Extruded reinforced industrial belt

Abstract

The present disclosure relates to a non-woven extruded industrial fabric. A method of manufacturing an industrial fabric is crosshead extrusion of a polymeric matrix material together with a linear component. The crosshead extruded linear component with the polymer matrix material may be a continuous system oriented in the machine direction. The polymeric resin matrix at least partially surrounds one or more of the linear components. The resin matrix may also be further reinforced by the inclusion of nanoparticles, nanomaterials, and / or chopped fibers. The front side of the industrial tape may be smooth or may include a texture or pattern.

Description

Technical Field

[0001] The present disclosure relates to a nonwoven extruded industrial fabric. An industrial fabric, such as a belt, is produced by coextruding a polymer matrix material together with a linear component oriented in the machine direction. The front side of the industrial fabric may be smooth or may include a texture or pattern. Background Art

[0002] During the papermaking process, a cellulosic fibrous web is formed by depositing a fibrous slurry (i.e., an aqueous dispersion of cellulose fibers) onto a moving forming fabric in the forming section of a paper machine. A large amount of water is drained from the slurry through the forming fabric, leaving the cellulosic fibrous web on the surface of the forming fabric.

[0003] From the forming section, the newly formed cellulosic fibrous web advances to a press section, which includes a series of press nips. The cellulosic fibrous web passes through a press nip supported by a press fabric, or usually between two such press fabrics. In the press nip, the cellulosic fibrous web is subjected to a compressive force that squeezes water out of it and adheres the cellulose fibers in the web to each other to transform the cellulosic fibrous web into paper. The water is received by the press fabric or fabrics and, ideally, does not return to the paper.

[0004] The paper eventually advances to a drying section that includes at least a series of rotatable drying drums or cylinders, the interior of which is heated by steam. The newly formed paper is sequentially passed around each of the series of drums in a serpentine path by drying fabrics that hold the paper tightly against the surfaces of the drums. The heated drums reduce the water content of the paper to the desired level by evaporation.

[0005] It should be understood that both the forming press and the dryer fabrics take the form of endless loops on a paper machine and function in the manner of a conveyor. It should also be understood that papermaking is a continuous process that is carried out at considerable speeds. That is, the fiber slurry is continuously deposited onto the forming fabric in the forming section, and the newly made paper is continuously wound onto a roll after exiting the dryer section.

[0006] Textured tapes in the papermaking and nonwoven fields are used to make three-dimensional nonwovens and tissue and towel structures. Typically, these tapes are used in the forming and pressurizing sections of, for example, papermaking processes, where the increase in the caliper of the tape can directly impart scale, volume, and three-dimensional patterns in the produced textured products (such as rolled goods). For this type of textured tape, there is typically a base weave pattern for, for example, dimensional stability and load-bearing properties. Typically, these tapes have a second layer of top surface added to the base weave pattern to specifically impart scale, texture, pattern, and volume. The top surface can be made of thermoplastic or thermosetting materials and applied directly in molten or liquid form, or first produced as a sheet and subsequently bonded to the surface of the base fabric of the tape. The bonding can be chemical or thermal, or a combination thereof. Summary of the invention

[0007] The present disclosure relates to an extruded nonwoven industrial fabric having linear components arranged along the machine direction (MD) of the fabric and an extruded polymer matrix material at least partially encapsulating one or more of the linear components. The present disclosure also provides a method for forming an extruded nonwoven industrial fabric having linear components arranged along the machine direction of the fabric and an extruded polymer matrix material at least partially encapsulating one or more of the linear components.

[0008] In some embodiments, the extruded polymer matrix material at least partially encapsulating one or more linear components provides sufficient cross-machine direction (CD) reinforcement to the industrial fabric. In other embodiments, all linear components in the industrial fabric are arranged along the MD.

[0009] In certain embodiments, the fabric is impermeable. In certain other embodiments, the fabric is permeable.

[0010] In certain embodiments, the matrix material completely encapsulates one or more of the linear components. In certain other embodiments, the matrix material completely encapsulates some or all of the linear components.

[0011] In certain embodiments, the linear component is a yarn. In certain other embodiments, the linear component is a multifilament, a monofilament, a cord, a spun yarn, or a ribbon. In other embodiments, the linear component is a thermoset, a thermoplastic, carbon, glass, a polyester, a polyolefin, or a polyamide. In some embodiments, the fabric includes at least two different types of linear components. In certain embodiments, the linear components differ in one or more of quantity, material composition, or size.

[0012] In certain embodiments, the linear component is extruded together with the polymer matrix material. In certain embodiments, this can be done by cross-head extrusion, and can be done in a spiral configuration.

[0013] In certain embodiments, the linear components are parallel to each other.

[0014] In certain embodiments, the linear component is in a single plane. In certain other embodiments, the linear component is in multiple planes.

[0015] In certain embodiments, the linear component has sufficient modulus to be load bearing.

