Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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INDUSTRIAL TWO-LAYER FABRIC
[TECHNICAL FIELD]
[0001] The present invention relates to a new industrial
two-layer fabric that has a thin net thickness, is excellent
in rigidity, wear resistance, dewaterability, and mark
suppression, and can be used in a high-speed paper machine.
In particular, the present invention relates to an industrial
two-layer fabric that has a flat yarn structure due to the
formation of an upper-surface-side fabric by a combination of
a warp rib weave structure of two upper-surface-side warps
and a flat warp and that further achieves slow dewatering and
low water retention effects due to a warp binding arrangement.
[BACKGROUND ART]
[0002] Traditionally, fabrics made of warp and weft have
been widely used as industrial fabrics. For example, the
fabrics include fabrics for paper manufacturing, conveying
belts, filter cloths, etc., and are each required to have
fabric characteristics suitable for their application and
usage environment. Of these fabrics, the demand for fabrics
for papermaking used in a papermaking process of, e.g.,
dewatering materials using the mesh of the fabrics is
particularly strict. For example, there is a demand for
fabrics that show excellent surface smoothness that prevents
wire marks of the fabrics from easily transferred to paper,
that have dewaterability for sufficiently and uniformly
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dewatering excess water contained in the materials and
rigidity and wear resistance that allow the fabrics to be
suitably used even in a harsh environment, and that can
maintain conditions necessary for producing better paper for
a long period of time. In addition, fiber supporting
properties, improvement in yield in paper manufacturing,
dimensional stability, running stability, etc., are required.
Furthermore, since the speed of papermaking machines has
increased in recent years, the demand for fabrics for
papermaking has become even stricter.
[0003] Taking, as an example, fabrics for papermaking
for which the demand is the strictest among industrial
fabrics, mark suppression by particularly excellent
dewaterability and surface smoothness is required with the
recent increase in the speed of paper machines. Although
dewaterability characteristics that are required differ
depending on paper machines and sheeted products,
dewaterability for uniform dewatering is an essential
condition for any sheeted product. Further, in recent years,
the use of used paper has increased, and a large amount of
fine fibers are mixed, resulting in insufficient dewatering.
Thus, sufficient and uniform dewatering is more important,
and it is becoming more difficult to satisfy the required
characteristics for fabrics for papermaking. Further, there
is also a demand for low water retention that reduces the
amount of water retained by industrial fabrics in their
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spaces during dewatering (hereinafter referred to as "the
amount of water retained"). For example, by reducing the net
thickness, the amount of water retained can be reduced.
Therefore, the diameter of the warp is simply reduced to
reduce the net thickness. However, in such a case, the mesh
becomes coarse, the rigidity due to the mesh strength
decreases, and an excessive mesh space is generated. As a
result, the material does not stay on the fabric and falls
off, causing a decrease in yield. Further, a layer of fibers
(hereinafter referred to as "initial mat") is formed on the
fabric by dewatering when the material is discharged onto the
fabric (hereinafter referred to as "initial dewatering").
When the dewatering speed of the fabric is high, for example,
the mesh of the fabric becomes clogged with the fibers,
resulting in the formation of a strong initial mat. A strong
initial mat clogs the mesh of the fabric before the
dewatering of the material is completed. Thus, the
subsequent dewatering becomes incomplete and causes poor
dewatering, which is, e.g., the cause for the worsening of
the texture of the paper. Therefore, the dewatering
performance is unstable. The dewatering speed of the fabric
is determined by the influence of the surface of the fabric,
the space inside thereof, etc. In particular, an industrial
fabric having a triple-woven structure in which the upper-
surface-side fabric and the lower-surface-side fabric are
bonded with a binding yarn has a high dewatering speed.
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Therefore, the dewatering speed is restrained by setting the
weft density to be high in order to suppress the initial
dewatering. However, when a strong initial mat is formed, a
more significant decrease in dewaterability occurs.
[0004] Meanwhile, fabrics having good dewaterability
include industrial two-layer fabrics or the like in which
dewatering holes are formed penetrating from the upper
surface side to the lower surface side. In particular, as
fabrics for the purpose of satisfying the surface property,
fiber supportability, and dewaterability required for
industrial two-layer fabrics, industrial two-layer fabrics
are known that use warp binding yarns that are woven with
upper-surface-side wefts and lower-surface-side wefts forming
upper-surface-side warp structures and lower-surface-side
warp structures. Patent Document 1 shows a two-layer fabric
using warp binding yarns. Such a conventional technology
represents a two-layer fabric in which a part of the warps
functions as binding yarns that allow an upper-surface-side
layer and a lower-surface-side layer to be interwoven, and
the paired warp binding yarns complement the upper-surface-
side warp structure and the lower-surface-side warp structure
so as to form the respective surface structures, allowing the
fabric to be excellent in surface properties and binding
strength. However, it is necessary to break knuckles at a
part of the structures so as to achieve binding, and it is
thus essential to complement the knuckles at such a part
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using another warp. It is known that since intersections
appear continuously between adjacent warps, dewatering
resistance occurs that is likely to cause marks on the paper
at this time.
