Weavexx Corporation

Thomas G Gulya

Hippolit Gstrein

Multi-layer papermaker's fabrics are provided which include flattened bottom fabric cross machine direction yarns that advantageously reduce the void volume and water carry of the fabric. These flattened yarns may be of oval, rectangular or other shape. These fabrics preferably include a relatively large number of cross machine direction yarns on the papermaking surface and/or a papermaking surface having single float machine direction knuckles, so as to provide a high level of fiber support and good papermaking qualities. The fabrics also preferably include good drainage paths between the flattened bottom cross machine direction yarns.

Low caliper multi-layer forming fabrics with machine side cross machine direction yarns having a flattened cross section

A method of forming a papermakers' felt first comprises providing a needle loom having a needle board, a plurality of needles mounted on the needle board, and a needle motion unit. The needle motion unit moves the needle board such that the needles mounted thereon travel on a predetermined path that includes upward and downward segments, wherein each of the upward and downward segments includes both forward and rearward motion. The method then comprises the step of continuously conveying a base fabric and a batt web overlying the base fabric in a first direction past the needle board. The base fabric includes a first set of machine direction yarns and a first set of cross machine direction yarns interwoven with the first set of machine direction yarns in a predetermine repeating pattern, and the batt web comprises batt fibers. The next step of the method is inserting batt fibers from the batt web into the base fabric with the plurality of needles as the base fabric is conveyed past the needle board and as the needle board travels along the predetermined path to form a batt layer attached to and overlying the base fabric. This method can reduce or eliminate negative effects on press felts resulting from needling.

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Raleigh, NC, United States of America

Thomas G Gulya