[0016] In certain embodiments, the polymer matrix material of extrusion comprises nanoparticle, nano material, fibrous material, glass, carbon, inorganic filler and / or polymer material.In some embodiments, nanoparticle, nano material, fibrous material, glass, carbon, inorganic filler and / or polymer material are incorporated into the whole polymer matrix material of extrusion or its part.In other embodiments, the polymer matrix material of extrusion can comprise thermoplastic, polyurethane, polyester, polyamide, copolyester, copolyamide, hot melt adhesive, thermoplastic polyurethane (TPU) and acrylic acid copolymer, TPU and polyester elastomer copolymer or TPU and polyamide elastomer copolymer.

[0017] In certain embodiments, the extruded polymer matrix material comprises a first side and a second side, and wherein the first side and the second side are planar, and the linear component does not extend through the first side or the second side. In certain other embodiments, at least a portion of the linear component at least partially extends through the first side and / or the second side.

[0018] In certain embodiments, the pattern is formed on the face of the fabric by laser etching, mechanical etching, embossing, or resin deposition.

[0019] In certain embodiments, the pattern is formed on the face of the fabric by an additive process such as resin deposition, such as three-dimensional printing technology or inkjet printing technology. In other embodiments, the pattern is formed on the face of the fabric by a subtractive process.

[0020] In certain embodiments, the nonwoven industrial fabric is selected from the group consisting of: a conveyor belt; a paper machine fabric ("PMC"), wherein the PMC is a forming fabric, a pressure fabric, a drying fabric, a shoe pressure belt, a transfer belt, a reel belt, a through air drying ("TAD") fabric, an imprinting fabric, an Energy Efficient Technology Advanced Drying ("eTAD") fabric, an Advanced Tissue Forming System ("ATMOS") fabric or belt, a New Tissue Technology ("NTT") fabric or belt, or a structured fabric; a double nip thickener ("DNT") fabric; a belt filter; a pulp cleaner; a belt, fabric or sleeve for producing airlaid, spunbond, meltspun or hydroentangled nonwoven materials; a belt for producing building products; a belt for producing oriented strand board ("OSB"); a corrugator belt; a textile finishing belt; a shrink-proof belt; a tanning belt; and a tanning sleeve. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 is a partially cutaway perspective view of an embodiment of a fabric of the present disclosure, including a textured front side.

[0022] Figure 2 is a partially cutaway perspective view of an embodiment of a fabric of the present disclosure, including a smooth front side.

[0023] Figure 3 is a cross-sectional view along the cross-machine direction (CD) of an embodiment of a fabric of the present disclosure.

[0024] Figure 4 is a cross-sectional view along the cross direction (CD) of another embodiment of the present disclosure, in which a linear component is partially exposed.

[0025] Figure 5 is a cross-sectional view along the cross-machine direction (CD) of an embodiment of a fabric of the present disclosure, wherein holes are passed through the fabric, thereby creating a permeable configuration.

[0026] Figure 6 is a cross-sectional view along the cross-machine direction (CD) of an embodiment of a fabric of the present disclosure having first and second types of linear components.

[0027] Figure 7 is a cross-sectional view along the cross-machine direction (CD) of an embodiment of a fabric of the present disclosure, wherein linear components are configured and arranged in a first parallel plane and a second parallel plane.

[0028] Figure 8 is a cross-sectional view along the cross-machine direction (CD) of an embodiment of a fabric of the present disclosure, including an upper coating or film.

[0029] Fig. 9 is a cross-sectional view along the cross-machine direction (CD) of an embodiment of a fabric of the present disclosure, illustrating an additive pattern that may be achieved by resin deposition on a front side of the fabric of the present disclosure.

[0030] Fig.10 Shows relative to Fig. 9 A continuous additive pattern (dark areas are additive) that can be achieved by resin deposition on the front side of the fabric of the present disclosure. Fig.10 It also shows that Fig.12 Continuous subtractive pattern (white areas are removed).

[0031] Fig.11 Shows relative to Fig. 9 A discrete additive pattern (dark areas are additive) that can be achieved by resin deposition on the front side of the fabric of the present disclosure. Fig.11 It also shows that Fig.12 Discrete subtractive pattern of (white areas are removed).

[0032] Fig.12 is a cross-sectional view along the cross-machine direction (CD) of an embodiment of a fabric of the present disclosure, illustrating a subtractive or removed pattern that may be achieved on a front side of a fabric of the present disclosure.

[0033] Fig.13 An apparatus for producing a spiral configuration of one embodiment of the fabric of the present disclosure is shown.

[0034] Fig.14 is a cross-sectional view along the machine direction of an embodiment of a fabric of the present disclosure.

[0035] Fig.15 is a plan view of a subtractive surface formed on a front side of an embodiment of a fabric of the present disclosure.

[0036] Fig.16 is a plan view of an additive surface formed on a front side of an embodiment of a fabric of the present disclosure, the additive surface including perforations within the additive material.

[0037] Fig.17 yes Fig.16 A plan view of the back side of the illustrated embodiment of the fabric further illustrates the perforations through the fabric.

[0038] Fig.18 yes Fig.16 and Fig.17 Cross-sectional view of the perforations of an embodiment of the fabric shown in FIG.

[0039] Fig.19 is a plan view of an additive surface formed on the front side of an embodiment of a fabric of the present disclosure, wherein the additive material is formed into an element similar to a bicycle chain and has no through holes.