5 [0005] Further, for the purpose of uniform dewatering,
an industrial two-layer fabric in which a set consisting of
an upper-surface-side warp and a warp binding yarn is
arranged is shown in cited document 2. In this fabric, a
uniform structure is formed on the surface by combining
upper-surface-side knuckles and the upper-surface-side warp
structure of the warp binding yarn that weaves the upper and
lower surfaces together. In this fabric, the two warps work
together to form the structure of a single warp on the
surface, and there is thus no collapsing of the structure.
However, the structure of one or both of the warps must be
collapsed, forming intersections when going back and forth
between the upper and lower surface sides, and the warps,
being a combination of two warps, are arranged as a single
warp. However, since the two warps are not overlapped on the
line of a single warp and are lined up side by side, the warp
binding yarn may block the mesh near the weaving of the
upper-surface-side weft, and the dewaterability
characteristics of the wire may be partially changed giving
marks to the paper. Further, in such an industrial two-layer
fabric, dewaterability is good since dewatering holes that
completely penetrate from the upper-surface-side layer to the
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lower-surface-side layer are arranged on the entire surface.
However, due to strong vacuum or the like, the sheet material
on the wire may stick into the fabric, and the fibers, filler,
etc., may come off, causing dewatering marks to be created
noticeably. Further, in conventional industrial two-layer
fabrics, an on-stack structure may be adopted in order to
improve the dewaterability. However, in such a structure,
when warps are formed with different diameters at the top and
bottom, the surface space becomes excessively large. Since
the spaces between the warps on the upper surface side become
large while the spaces between the warps on the lower surface
side become small, the control of the dewatering speed is not
sufficient.
[0006] Patent Document 1: Japanese Patent Application
Publication No. 2004-36052
Patent Document 2: Japanese Patent Application
Publication No. 2004-68168
[DISCLOSURE OF INVENTION]
[TECHNICAL PROBLEM]
[0007] A purpose of the present invention is to provide
an industrial two-layer fabric satisfying basic
characteristics of a fabric such as rigidity, wear resistance,
dewaterability, mark suppression, and low water retention for
reducing the amount of water retained. The present invention
also provides a new industrial two-layer fabric that is
compatible with a high-speed paper machine. That is, the
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correlation between dewaterability and water retention is an
important factor for increasing the speed of industrial two-
layer fabrics, and further, high yield is required by
suppressing the loss of the materials. Therefore, a purpose
of the present invention is to provide an industrial two-
layer fabric that improves dewaterability and realizes low
water retention by improving the opening on the upper and
lower surface sides and internal space so as to, e.g.,
increase the dewatering amount while suppressing the initial
dewatering. Further, since the difference in space density
can be arbitrarily set by making the warp space ratio of the
upper-surface-side fabric and the warp space ratio of the
lower-surface-side fabric to be about the same and allowing
the diameter of the upper-surface-side weft and the diameter
of the lower-surface-side weft to be different, a purpose of
the present invention is to provide an industrial two-layer
fabric whose dewaterability and water retention can be
adjusted by changing the ratio between the upper-surface-side
weft and the lower-surface-side weft.
[SOLUTION TO PROBLEM]
[0008] An industrial two-layer fabric according to the
present invention is characterized in that the upper-surface-
side warps are arranged in a combination of two and that at
least one warp of the combination of two warps has a first
structure as a warp having a binding function and a second
structure in which a flat yarn is used for an upper-surface-
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side warp, thereby realizing high dewaterability and low
water retention while having rigidity. That is, the
following features are employed in the present invention in
order to solve the above problems.
[0009] The following features are employed in the
present invention in order to solve the above problems of the
prior art. (1) An industrial two-layer fabric including an
upper-surface-side fabric formed from upper-surface-side
warps and upper-surface-side wefts, lower-surface-side warps,
and lower-surface-side wefts, wherein the industrial two-
layer fabric has at least a first structure and a second
structure in a weave repeat thereof, the first structure
being formed by a combination of two upper-surface-side warps
and a single lower-surface-side warp, the second structure
being formed by a single upper-surface-side warp and a single
lower-surface-side warp, the first structure and the second
structure being disposed adjacent to each other, the upper-
surface-side warps in the first structure being formed by a
warp binding yarn having the function of binding an upper-
surface-side fabric and a lower-surface-side fabric, the
combination of two upper-surface-side warps forming the first
structure being disposed adjacent to each other and
constituting a partial rib weave at the surface of the upper-
surface-side fabric, the diameter of the lower-surface-side
warp being larger than the diameter of the upper-surface-side
warp forming the first structure, and the upper-surface-side
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warp in the second structure being formed by a flat warp.
