Astenjohnson, Inc.

Jwi Ltd.

Ronald H Seabrook

Dale B Johnson

Richard Stone

Rex Barrett

Roger Danby

Derek G Chaplin

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 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.

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Stittsville, Canada

Ronald H Seabrook