[0040] Fig. 20 is a plan view of an additive surface formed on the front side of an embodiment of a fabric of the present disclosure, wherein the additive material is formed into a dumbbell-type shape and has no through-holes.

[0041] Fig.21 is another plan view of an additive surface formed on a front side of an embodiment of a fabric of the present disclosure, wherein the additive material is formed into a dumbbell-type shape and has no through-holes.

[0042] Fig. 22 is a cross-sectional view of an embodiment of a fabric of the present disclosure showing filler particles within a resin matrix. DETAILED DESCRIPTION

[0043] The terms "include" and "comprising" in this disclosure may mean "list as part of" or "make part of", or may have the meanings commonly given to the terms "include" or "comprising" in U.S. patent law. If the terms "consisting essentially of" or "consisting essentially of" are used in a claim, they have the meanings ascribed to them by U.S. patent law. Other aspects of the disclosure are described in this disclosure or are known to those of skill in the art after reading this disclosure.

[0044] The terms "yarn" and "fiber" are used interchangeably in the following disclosure, and can refer to monofilament yarn, multifilament yarn, twisted yarn, textured yarn, coated yarn, other entangleable materials, and yarn made of tensile break fibers known to those skilled in the art. Yarn can be made of carbon, rayon, glass fiber, cotton, ceramic, aramid, polyester, polyolefin, metal, polyethylene, glass, polyamide, polyphenylene sulfide (PPS) and / or polyetheretherketone (PEEK) materials in the form of multifilament, monofilament, cord, spinning, tape, twisted short hemp yarn, untwisted short hemp yarn and / or other materials and forms showing desired physical, thermal, chemical or other properties. Yarn can also be thermoplastic, thermosetting elastomer (elastomer), high modulus elastomer (e.g., sufficient to bear) and / or inelastic, and can also be a fusible sheath / core yarn with a melting point core higher than the surrounding sheath.

[0045] The terms "machine direction" (MD) and "cross direction" (CD) used in the following disclosure are used according to their well-understood meanings in the art. That is, the MD of an industrial fabric (such as a belt) refers to the direction in which the industrial fabric moves in a manufacturing process (such as a tissue / towel or nonwoven manufacturing process), while the CD refers to the direction perpendicular to the MD of the industrial fabric.

[0046] The present disclosure relates to a nonwoven industrial fabric (such as a belt) that can be used in any number of industrial processes, including papermaking processes. The fabric or belt includes linear components arranged along the MD and a matrix material that at least partially encapsulates one or more of the linear components. For example, the fabric or belt can be produced by various methods that make its production relatively simple, such as spiral technology with co-extruded polymers that form the matrix, thereby encapsulating the linear components and forming the first side and the second side of the fabric or belt.

[0047] The linear component can be a continuous system, such as a yarn, a cord, a strip or a similar windable material. The linear component can be tensile and / or flexible. In certain embodiments, the linear component has a sufficiently high modulus to carry. The linear component of the present invention may include any suitable material, such as elastic or non-elastic thermosetting plastics, thermoplastics, carbon, rayon, fiberglass, cotton, ceramic, aromatic polyamide, polyester, metal, polyethylene, glass, polyamide, polyphenylene sulfide (PPS) and / or polyetheretherketone (PEEK) materials in the form of multifilaments, monofilaments, cords, spun yarns, strips, twisted short hemp yarns, untwisted short hemp yarns and / or other materials and forms exhibiting desired physical, thermal, chemical or other properties. Other embodiments of the linear component include linear components comprising a coating and embodiments in which the linear component comprises a core and a fusible sheath, such as an embodiment in which the melting point of the core material is higher than the melting point of the fusible sheath material.

[0048] Linear components (such as yarns) are arranged along the MD of the industrial fabric of the present invention. The linear components can be arranged adjacent to each other along the MD and spaced a certain distance from each other. In some embodiments, the linear components are arranged in a substantially parallel array along the MD. In other embodiments, the linear components are in substantially the same plane. In other embodiments, the linear components are in different planes. In other embodiments, the industrial fabric includes multiple planes of linear components, wherein the planes are not parallel to each other in whole or in part. In yet other embodiments, at least two linear components are in planes parallel to each other, while other linear components in the industrial fabric are in planes that are not parallel to the planes of the at least two linear components.

[0049] The industrial fabric of the present invention may comprise one or more layers of linear components extending along the MD, which are at least partially encapsulated by the polymer matrix material. In certain embodiments, the linear components are completely encapsulated by the polymer matrix material.

[0050] In the industrial fabrics of the present invention, the number, material composition and / or size (eg, yarn diameter) of the linear components may vary. In certain embodiments, the linear components each comprise the same material and have the same size (eg, diameter).

[0051] When making the industrial fabric of the present invention, strips of polymer matrix material (e.g., resin) are usually extruded together with linear components along the longitudinal direction of the fabric or belt. This extrusion of polymer matrix material and linear components can be referred to as coextrusion, i.e., synchronous extrusion or simultaneous extrusion. Crosshead extrusion can be used for this operation, wherein the polymer matrix material is melted and extruded together with the previously manufactured linear components. Some embodiments can use extrusion that is only a few inches wide.