[0010] The rib weave means that two upper-surface-side
warps are disposed adjacent to each other, and both warps
pass above and below the upper-surface-side weft to form
knuckles on the surface of the fabric. In the present
invention, the two upper-surface-side warps are binding yarns,
and since the warps complement each other and exert a binding
function, there are some parts that are not rib-woven. By
forming the rib weave with the two upper-surface-side warps,
it is possible to obtain a pseudo effect to make it appear as
if flat yarns were used. More specifically, the knuckle
shape can be flattened, and surface smoothness and fiber
supportability can be improved. Further, by arranging the
flat yarns described later to be adjacent to each other, the
effect of a warp ground yarn binding type two-layer fabric
can be exhibited. Further, the flat yarns in the present
invention mean yarns having a shape in which the cross-
sectional shape is not circular and the upper and lower
surfaces are substantially flat. The flat yarns according to
the present invention include not only those whose cross-
sectiona] shape is rectangular but also those whose cross-
sectional shape is elliptical; however, those having a width
that is larger than the vertical diameter are used. The
preferred aspect ratio is 1.1 to 2Ø By using such flat
yarns, the net thickness in the industrial two-layer fabric
can be suppressed.
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[0011] Further, the diameter of the yarns constituting a
fabric is conventionally reduced to suppress the net
thickness. However, in the case of an industrial two-layer
fabric having different diameters at the top and bottom, the
5 warp space on the upper surface side is larger than that on
the lower surface side. Therefore, it is difficult to
suppress dewatering and reduce net thickness at the same time.
In the present invention, since the net thickness is reduced
by the combination of two thin warps and flat warps, the
10 dewatering speed can be controlled. Further, the present
invention has arrangement in which a weave structure is
formed by two warps and is bound. Therefore, for a binding
yarn, at least one of the two warps has both a weave
structure arrangement and a binding structure arrangement,
and the other warp of the pair forming the upper surface at
that portion can achieve the effect of minimizing the
collapse of the weave structure at the binding part.
[0012] (2) The industrial two-layer fabric according to
(1) above, wherein the diameter of the lower-surface-side
warp forming the first structure is 130% to 300% of the
diameter of the upper-surface-side warp forming the first
structure. When the diameter of the lower-surface-side warp
is less than 130% of the diameter of the upper-surface-side
warp, the difference in diameter between the upper-surface-
side warp and the lower-surface-side warp becomes small,
causing the stretching of the fabric, etc., which cause a
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risk of affecting rigidity and dewaterability. On the other
hand, when the diameter of the lower-surface-side warp
exceeds 300% of the diameter of the upper-surface-side warp,
the space of the fabric itself becomes small, causing a risk
that a problem may occur from the viewpoint of the dewatering
speed. (3) The industrial two-layer fabric according to (1)
or (2) above, wherein the aspect ratio of the flat warp is
1.1 to 2.0 in the second structure. When the aspect ratio of
the flat warp is less than 1.1, a sufficiently thin net
thickness cannot be obtained. On the other hand, when the
aspect ratio of the flat warp exceeds 2.0, the flat yarn
itself becomes thin, the space of the fabric itself becomes
small, and the strength of the fabric decreases, causing a
risk of affecting the dewaterability.
[0013] (4) The
industrial two-layer fabric according to
any one of (1) through (3) above, wherein the first structure
and the second structure are formed being arranged
alternately. As yarns forming the industrial two-layer
fabric according to the present invention, there are an
upper-surface-side warp to be woven with an upper-surface-
side weft and a warp binding yarn to be woven with both the
upper-surface-side weft and a lower-surface-side weft, and
the yarns form a set of warp binding yarns where the upper-
surface-side warp and the warp binding yarn are arranged
vertically. Although the yarns are described to be arranged
vertically, since the upper-surface-side warp is woven only
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with the upper-surface-side weft and the warp binding yarn is
woven with both the upper-surface-side weft and the lower-
surface-side weft, the yarns are not arranged in such a way
the yarns completely overlap with each other and are actually
arranged in such a way the yarns are not aligned. Further,
in addition to the set of warp binding yarns, a set of upper
and lower warps formed of an upper-surface-side warp to be
woven with an upper-surface-side weft and a lower-surface-
side warp to be woven with a lower-surface-side weft may be
arranged.
[ADVANTAGEOUS EFFECTS OF THE INVENTION]
[0014] By employing the configuration of the industrial
two-layer fabric according to the present invention,
advantages of satisfying the basic characteristics of a
fabric, such as rigidity, wear resistance, dewaterability,
mark suppression, and low water retention for reducing the
amount of water retained can be obtained. Further, by
employing the configuration of the industrial two-layer
fabric according to the present invention, it is possible to
provide a new industrial two-layer fabric that is compatible
with a high-speed paper machine. In the present invention,
by combining a warp rib weave with a flat warp, slow
dewatering and low water retention due to a warp binding
arrangement having a fabric of a flat yarn structure can be
realized, and therefore excellent advantages of greatly
improving dewaterability compared to that of a conventional
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fabric and having low water retention can be achieved.
