low micro density differences, which provides enhanced printability.

A composite forming fabric in which the woven paper and machine side layers are interconnected by pairs of intrinsic weft binder yarns which interweave with the paper side layer to occupy an unbroken weft path. Each member interweaves sequentially with the warps of the paper side layer and with at least one warp of the machine side layer. Each part of the unbroken weft path is separated from adjacent parts by at least one paper side layer warp yarn. The unbroken weft path is the same, or different, to the weft path of the immediately adjacent paper side layer weft yarns. This arrangement overcomes the paper side layer surface imperfections, which cause an unacceptable level of marking, hitherto associated with the use of intrinsic weft binder yarns in composite fabrics.

Composite papermaking fabric with paired weft binding yarns

This invention discloses a fiber suitable for a papermaker's forming fabric, comprising a blend of 60 to 90% by weight of a polyethylene terephthalate, together with 40 to 10% by weight of a thermoplastic polyurethane, which may be an ester or ether-based type. Additionally, it is contemplated that the blend may contain up to 5% by weight of a hydrolysis stabilizer. The high abrasion resistance of these blended monofilaments makes them particularly advantageous for use in replacing the nylon-6 and nylon-66 monofilaments currently used in paper machine forming fabrics.

Melt-extruded monofilament comprised of a blend of polyethylene

This invention discloses a paper-maker's forming fabric wherein some of the yarns are melt-extruded monofilaments, that are a blend of 60 to 90% by weight of a polyethylene terephthalate, together with 40 to 10% by weight of a thermoplastic polyurethane, which may be an ester or ether-based type, Additionally, it is contemplated that the blend may contain up to 5% by weight of a hydrolysis stabilizer. The high abrasion resistance of these blended monofilaments makes them particularly advantageous for use in replacing the nylon-6 and nylon-66 monofilaments currently used in paper machine forming fabrics.

Paper makers forming fabric

A composite paper making fabric comprising at least two complete weaves each formed by its own set of warp and weft yarns and interconnected by a binder yarn which is interwoven with the two complete weaves. An upper one of the complete weaves constitutes a paper-side weave which is comprised of flattened warp yarns interwoven with its weft yarns.

Growing community of inventors

Ottawa, Canada

Dale B Johnson