[0052] It is contemplated that the industrial fabrics of the present invention are produced in endless belt form, but some embodiments may be produced in flat form.

[0053] A polymer matrix material (such as a resin) encapsulates one or more of the linear components. The encapsulation of one or more linear components in the polymer matrix material joins the linear components to make the nonwoven industrial fabric of the present invention. In some embodiments, one or more linear components are partially encapsulated in the matrix material. In other embodiments, one or more linear components are completely encapsulated in the matrix material. In certain embodiments, all linear components in the industrial fabric of the present invention are completely encapsulated by the polymer matrix material.

[0054] The polymer matrix material (e.g., resin) can be made of any suitable polymer material for encapsulating one or more linear components. It is contemplated that many different extrudable polymer systems may be used, including but not limited to thermoplastics, polyurethanes, polyesters, polyamides, copolyesters, copolyamides, hot melt adhesives, copolymers of thermoplastic polyurethanes and acrylics, polyester elastomers, polyamide elastomers, and similar polymer systems. Typically, the polymer matrix material has a melting temperature that is lower than the melting temperature of the linear components.

[0055] The polymer matrix material can be further enhanced by comprising fiber equally, and this fiber can be chopped, such as carbon, glass, spunbond polyethylene, polyamide, polyester or similar material, such as polymer fiber, air-laid, fine woven fabric etc.The polymer matrix material can also comprise spunbond, spunlace, melt-blown or needle-punched fiber structure or fabric, to improve the integrity and the overall strength of fabric.Similarly, the polymer matrix material can be further enhanced by comprising nanoparticle, nanomaterial, inorganic filler particles (for example, clay, SiO ) and / or fibrous material (such as but not limited to glass, carbon, inorganic filler or polymer material), to increase the physical property of gained matrix.Reinforcement (such as nanoparticle or nanomaterial) can be combined in whole polymer matrix material or be combined in one or more parts of polymer matrix material.In some embodiments, reinforcement (such as nanoparticle or nanomaterial) is evenly combined in whole polymer matrix material.

[0056] The polymer matrix material in which the MD linear components are at least partially encapsulated provides sufficient reinforcement in the cross direction (CD) of the extruded industrial fabric of the present invention, so that linear components extending in CD are not required. Therefore, in various embodiments of the present invention, all linear components are arranged along the MD of the extruded industrial fabric. In these embodiments, no linear components are arranged along the CD of the extruded industrial fabric. Similarly, in other embodiments, the polymer matrix material of the industrial fabric of the present invention provides sufficient CD reinforcement so that a woven fabric layer with interlaced weft yarns (CD), such as a woven base fabric with interlaced warp yarns and weft yarns, is not required. Therefore, in various embodiments, the industrial fabric of the present invention only comprises an extruded polymer matrix material in which the MD linear components are at least partially encapsulated, wherein the fabric optionally comprises an applied coating or film on its front or machine side surface and / or is patterned on its front or machine side surface. In some of these embodiments, the extruded polymer matrix comprises additional reinforcements as described above, such as chopped fibers, nanoparticles, nanomaterials, organic fillers, etc., which are combined in whole or in part in a random manner (e.g., randomly in the CD of the fabric) throughout the polymer matrix material.

[0057] Industrial fabrics (such as belts) of the present invention can be used in any number of industrial processes, including papermaking processes. In some embodiments, the industrial fabrics of the present invention are suitable for use as paper machine fabrics ("PMC"), such as forming fabrics, press fabrics, drying fabrics, shoe press belts, transfer belts, reel belts, through air drying ("TAD") fabrics, imprinting fabrics, energy-saving technology advanced drying ("eTAD") fabrics, advanced tissue molding systems ("ATMOS") fabrics or belts, new tissue technology ("NTT") fabrics or belts, structured fabrics, and double nip thickener ("DNT") fabrics, belt filters, pulp cleaner fabrics, belts / fabrics / sleeves for producing nonwovens (e.g., airlaid, spunbond, meltspun, hydroentangled), belts for producing building products (e.g., oriented strand board ("OSB")), corrugator belts, textile finishing belts (e.g., pre-shrink finishing belts), or leather belts or sleeves.

[0058] Various embodiments of the present invention include fabrics with flat, patterned (impermeable), drilled patterned (permeable) or patterned and drilled patterned, additive or removal of patterned front (or paper side) surface. These embodiments can be used for, for example, conveyor belts, NTT belts, PMC or conveyor belt applications. In order to optimize the fabric (for example, belt) used in the dewatering process, such as forming section, pressurizing section or drying section, and as the conveyor belt or conveyor belt in a paper machine or tissue production machine, the surface should allow uniform pressure distribution and / or include a pattern to be imprinted on the front of paper, board, tissue or other materials produced thereon. In certain embodiments, the fabric of the present invention or bands including patterned or non-patterned fronts can be used for following industrial applications, such as the production of nonwovens, spunlace, building products, tissue, towels, boards, roofing boards, medium density fiberboard (MDF) and similar products. Fabric or bands can be constructed to include the front and back sides formed by a polymer matrix so as to be impermeable to gas and / or liquid (such as water). However, in certain other embodiments, the fabric or belt may include perforations formed by mechanical, laser, or similar methods to provide gas and / or liquid permeability.Other embodiments of industrial fabrics may include permeable and impermeable portions or sections.