Further, by employing the structure of the industrial two-
layer fabric according to the present invention, the warp
space ratio of the upper-surface-side fabric and the warp
space ratio of the lower-surface-side fabric can be made to
be about the same. Thus, by allowing the diameter of the
upper-surface-side weft and the diameter of the lower-
surface-side weft to be different, the difference in space
density can be arbitrarily set, and the effect of allowing
for the adjustment of the dewaterability and water retention
can be obtained by changing the ratio between the upper-
surface-side weft and the lower-surface-side weft.
[BRIEF DESCRIPTION OF DRAWINGS]
[0015] Figs. 1A-1C are conceptual diagrams for
explaining the operation and effect of a fabric having the
knuckle shapes and heights of a warp and a weft that form the
present invention. Fig. 1A is a conceptual diagram of a
conventional warp and weft. Figs. 1B and 1C are conceptual
diagrams of the warp and the weft that form the present
invention.
Fig. 2 is a design diagram showing a weave repeat
according to the first embodiment of the present invention;
Fig. 3 is a partial side layout view showing a state of
warps as viewed from the side according to the first
embodiment of the present invention;
Fig. 4 is a design diagram showing a weave repeat
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according to the second embodiment of the present invention;
Fig. 5 is a partial side layout view showing a state of
warps as viewed from the side according to the second
embodiment of the present invention;
Fig. 6 is a design diagram showing a weave repeat
according to the third embodiment of the present invention;
Fig. 7 is a partial side layout view showing a state of
warps as viewed from the side according to the third
embodiment of the present invention;
Fig. 8 is a design diagram showing a weave repeat
according to the fourth embodiment of the present invention;
and
Fig. 9 is a partial side layout view showing a state of
warps as viewed from the side according to the fourth
embodiment of the present invention.
[DESCRIPTION OF EMBODIMENTS]
[0016] Hereinafter, embodiments of an industrial two-
layer fabric according to the present invention will be
described. The embodiments shown below are examples of the
present invention and do not limit the present invention.
The industrial two-layer fabric according to the present
invention includes an upper-surface-side fabric formed from
upper-surface-side warps and upper-surface-side wefts, lower-
surface-side warps, and lower-surface-side wefts, and the
industrial two-layer fabric has at least a first structure
and a second structure in a weave repeat thereof, the first
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structure being formed by a combination of two upper-surface-
side warps and a single lower-surface-side warp, the second
structure being formed by a single upper-surface-side warp
and a single lower-surface-side warp, the first structure and
5 the second structure being disposed adjacent to each other,
the upper-surface-side warps in the first structure being
formed by a warp binding yarn having the function of binding
an upper-surface-side fabric and a lower-surface-side fabric,
the combination of two upper-surface-side warps forming the
10 first structure being disposed adjacent to each other and
constituting a partial rib weave at the surface of the upper-
surface-side fabric, the diameter of the lower-surface-side
warp being larger than the diameter of the upper-surface-side
warp forming the first structure, and the upper-surface-side
15 warp in the second structure being formed by a flat warp.
[0017] The yarn used in the present invention may be
selected depending on the intended use. For example, in
addition to monofilaments, multifilaments, spun yarn,
processed yarn generally referred to as textured yarn, bulky
yarn, stretch yarn, etc., on which crimping, bulk processing,
or the like has been performed, or yarn into which these
yarns are combined by, e.g., twisting can be used. Further,
regarding the cross-sectional shape of yarn other than a flat
warp, not only those of a circular shape but also a star-
shaped, rectangular, or polygonal yarn or an elliptical yarn,
a hollow yarn, or the like can be used. Also, the material
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of the yarn can be freely selected, and polyester, polyamide,
polyphenylene sulfide, polyvinylidene fluoride, polypro,
aramid, polyetheretherketone, polyethylene naphthalate,
polytetrafluoroethylene, cotton, wool, metal, etc., can be
used. Needless to say, a yarn may be used that is obtained
by blending or including various substances in a copolymer or
in these materials depending on the purpose. In general, for
an industrial fabric, a polyester monofilament is preferably
used that allows the upper-surface-side warps, the lower-
surface-side warps, the lower warp binding yarns, and the
upper-surface-side wefts to have rigidity and is excellent in
dimensional stability. Further, for the lower-surface-side
wefts, which are required to have rigidity and wear
resistance, polyester monofilaments and polyamide
monofilaments can be mixed-woven by, e.g., alternately
arranging the polyester monofilaments and the polyamide
monofilaments.
[0018] Further, in the present invention, the
combination of two warps in the first structure is rib woven
in cooperation by arranging the warps in parallel. Figs. 1A-
1C are conceptual diagrams for explaining the knuckle shape
and height of a warp that forms the present invention. Fig.
