High stability stacked warp yarn dryer fabric with long warp floats

Abstract

An industrial textile is provided, preferably suitable for use as a dryer fabric in a papermaking machine. The industrial textile has first and second surfaces and is defined by first and second systems of warp yarns interwoven with a system of weft yarns in a repeating pattern. In the repeating pattern, each of the warp yarns in the first system of warp yarns is interwoven with the system of weft yarns with a float on the first surface over at least 5 of the weft yarns, under 1 of the weft yarns, over 1 of the weft yarns, and under 1 of the weft yarns. Additionally, each of the warp yarns in the second system of warp yarns is interwoven with the system of weft yarns with a float on the second surface under at least 5 of the weft yarns, over 1 of the weft yarns, under 1 of the weft yarns, and over 1 of the weft yarns in the repeating pattern. Each of the warp yarns of the first system of warp yarns is stacked over a corresponding one of the warp yarns of the second system of warp yarns to form stacked pairs of the warp yarns.

1 . An industrial textile having first and second surfaces, the textile comprising:
 first and second systems of warp yarns interwoven with a system of weft yarns in a repeating pattern in which:   each of the warp yarns in the first system of warp yarns is interwoven with the system of weft yarns on the first surface over at least 5 of the weft yarns, under 1 of the weft yarns, over 1 of the weft yarns, and under 1 of the weft yarns in the repeating pattern forming a float on the first surface over the at least 5 of the weft yarns,   each of the warp yarns in the second system of warp yarns is interwoven with the system of weft yarns on the second surface under at least 5 of the weft yarns, over 1 of the weft yarns, under 1 of the weft yarns and over 1 of the weft yarns in the repeating pattern forming a float on the second surface under the at least 5 of the weft yarns, and   each of the warp yarns of the first system of warp yarns is stacked over a corresponding one of the warp yarns of the second system of warp yarns to form stacked pairs of the warp yarns.   
     
     
         2 . The industrial textile of  claim 1 , wherein the float on the first surface is over 7 weft yarns, and the float on the second surface is under 7 weft yarns. 
     
     
         3 . The industrial textile of  claim 1 , wherein the system of weft yarns includes alternating larger diameter filler wefts and smaller diameter critical picks. 
     
     
         4 . The industrial textile of  claim 3 , wherein the warp yarns of the first system of warp yarns only weave under the critical picks, and the warp yarns of the second system of warp yarns only weave over the critical picks. 
     
     
         5 . The industrial textile of  claim 1 , wherein the repeating pattern of the warp yarns of the first system of warp yarns of under 1 of the weft yarns, over 1 of the weft yarns, and under 1 of the weft yarns forms a locking weave for maintaining a position of the warp warns of the first system of warp yarns, and the repeating pattern of the warp yarns of the second system of warp yarns of over 1 of the weft yarns, under 1 of the weft yarns, and over 1 of the weft yarns forms a locking weave for maintaining a position of the warp warns of the second system of warp yarns. 
     
     
         6 . The industrial textile of  claim 1 , wherein the stacked pairs of the warp yarns are spaced apart to form an open mesh pattern. 
     
     
         7 . The industrial textile of  claim 6 , wherein the stacked pairs of the warp yarns are spaced apart by at least 40% of a cross-direction dimension of one of the warp yarns. 
     
     
         8 . The industrial textile of  claim 1 , wherein the floats on the first surface are arranged with a diagonal twill. 
     
     
         9 . The industrial textile of  claim 1 , wherein the first system of warp yarns is made from a different material than the second system of warp yarns. 
     
     
         10 . The industrial textile of  claim 1 , wherein the warp yarns of the first and second systems of warp yarns have a rectangular cross-section. 
     
     
         11 . The industrial textile of  claim 10 , wherein the cross-section of the warp yarns of the first and second systems of warp yarns are the same. 
     
     
         12 . The industrial textile of  claim 10 , wherein the weft yarns have a circular cross-section. 
     
     
         13 . The industrial textile of  claim 12 , wherein the system of weft yarns includes alternating larger filler wefts having a diameter D 1  and smaller critical picks having a diameter D 2 , the warp yarns of the first and second systems of warp yarns with the rectangular cross-section have a thickness t, wherein D 1 >D 2 , and (D 1 −D 2 )/2≈t. 
     
     
         14 . The industrial textile of  claim 1 , wherein the first system of warp yarns and second systems of warp yarns each have at least 100% warp fill. 
     
     
         15 . The industrial textile of  claim 1 , wherein the first and second systems of warp yarns are woven with 8 sheds in 10 steps. 
     
     
         16 . The industrial textile of  claim 1 , wherein the industrial textile is a papermaking fabric. 
     
     
         17 . The industrial textile of  claim 1 , wherein the industrial textile is a dryer fabric for a papermaking fabric. 
     
     
         18 . An industrial textile having first and second surfaces, the textile comprising:
 first and second systems of warp yarns interwoven with a system of weft yarns in a repeating pattern in which:   adjacent pairs of the warp yarns in the first system of warp yarns are interwoven along a same path with the system of weft yarns on the first surface over at least 5 of the weft yarns and under 1 of the weft yarns in the repeating pattern forming adjacent pairs of floats on the first surface over the at least 5 of the weft yarns,   adjacent pairs of the warp yarns in the second system of warp yarns are interwoven along a same path with the system of weft yarns on the second surface under at least 5 of the weft yarns and over 1 of the weft yarns in the repeating pattern forming adjacent pairs of floats on the second surface under the at least 5 of the weft yarns, and   the adjacent pairs of warp yarns of the first system of warp yarns are stacked over corresponding ones of the adjacent pairs of warp yarns of the second system of warp yarns to form stacked, adjacent pairs of the warp yarns.   
     
     
         19 . The industrial textile of  claim 18 , wherein the system of weft yarns includes alternating larger diameter filler wefts and smaller diameter critical picks. 
     
     
         20 . The industrial textile of  claim 19 , wherein the warp yarns of the first system of warp yarns only weave under the critical picks, and the warp yarns of the second system of warp yarns only weave over the critical picks.