[0059] In some embodiments, when patterning, the pattern on the front side (or "paper side") can vary in depth up to the maximum measurement of the final product (e.g., tissue or towel) produced thereon, but is not limited to methods such as laser, etching or other types of surface removal techniques (similar to gravure printing or negative relief). Patterning can be prepared by the following techniques, but is not limited to embossing techniques (e.g., from patterned rollers, belts or other patterned media) or patterning by resin deposition onto the surface (e.g., similar to relief printing or positive relief). Resin deposition can be applied by three-dimensional printing techniques, such as inkjet printing techniques or other resin injection techniques. A variety of patterns can be produced, such as, but not limited to, continuous or discontinuous lines, dots, logos, pictures, images, scripts and texts. Other possibilities of pattern elements include shapes such as, but not limited to, circles, polygons, curves, letters, numbers, words, waves, slits, pictures, trademarks or any desired shape or combination of shapes to create any random or orderly desired pattern. In some embodiments, the circular shape is a circle or an ellipse. These patterns are typically implemented on the front side of the fabric of the present invention in a configuration such as inverted, reversed or negative relief so that the corresponding desired image is impressed on the paper, board, tissue or other product material produced on the industrial fabric of the present invention (such as a belt).

[0060] In certain embodiments, spiral technology can provide channels on the ventilation back side of industrial fabrics (e.g., belts) to help guide and stabilize. In specific embodiments, the channels on the ventilation back side will prevent slipping on wet rotating rollers. In further embodiments, industrial fabrics can be ventilated by drilling holes through the fabric completely, making it permeable. In other embodiments, the back side can be smooth (planar) or have variable roughness (including but not limited to ground, added fibers or patterned), depending on application needs, or include batting fibers incorporated into the structure of fabrics (e.g., belts). Some other embodiments can include drilling holes or ventilation portions through industrial fabrics or belts.

[0061] Other embodiments include a front side with a coating or film, for example to increase sheet adhesion. For example, in some embodiments, a thin coating (such as a water-based polyurethane topcoat) can be applied to the front side of the fabric of the present invention to increase surface energy, thereby improving sheet adhesion. The coating can be sprayed, coated or extruded. Other coatings or films in some embodiments can consider hydrophobicity or other specific properties and are applied to industrial fabrics of the present invention. In certain embodiments, the material is applied to the front surface of the fabric of the present invention as a coating to improve sheet adhesion. In other embodiments, the material can be applied as a laminated film. The coating or film can be applied to the fabric of the present invention, which is impermeable, permeable, or a fabric with an impermeable portion and a permeable portion.

[0062] Furthermore, certain embodiments may involve producing an endless belt by laminating an impermeable or permeable polymer film on the front surface. In certain embodiments, the film is patterned by the methods described for other embodiments.

[0063] Now referring to the accompanying drawings in detail, it can be seen that Figure 1 and Figure 2 An embodiment of an industrial fabric 10 (such as a belt) of the present disclosure is shown in cross-section. The linear components 12 are oriented in the machine direction and generally have a high elastic modulus, thereby providing reinforcement and load-bearing capacity to the fabric or belt 10, particularly under machine direction tensile loads. The linear components 12 may be substantially parallel to each other and substantially in one or more planes (see FIG. Figure 7 ). The linear component 12 can be a continuous system, such as but not limited to a yarn, a cord, a strip or a similar spoolable material. The linear component 12 can also be configured as a multifilament yarn, a monofilament yarn, a cord, a spun yarn or a strip.

[0064] The linear component 12 is typically coextruded with a polymer matrix material (e.g., a resin), such as via cross-head extrusion, to form a resin matrix 14, wherein the linear component 12 is enclosed within the resin matrix 14. Many different extrudable polymer resin systems may be used, including but not limited to thermoplastics, polyurethanes, polyesters, polyamides, copolyesters, copolyamides, hot melt adhesives, copolymers of thermoplastic polyurethane (TPU) and acrylic, polyester elastomers, polyamide elastomers, and similar polymer systems. Although Figure 1 and Figure 2 The linear components 12 are shown in cross-section to reveal the linear components 12, but the linear components 12 of the finished fabric or tape 10 may be as shown. Figure 3 As shown, it is completely surrounded by the resin matrix 14, or as shown Figure 4 Partially exposed as shown, or some combination of the two.

[0065] The resin matrix 14 can also be further enhanced by including fibers, which can be chopped, such as carbon, glass, spunbonded polyethylene, polyamide, polyester, or similar materials such as polymer fibers, air-laid, fine woven fabrics, etc. The resin matrix 14 can also include spunbonded, spunlaced, melt-blown or needle-punched fiber structures or fabrics to improve the integrity and overall strength of the fabric of the present invention. Similarly, the resin matrix 14 can be further enhanced by including nanoparticles, nanomaterials, inorganic filler particles (e.g., clay, SiO2) and / or fiber materials (such as but not limited to glass, carbon, inorganic materials or polymer materials) to improve the physical properties of the resulting matrix. Fig. 22 Filler particles 30, which are typically inorganic, are shown for use, for example, in the fabric of the present invention.