1A is a conceptual diagram showing a conventional interwoven
portion of a warp and a weft. Also, Fig. 1A is a conceptual
diagram that shows a knuckle shape and a height using a warp
and a weft having diameters in a fabric. Further, Fig. 1B is
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a diagram in which a combination of two upper-surface-side
warps it and 2t in the first structure is arranged under an
upper-surface-side weft 1'u. Also, Fig. 1C is a diagram in
which a flat warp 3h in the second structure is arranged
under the upper-surface-side weft 1'u. The warps used for
the first structure in the present invention is characterized
in that the upper-surface-side warp has a smaller diameter
than the lower-surface-side warp. Therefore, as shown in
Figs. 1A-1C, the vertical lengths L2 and L3 of respective
knuckle shapes formed by the upper-surface-side warps it and
2t and by the flat warp 3h are found to be smaller than the
vertical length L1 of a knuckle shape formed by a yarn of a
conventional diameter. Therefore, since the industrial two-
layer fabric according to the present invention can form a
flat knuckle shape on the upper surface structure side as
compared with conventional industrial two-layer fabrics, a
fabric having a reduced net thickness can be obtained.
Further, since the knuckle shape of a weft woven into the
combination of two warps or the flat warp becomes flattened,
surface smoothness and fiber supportability can be improved.
Further, since the mesh can be adjusted to be small without
increasing the thickness, unprecedented dewatering
characteristics can be provided. The present invention has a
structure in which a weave structure is formed by two warps
and is bound. Therefore, for a binding yarn, one of the two
warps in a set has both a structure arrangement and a binding
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structure arrangement, and the other yarn forming the upper
surface side allows the collapse of the weave structure at
the binding part to be minimized.
[0019] Further, in the industrial two-layer fabric
according to the present invention, the respective diameters
of the upper-surface-side warps can be all set to be the same.
Also, the respective diameters of the lower-surface-side
warps may be all set to be the same. Further, the diameter
of the lower-surface-side warps may be set to be 130 to 300%
of the diameter of the upper-surface-side warps. With this
configuration, in a rib weave formed by two relatively thin
warps, the upper-surface-side fabric and the lower-surface-
side fabric can be bound by one of the yarns. Therefore,
regarding the diameter of the binding yarn going up and down
inside the fabric, the binding yarn can be formed from a yarn
that is thinner than a warp binding yarn in an industrial
two-layer fabric using a conventional warp binding yarn.
Therefore, the occurrence of partial dewatering unevenness
can be minimized. Further, the diameter of the yarns forming
a fabric is conventionally controlled to suppress the net
thickness. However, in the case of an industrial two-layer
fabric having different diameters at the top and bottom, the
warp space on the upper surface side is larger than that on
the lower surface side. Therefore, it is difficult to
suppress dewatering and reduce net thickness at the same time.
In the present invention, the dewatering speed can be
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adjusted while maintaining the net thickness by combining two
thin warps and a flat warp.
[0020] Further, in the present invention, the respective
diameters of the two upper-surface-side warps forming the
first structure may be smaller than the diameter of the
single upper-surface-side warp forming the second structure.
By reducing the respective diameters of the two upper-
surface-side warp forming the first structure, the force
applied to the weft when forming a knuckle can be made to be
about the same as that in the case of a single upper-surface-
side warp, and the surface smoothness, fiber supportability,
etc., can thus be improved. Further, since the diameter can
be adjusted by selecting the diameter in accordance with the
wire, the diameter and the wire can be appropriately selected.
Also, in the present invention, an on-stack arrangement may
be employed. By using the on-stack arrangement, high
dewaterability can be obtained, and an excessive difference
in opening between the upper surface side and the lower
surface side can be suppressed by appropriately closing a
vertical opening with two yarns since the surface structure
is a rib weave. Therefore, the dewatering speed can be
controlled.
[0021] Next, embodiments pertaining to the industrial
two-layer fabric of the present invention will be described
with reference to the drawings. Figs. 2 to 9 are design
diagrams and partial side layout views showing examples
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pertaining to the industrial two-layer fabric of the present
invention. A design drawing shows the smallest repeating
unit of a fabric structure, and this weave repeat is
connected vertically and horizontally to form the structure
5 of the entire fabric. In the design drawings, warps are
indicated by Arabic numerals, for example, 1, 2, 3 .... Wefts
are indicated by Arabic numerals with dashes, for example, 1',
2', 3' .... A binding yarn is an upper-surface-side warp that
constitutes the first structure. Further, a cross mark
10 indicates that one upper-surface-side warp that constitutes
the first structure is located above an upper-surface-side
weft, a triangle mark indicates that an upper-surface-side
warp is located under a lower-surface-side weft, and a circle
mark indicates that a lower-surface-side warp is located
15 under a lower-surface-side weft. An upper-surface-side warp
and a lower-surface-side warp, and an upper-surface-side weft
and a lower-surface-side weft with the same number are
arranged vertically. In the design drawings, yarns are
arranged so as to be exactly overlapped vertically, or a
20 lower-surface-side warp is arranged at the midpoint between
two upper-surface-side warps. This is for the convenience of
the drawings, and the yarns may be arranged with a slight
deviation in the actual fabric.
