Structured fabric for use in a papermaking machine and the fibrous web produced thereon

Abstract

A papermaking machine for the production of a fibrous web. The papermaking machine including a plurality of rollers and a structured fabric moving along the plurality of rollers. The structured fabric includes a plurality of weft yarns and a plurality of warp yarns woven with the plurality of weft yarns to produce a weave pattern. The plurality of warp yarns being a plurality of paired warp yarn sets. Each paired warp yarn set including a first warp yarn and a second warp yarn, within the weave pattern the first warp yarn forms a float over at least three weft yarns and weaves with a single weft yarn immediately adjacent to the float. The second warp yarn having a reverse pattern to the first warp yarn. The float of the first warp yarn having a start that is at the same position as a finish of the float of the second warp yarn.

What is claimed is: 
     
         1 . A papermaking machine for the production of a fibrous web, the papermaking machine, comprising:
 a plurality of rollers; and   a structured fabric moving along said plurality of rollers, said structured fabric including:
 a plurality of weft yarns; and 
 a plurality of warp yarns woven with said plurality of weft yarns to produce a weave pattern, said plurality of warp yarns being a plurality of paired warp yarn sets, each paired warp yarn set including a first warp yarn and a second warp yarn, within said weave pattern said first warp yarn forming a float over at least three weft yarns and weaving with a single weft yarn immediately adjacent to said float, said second warp yarn having a reverse pattern to said first warp yarn, said float of said first warp yarn having a start that is at the same position as a finish of said float of said second warp yarn. 
   
     
     
         2 . The papermaking machine of  claim 1 , wherein said yarn weave of said plurality of warp yarns of said structured fabric additionally has a weave with two of said weft yarns adjacent to said float. 
     
     
         3 . The papermaking machine of  claim 2 , wherein said weave pattern is repeated every ten warp yarns and every ten weft yarns. 
     
     
         4 . The papermaking machine of  claim 3 , wherein said yarn weave is repeating sequentially going over three weft yarns in said float, under one weft yarn, over the next weft yarn, under the next two weft yarns, over the next one weft yarn, then under the next two weft yarns. 
     
     
         5 . The papermaking machine of  claim 1 , wherein each said warp yarn has a cross-sectional dimension of between approximately 0.10 mm and approximately 1.0 mm. 
     
     
         6 . The papermaking machine of  claim 1 , wherein the papermaking machine is one of a TAD system, an ATMOS system, an E-TAD system, and a Metso system. 
     
     
         7 . The papermaking machine of  claim 1 , wherein at least one of said plurality of warp yarns of said weave pattern have a polygonal cross-section. 
     
     
         8 . The papermaking machine of  claim 1 , wherein said weave pattern results in pockets, said pockets having a quantity that is between approximately 50/in 2  and approximately 500/in 2 . 
     
     
         9 . A structured fabric for use with a papermaking machine for the production of a fibrous web, the structured fabric, comprising:
 a plurality of weft yarns; and   a plurality of warp yarns woven with said plurality of weft yarns to produce a weave pattern, said plurality of warp yarns being a plurality of paired warp yarn sets, each paired warp yarn set including a first warp yarn and a second warp yarn, within said weave pattern said first warp yarn forming a float over at least three weft yarns and weaving with a single weft yarn immediately adjacent to said float, said second warp yarn having a reverse pattern to said first warp yarn, said float of said first warp yarn having a start that is at the same position as a finish of said float of said second warp yarn.   
     
     
         10 . The structured fabric of  claim 9 , wherein said yarn weave of said plurality of warp yarns additionally has a weave with two of said weft yarns adjacent to said float. 
     
     
         11 . The structured fabric of  claim 10 , wherein said weave pattern is repeated every ten warp yarns and every ten weft yarns. 
     
     
         12 . The structured fabric of  claim 11 , wherein said yarn weave is repeating sequentially going over three weft yarns in said float, under one weft yarn, over the next weft yarn, under the next two weft yarns, over the next one weft yarn, then under the next two weft yarns. 
     
     
         13 . The structured fabric of  claim 9 , wherein said warp yarns have a diameter of between approximately 0.10 mm and approximately 1.0 mm. 
     
     
         14 . The structured fabric of  claim 9 , wherein the papermaking machine is one of a TAD system, an ATMOS system, an E-TAD system, and a Metso system. 
     
     
         15 . The structured fabric of  claim 9 , wherein at least one of said plurality of warp yarns of said weave pattern have a polygonal cross-section. 
     
     
         16 . The structured fabric of  claim 9 , wherein said weave pattern results in pockets, said pockets having a quantity that is between approximately 50/in 2  and approximately 500/in 2 . 
     
     
         17 . A fibrous web, comprising:
 a fibrous construct having at least one formed surface feature, said surface feature including a topographical pattern reflective of a weave pattern in a fabric used in a papermaking machine, the fabric including:   a plurality of weft yarns; and   a plurality of warp yarns woven with said plurality of weft yarns to produce a weave pattern, said plurality of warp yarns being a plurality of paired warp yarn sets, each paired warp yarn set including a first warp yarn and a second warp yarn, within said weave pattern said first warp yarn forming a float over at least three weft yarns and weaving with a single weft yarn immediately adjacent to said float, said second warp yarn having a reverse pattern to said first warp yarn, said float of said first warp yarn having a start that is at the same position as a finish of said float of said second warp yarn.   
     
     
         18 . The fibrous web of  claim 17 , wherein said yarn weave of said plurality of warp yarns additionally has a weave with two of said weft yarns adjacent to said float. 
     
     
         19 . The fibrous web of  claim 18 , wherein said weave pattern is repeated every ten warp yarns and every ten weft yarns. 
     
     
         20 . The fibrous web of  claim 19 , wherein the fibrous web has at least one, preferably all of the following properties:
 a basis weight in the range of 17-19.5 gram/m 2 ;   a caliper of 0.45 to 0.49 mm;   a bulk of 22 to 27 cm 3 /gram; and   an absorbency of 15-18 gram of water/gram of paper.