[0066] In certain embodiments, the resin matrix 14 completely surrounds the linear component 12, thereby forming an impermeable front side (or paper side) 16 and an impermeable back side (or machine side) 18, such as Figure 3 In this and similar embodiments, the linear component 12 can be extruded synchronously with the resin matrix 14 in a spirally wound manner onto a dual roller system and an endless belt is produced from the creel 104 (see Fig.13 The extrudate may be only a few inches wide, with the linear component 12 passing through the extruder (see Fig.13 , extruder 102). Embodiments include fabrics having a flat, patterned (impermeable), perforated patterned (permeable), or patterned and perforated patterned, additive or removal patterned front (or paper side) surface. These embodiments can be used, for example, in conveyor belt, NTT belt, PMC or conveyor belt applications. In some embodiments, such as Figure 3As shown, the linear component 12 does not appear and does not pass through or extend through the impermeable front surface 16 or the impermeable back surface 18 of the finished fabric or belt 10. In other embodiments, such as Figure 4 As shown, the linear component 12 partially extends through the back side 18 of the resin matrix 14 so as to be partially exposed. Figure 5 , Fig. 9 and Fig.12 As shown, the industrial fabric or belt 10 may include holes or vents 21 drilled or otherwise formed through the resin matrix 14 to create a permeable structure. Figure 8 As shown, the impermeable front side 16 may include a thin "film" 20, such as a water-based polyurethane top coating, to increase the surface energy, thereby improving sheet adhesion. The film 20 may be sprayed, coated, or extruded. Other coatings or films in some embodiments may take into account hydrophobicity or other specific properties and be applied to the industrial fabrics of the present invention. In certain embodiments, the material is applied to the front surface of the fabric of the present invention as a coating to improve sheet adhesion. In other embodiments, the material may be applied as a laminated film.

[0067] Fig.14 A cross-sectional view of the fabric of the present invention along the longitudinal direction is shown in FIG, which shows the linear component 12 (polyethylene terephthalate (PET) yarn fibers) enclosed in a resin matrix 14 (TPU extrusion above and below the linear component 12), wherein the resin coating 20 is located on the front side 16 to improve sheet release of paper.

[0068] like Figure 6 As shown, the linear components shown as two different types of linear components 12A and 12B can be multiple types of linear components, such as but not limited to different multifilament yarns, monofilament yarns, cords, spun yarns or strips arranged in a parallel configuration. Figure 7 As shown, the linear components 12C, 12D may be configured in multiple planes. Figure 7 The linear component 12C is shown in the first plane, and Figure 7 The linear component 12D is shown in a second plane parallel to the first plane. Additional multiple similar parallel planes including linear components can be implemented. Another embodiment can include multiple planes of linear components, where the planes are not parallel to each other in whole or in part.

[0069] When passing something like Fig.13 In the method shown for producing an industrial fabric or tape 10, sequential extrusion passes (e.g., through crosshead extrusion) of a linear component 12 and a resin matrix 14 may be joined by a weld line 15, such as Figures 3 to 9 and Fig.12As shown. This weld line 15 may be the result of self-bonding of the resin because it is placed next to a previous passage of the resin. Certain embodiments use a bonded material that is green enough to undergo consolidation to transform multiple strips into one ribbon. Other options for forming a bond between strips are hot air, infrared, and laser bonding.

[0070] To optimize the use of dewatering processes such as forming, pressing or drying sections and as a paper machine or tissue production machine such as Valmet's Advantinge TM For example, a fabric (e.g., a belt) used for a conveyor belt or a conveyor belt in a papermaking machine (or other textured tissue production machine), the surface of the front side 16 should be prepared to allow uniform pressure distribution and / or a pattern to be imprinted in the produced paper, board or tissue. Such patterned belts can also be used in other industrial applications, such as building products, etc. In certain embodiments, the industrial fabrics (such as belts) of the present invention are completely impermeable to air and / or water. Other embodiments of industrial fabrics may include permeable and impermeable portions. In other embodiments, the fabric or belt 10 can be perforated via various means (e.g., laser or mechanical) to provide permeability to gases and / or liquids.

[0071] In certain embodiments, when patterned by an additive process, the pattern of front side 16 may vary in depth, for example, up to the maximum measure of the finished product produced on the fabric. Fig. 9 As can be seen in FIG. 1 , the front face 16 may include additive pattern elements 22 that may be formed by a process such as resin deposition on the resin matrix 14 while maintaining the impermeability of the front face 16 in embodiments without holes or vents 21. These additive pattern elements 22 may be formed as Fig.10 The continuous additive pattern 22 shown (the dark areas are additive) may be formed as shown in FIG. Fig.11 Discrete additive pattern shown (dark areas are additive). A wide variety of patterns can be produced, such as, but not limited to, continuous or discontinuous lines, dots, logos, pictures, images, scripts, and text. Other possibilities for pattern elements include shapes such as, but not limited to, circles, polygons, waves, slits, pictures, logos, or any desired shape or combination of these shapes to create any desired pattern, whether random or ordered.