First Embodiment
[0022] Fig. 2 is a design diagram of the first
embodiment pertaining to the industrial two-layer fabric of
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the present invention. Fig. 3 is a partial side layout view
of the first embodiment pertaining to the industrial two-
layer fabric of the present invention. The first structure
according to the first embodiment is composed of a
combination of two upper-surface-side warps and a single
lower-surface-side warp. The upper-surface-side warps in the
first structure are formed by warp binding yarns having a
function of binding the upper-surface-side fabric and the
lower-surface-side fabric. Further, the combination of two
upper-surface-side warps forming the first structure are
disposed adjacent to each other and forms a partial rib weave
on the surface of the upper-surface-side fabric. Also, the
second structure is composed of a single upper-surface-side
warp and a single lower-surface-side warp. The upper-
surface-side warp in the second structure is formed by a flat
warp. Further, as shown in Fig. 2, the first structures 1, 3,
and 5 and the second structures 2, 4, and 6 are formed being
adjacent to one another and arranged alternately. Further,
the diameter of the lower-surface-side warp is formed to be
larger than the diameter of the upper-surface-side warp
forming the first structure.
[0023] More specifically, as shown in Figs. 2 and 3, a
structure is formed where one upper-surface-side warp 1 in
the first structure passes under a lower-surface-side weft 1'
and passes above upper-surface-side wefts 5', 7', 9', 11',
13', 15', 17', 19', and 21'. Then, a structure is formed
Date Recue/Date Received 2021-01-28
CA 03108343 21321-8
22
where the other upper-surface-side warp 1 in the first
structure passes above upper-surface-side wefts 1', 3', 5',
7', and 9', passes under a lower-surface-side weft 13', and
further pass above upper-surface-side wefts 17', 19', 21',
and 23'. The lower-surface-side warp 1 passes under the
lower-surface-side wefts 1' and 13'. Therefore, as is clear
from Fig. 3, the combination of two upper-surface-side warps
1 in the first structure forms a partial rib weave at the
upper-surface-side wefts 5', 7', 9', 17', 19', and 21' on the
surface of the upper-surface-side fabric. Next, an upper-
surface-side warp 2 serving as a flat warp in the second
structure passes above upper-surface-side wefts 2', 4', 6',
8', 10', 12', 14', 16', 18', 20', 22', and 24' so as to form
a plain weave. A lower-surface-side warp 2 in the second
structure passes under lower-surface-side wefts 3' and 15'.
[0024] The first structure in the industrial two-layer
fabric according to the first embodiment can form a pseudo-
flat yarn by forming a rib weave by arranging two thin upper-
surface-side warps in parallel on a part of the surface of
the upper-surface-side fabric. Furthermore, by arranging the
flat warp in the second structure adjacent to the first
structure, suitable rigidity and elongation resistance can be
ensured while suppressing the thickness, and a fabric
excellent in wear resistance, suitable dewaterability, low
water retention, and surface smoothness can be provided, in
Date Recue/Date Received 2021-01-28
CA 03108043 2021-01-28
23
the same way as in a fabric in which only flat yarns are used
to form a surface structure. Further, by employing the
fabric structure according to the first embodiment, it is
possible to reduce the mesh size while suppressing the
thickness of the fabric. Therefore, the dewaterability and
the water retention property can be adjusted by selecting the
diameter of the yarn. Furthermore, since the knuckle shape
of the weft can be flattened by two rib weave structures, the
surface smoothness and the fiber supportability can be
improved.
Second Embodiment
[0025] Fig. 4 is a design diagram of the first
embodiment pertaining to the industrial two-layer fabric of
the present invention. Fig. 5 is a partial side layout view
of the second embodiment pertaining to the industrial two-
layer fabric of the present invention. The first structure
according to the second embodiment is composed of a
combination of two upper-surface-side warps and a single
lower-surface-side warp. The upper-surface-side warps in the
first structure are formed by warp binding yarns having a
function of binding the upper-surface-side fabric and the
lower-surface-side fabric. Further, the combination of two
upper-surface-side warps forming the first structure are
disposed adjacent to each other and forms a partial rib weave
on the surface of the upper-surface-side fabric. Also, the
second structure is composed of a single upper-surface-side
Date Recue/Date Received 2021-01-28
CA 03108043 2021-01-28
24
warp and a single lower-surface-side warp. The upper-
surface-side warp in the second structure is formed by a flat
warp. Further, as shown in Fig. 4, the first structures 1, 3,
and 5 and the second structures 2, 4, and 6 are formed being
adjacent to one another and arranged alternately. Further,
the diameter of the lower-surface-side warp is formed to be
larger than the diameter of the upper-surface-side warp
forming the first structure.
[0026] More specifically, as shown in Figs. 4 and 5, a
structure is formed where one upper-surface-side warp 1 in
the first structure passes above upper-surface-side wefts 1',
3', 5', and 7', passes under a lower-surface-side weft 10',
and further pass above upper-surface-side wefts 13', 15', and
17'. Further, a structure is formed where the other upper-
surface-side warp 1 in the first structure passes under a
lower-surface-side weft 1' and passes above upper-surface-
side wefts 3', 5', 7', 9', 11', 13', 15', and 17'. The
lower-surface-side warp 1 passes under the lower-surface-side
wefts 1' and 10'. Therefore, as is clear from Fig. 5, the
combination of two upper-surface-side warps 1 in the first
structure forms a partial rib weave at the upper-surface-side
wefts 3', 5', 7', 13', 15', and 17' on the surface of the
upper-surface-side fabric. Next, an upper-surface-side warp
2 serving as a flat warp in the second structure passes above
upper-surface-side wefts 2', 4', 6', 8', 10', 12', 14', 16',
and 18' so as to form a plain weave. A lower-surface-side
Date Recue/Date Received 2021-01-28
CA 03108043 2021-01-28
warp 2 in the second structure passes under lower-surface-
side wefts 2' and 11'.
[0027] The first structure in the industrial two-layer
fabric according to the second embodiment can form a pseudo-
5 flat yarn by forming a rib weave by arranging two thin upper-
surface-side warps in parallel on a part of the surface of
the upper-surface-side fabric. Furthermore, by arranging the
flat warp in the second structure adjacent to the first
structure, suitable rigidity and elongation resistance can be
10 ensured while suppressing the thickness, and a fabric
excellent in wear resistance, suitable dewaterability, and
surface smoothness can be provided, in the same way as in a
fabric in which only flat yarns are used to form a surface
structure. Further, by employing the fabric structure
15 according to the second embodiment, it is possible to reduce
the mesh size while suppressing the thickness of the fabric.
Therefore, the dewatering characteristics can be adjusted by
selecting the diameter of the yarn. Furthermore, since the
knuckle shape of the weft can be flattened by two rib weave
20 structures, the surface smoothness and the fiber
supportability can be improved.
Third Embodiment
[0028] Fig. 6 is a design diagram of the third
embodiment pertaining to the industrial two-layer fabric of
25 the present invention. Fig. 7 is a partial side layout view
of the third embodiment pertaining to the industrial two-
Date Recue/Date Received 2021-01-28
CA 03108043 2021-01-28
26
layer fabric of the present invention. The first structure
according to the third embodiment is composed of a
combination of two upper-surface-side warps and a single
lower-surface-side warp. The upper-surface-side warps in the
first structure are formed by warp binding yarns having a
function of binding the upper-surface-side fabric and the
lower-surface-side fabric. Further, the combination of two
upper-surface-side warps forming the first structure are
disposed adjacent to each other and forms a partial rib weave
on the surface of the upper-surface-side fabric. Also, the
second structure is composed of a single upper-surface-side
warp and a single lower-surface-side warp. The upper-
surface-side warp in the second structure is formed by a flat
warp. Further, as shown in Fig. 6, the first structures 1, 3,
and 5 and the second structures 2, 4, and 6 are formed being
disposed adjacent to one another. Further, the diameter of
the lower-surface-side warp is formed to be larger than the
diameter of the upper-surface-side warp forming the first
structure.
[0029] More specifically, as shown in Figs. 6 and 7, a
structure is formed where one upper-surface-side warp 1 in
the first structure passes above upper-surface-side wefts 1',
3', 5', and 7', passes under a lower-surface-side weft 10',
and further pass above upper-surface-side wefts 13', 15', and
17'. The lower-surface-side warp 1 passes under the lower-
surface-side wefts 1' and 10'. A structure is formed where
Date Recue/Date Received 2021-01-28
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27
the other upper-surface-side warp 1 in the first structure
passes under a lower-surface-side weft 1' and passes above
upper-surface-side wefts 5', 7', 9', 11', 13', and 15'.
Therefore, as is clear from Fig. 7, the combination of two
upper-surface-side warps 1 in the first structure forms a
partial rib weave at the upper-surface-side wefts 5', 7', 13',
and 15' on the surface of the upper-surface-side fabric.
Next, an upper-surface-side warp 2 serving as a flat warp in
the second structure passes above upper-surface-side wefts 2',
4', 6', 8', 10', 12', 14', 16', and 18' so as to form a plain
weave. A lower-surface-side warp 2 in the second structure
passes under lower-surface-side wefts 2' and 11'.