[0072] Fig.16 , Fig.19 , Fig. 20 and Fig.21 An example of an additive pattern element on the front side 16 of the fabric 10 is shown in FIG. Fig.16 Resin is shown deposited on the front side 16 of the extruded fabric 10 to form additive elements 22 with perforations 21 between the additive elements 22 . Fig.17Shows the corresponding Fig.16 The back side 18 of the fabric 10 further shows perforations 21 . Fig.18 The diagram shows the area near the perforation 21. Fig.16 1 is a cross-sectional view of a fabric 10 in cross-section (CD). The drilled perforations 21 are shown with additive elements 22 around the periphery of the drilled perforations 21 and may also be formed by the drilled perforations or protrusions caused by the formation of the drilled perforations. A circular end view of the linear component 12 is further shown in the extruded polymer matrix 14 in this figure. Fig.19 An additive element 22 is shown that is shaped like a bicycle chain. Similarly, Fig. 20 and Fig.21 An additive element 22 similar to a dumbbell is included on the front side 16 . Figures 19 to 21 The illustrated embodiment does not include any perforations, holes or vents 21. However, it is contemplated that embodiments of the present disclosure include Figures 19 to 21 , but including perforations, vents or drillings 21. It should be noted that Fig.19 and Fig. 20 The white lines on the additive element 22 in FIG. 5 are due to light reflections during the photographic process.

[0073] Similarly, if Fig.12 As shown, the front side 16 may include subtractive pattern elements 24, such as voids and patterns in the resin matrix 14, which are formed by material removal, such as but not limited to laser, etching or other types of surface removal techniques (similar to gravure printing or negative relief), while maintaining the impermeability of the front side 16 in the absence of holes or vents 21. These subtractive pattern elements 24 can be formed as shown. Fig.10 The continuous subtractive pattern shown (white areas are removed) or can be formed as Fig.11 Discrete subtractive pattern 24 is shown (white areas are removed). A wide variety of subtractive patterns can be produced, such as, but not limited to, continuous or discontinuous lines, dots, logos, pictures, images, scripts, and text. Other possibilities for pattern elements include shapes such as, but not limited to, circles, polygons, waves, slits, pictures, logos, or any desired shape or combination of these shapes to create any random or ordered pattern. Fig.15 An embodiment of the present disclosure is shown in which the front face 16 includes a subtractive element 24 .

[0074] In general, the pattern can be prepared by the following techniques (but not limited to): laser technology or embossing technology (for example, from a patterned roller, belt or other patterned medium) or by resin deposition onto the surface to pattern (similar to relief printing or positive relief). The resin deposition can be applied by three-dimensional printing technology, such as inkjet printing technology or other resin injection technology. A variety of patterns can be produced, such as but not limited to continuous or discontinuous lines, dots, logos, pictures, images, scripts and text. Other possibilities for pattern elements include shapes such as but not limited to circles, polygons, waveforms, slits, pictures, trademarks or any desired shape or combination of these shapes to create any random or ordered desired pattern.

[0075] These patterns are typically implemented in an inverted, reversed or negative relief configuration on the front side of the fabric of the present invention so that the corresponding desired image is impressed on the paper, board, tissue or other product material produced on the industrial fabric of the present invention (such as belt).

[0076] Fig.13 An apparatus 100 is shown for forming an industrial fabric or industrial belt 10. A resin extruder 102 is provided to cross-head extrude resin material (of the resin matrix 14) and material of the linear component 12 received from a spool 104. A strip of resin material surrounding the linear component is helically wound around two parallel supporting "head and tail" rollers 106, 108 (the distance between the rollers 106, 108 defining the length of the resulting industrial belt 10), with adjacent passages of extruded material joined together at a weld line 15 (see also Figure 3 and Figure 4 ).

[0077] In certain embodiments, spiral technology can provide channels on the back side of the ventilation to help dewatering, guide and stabilize. In other embodiments, the back side can be smooth or planar, have variable roughness or include batting fibers incorporated into the structure of the fabric (e.g., belt).

[0078] Variations to the above will be obvious to those skilled in the art, but will not cause the invention so varied to exceed the scope of the invention. The appended claims should be interpreted to cover such cases.

Claims

1. A nonwoven industrial fabric comprising: a linear component arranged along the machine direction (MD) of the fabric; and An extruded polymer matrix material at least partially encapsulates one or more of the linear components, wherein the nonwoven industrial textile is impermeable.

2. A nonwoven industrial fabric comprising: a linear component arranged along the machine direction (MD) of the fabric; an extruded polymer matrix material that at least partially encapsulates one or more of the linear components, and wherein the extruded polymeric material comprises a first side and a second side, and wherein the first side and the second side are planar, and wherein one or more of the linear components at least partially extends through at least one of the first side and the second side.