[0030] The first structure in the industrial two-layer
fabric according to the third embodiment can form a pseudo-
flat yarn by forming a rib weave by arranging two thin upper-
surface-side warps in parallel on a part of the surface of
the upper-surface-side fabric. Furthermore, by arranging the
flat warp in the second structure adjacent to the first
structure, suitable rigidity and elongation resistance can be
ensured while suppressing the thickness, and a fabric
excellent in wear resistance, suitable dewaterability, and
surface smoothness can be provided, in the same way as in a
fabric in which only flat yarns are used to form a surface
structure. Further, by employing the fabric structure
according to the third embodiment, it is possible to reduce
the mesh size while suppressing the thickness of the fabric.
Date Recue/Date Received 2021-01-28
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28
Therefore, the dewatering characteristics can be adjusted by
selecting the diameter of the yarn. Furthermore, since the
knuckle shape of the weft can be flattened by two rib weave
structures, the surface smoothness and the fiber
supportability can be improved.
Fourth Embodiment
[0031] Fig. 8 is a design diagram of the fourth
embodiment pertaining to the industrial two-layer fabric of
the present invention. Fig. 9 is a partial side layout view
of the fourth embodiment pertaining to the industrial two-
layer fabric of the present invention. The first structure
according to the fourth embodiment is composed of a
combination of two upper-surface-side warps and a single
lower-surface-side warp. The upper-surface-side warps in the
first structure are formed by warp binding yarns having a
function of binding the upper-surface-side fabric and the
lower-surface-side fabric. Further, the combination of two
upper-surface-side warps forming the first structure are
disposed adjacent to each other and forms a partial rib weave
on the surface of the upper-surface-side fabric. Also, the
second structure is composed of a single upper-surface-side
warp and a single lower-surface-side warp. The upper-
surface-side warp in the second structure is formed by a flat
warp. Further, as shown in Fig. 8, the first structure 1 and
the second structures 2 and 8 are formed being disposed
adjacent to each other, and the first structure 5 and the
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29
second structures 4 and 6 are formed being disposed adjacent
to each other. Further, the diameter of the lower-surface-
side warp is formed to be larger than the diameter of the
upper-surface-side warp forming the first structure.
[0032] More specifically, as shown in Figs. 8 and 9, a
structure is formed where one upper-surface-side warp 1 in
the first structure passes above upper-surface-side wefts 1',
3', 5', 7', 9', and 11', passes under a lower-surface-side
weft 13', and further pass above upper-surface-side wefts
15', and 17'. The lower-surface-side warp 1 passes under the
lower-surface-side wefts 1', 7', and 13'. A structure is
formed where the other upper-surface-side warp 1 in the first
structure passes under a lower-surface-side weft 1' and
passes above upper-surface-side wefts 3', 5', 7', 9', 11',
13', 15', and 17'. Therefore, as is clear from Fig. 9, the
combination of two upper-surface-side warps 1 in the first
structure forms a partial rib weave at the upper-surface-side
wefts 3', 5', 7', 9', 11', 15', and 17' on the surface of the
upper-surface-side fabric. Next, an upper-surface-side warp
2 serving as a flat warp in the second structure passes above
upper-surface-side wefts 2', 4', 6', 8', 10', 12', 14', 16',
and 18' so as to form a plain weave. A lower-surface-side
warp 2 in the second structure passes under lower-surface-
side wefts 2', 8', and 14'. Next, an upper-surface-side warp
3 serving as a flat warp in the second structure passes above
upper-surface-side wefts 1', 3', 5', 7', 9', 11', 13', 15',
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CA 03108343 21321-8
and 17' so as to form a plain weave. A lower-surface-side
warp 3 in the second structure passes under lower-surface-
side wefts 4', 10', and 16'. Next, an upper-surface-side
warp 4 serving as a flat warp in the second structure passes
5 above upper-surface-side wefts 2', 4', 6', 8', 10', 12', 14',
16', and 18' so as to form a plain weave. A lower-surface-
side warp 4 in the second structure passes under lower-
surface-side wefts 5', 11', and 17'.
[0033] The first structure in an industrial two-layer
10 fabric according to the fourth embodiment can form a pseudo-
flat yarn by forming a rib weave by arranging two thin upper-
surface-side warps in parallel on a part of the surface of
the upper-surface-side fabric. Furthermore, by arranging the
flat warp in the second structure adjacent to the first
15 structure, suitable rigidity and elongation resistance can be
ensured while suppressing the thickness, and a fabric
excellent in wear resistance, suitable dewaterability, and
surface smoothness can be provided, in the same way as in a
fabric in which only flat yarns are used to form a surface
20 structure. Further, by employing the fabric structure
according to the fourth embodiment, it is possible to reduce
the mesh size while suppressing the thickness of the fabric.
Therefore, the dewatering characteristics can be adjusted by
selecting the diameter of the yarn. Furthermore, since the
25 knuckle shape of the weft can be flattened by two rib weave
structures, the surface smoothness and the fiber
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31
supportability can be improved.
[REFERENCE SIGNS LIST]
[0034] 1-8 warp
1'-24' weft
Date Recue/Date Received 2021-01-28