3. A nonwoven industrial fabric comprising: linear components arranged in a plurality of planes along the machine direction (MD) of the fabric; and An extruded polymer matrix material at least partially encapsulates one or more of the linear components arranged in the plurality of planes.

4. A nonwoven industrial fabric for texturing a product, comprising: a linear component arranged along the machine direction (MD) of the fabric; and an extruded polymer matrix material at least partially encapsulating one or more of said linear components, The first side of the nonwoven industrial textile comprises a pattern formed by additive and / or subtractive elements for imparting a desired texture on the product.

5. The nonwoven industrial textile of any one of claims 1 to 4, wherein the extruded polymer matrix material completely encapsulates one or more of the linear components.

6. The nonwoven industrial textile according to any one of claims 1 to 5, wherein the linear components are substantially parallel to each other.

7. The nonwoven industrial textile according to any one of claims 1 to 6, wherein the linear component is cross-head extruded together with the polymer matrix material.

8. The nonwoven industrial textile of any one of claims 1 to 7, wherein the linear component comprises a material selected from the group consisting of thermosets, thermoplastics, carbon, glass, polyesters, polyolefins, and polyamides.

9. The nonwoven industrial textile of any one of claims 1 to 8, wherein the extruded polymer matrix material comprises nanoparticles, nanomaterials, fiber materials, glass, carbon, inorganic fillers and / or polymer materials, optionally incorporated into the entire extruded polymer matrix material or a portion thereof.

10. The nonwoven industrial textile according to any one of claims 1 to 9, wherein the extruded polymer matrix material is selected from the group consisting of thermoplastics, polyurethanes, polyesters, polyamides, copolyesters, copolyamides, hot melt adhesives, copolymers of thermoplastic polyurethane (TPU) and acrylic, copolymers of TPU and polyester elastomers, and copolymers of TPU and polyamide elastomers.

11. The nonwoven industrial textile according to any one of claims 1, 3 to 10, wherein the extruded polymer matrix material completely encapsulates all of the linear components.

12. The nonwoven industrial textile of any one of claims 1, 3 to 10, wherein the extruded polymer matrix material comprises a first side and a second side, and wherein the first side and the second side are planar and the linear component does not extend through the first side or the second side.

13. The nonwoven industrial textile of any one of claims 1 to 10, wherein the extruded polymeric material comprises a first side and a second side, and wherein the first side and / or the second side are planar, and wherein one or more linear components extend at least partially through at least one of the first side and the second side.

14. The nonwoven industrial textile of any one of claims 1, 2, 4 to 13, wherein the linear components are substantially in the same plane.

15. The nonwoven industrial textile of any one of claims 1 to 13, wherein the linear components are in multiple planes.

16. The nonwoven industrial textile of any one of claims 1 to 15, wherein the first side of the nonwoven industrial textile comprises a pattern.

17. The nonwoven industrial textile of claim 16, wherein the pattern on the first side is formed by an additive and / or subtractive process.

18. The nonwoven industrial textile according to any one of claims 16 to 17, wherein the pattern on the first side is formed by a method selected from the group consisting of: laser etching, mechanical etching, embossing and resin deposition.

19. The nonwoven industrial textile according to any one of claims 16 to 18, wherein the pattern on the first side is formed by a resin deposition technique selected from the group consisting of: a three-dimensional printing technique and an inkjet printing technique.

20. The nonwoven industrial fabric of any one of claims 1 to 19, wherein the nonwoven industrial fabric is selected from the group consisting of: a conveyor belt; a paper machine fabric ("PMC"), wherein the PMC is a forming fabric, a pressure fabric, a drying fabric, a shoe pressure belt, a transfer belt, a reel belt, a through air drying ("TAD") fabric, an imprinting fabric, an Energy Efficient Technology Advanced Drying ("eTAD") fabric, an Advanced Tissue Forming System ("ATMOS") fabric or belt, a New Tissue Technology ("NTT") fabric or belt, or a structured fabric; a double nip thickener ("DNT") fabric; a belt filter; a pulp washer; a belt, fabric or sleeve for producing airlaid, spunbond, meltspun or hydroentangled nonwoven materials; a belt for producing building products; a belt for producing oriented strand board ("OSB"); a corrugator belt; a textile finishing belt; a shrink-proof belt; a tanning belt; and a tanning sleeve.

21. The nonwoven industrial textile of any one of claims 1 to 20, wherein the nonwoven industrial textile is a paper machine clothing ("PMC").

22. The nonwoven industrial textile according to any one of claims 1 to 21, wherein the textile comprises at least two different types of linear components.

23. The nonwoven industrial textile of any one of claims 1 to 22, wherein the linear components differ in one or more of number, material composition, or size.

24. The nonwoven industrial textile of any one of claims 1 to 23, wherein the extruded polymer matrix provides sufficient cross direction (CD) reinforcement to the textile.

25. The nonwoven industrial textile according to any one of claims 1 to 24, wherein all linear components are arranged along MD.

26. The nonwoven industrial textile of any one of claims 1 to 25, wherein the linear components are yarns.

27. The nonwoven industrial textile of any one of claims 1 to 26, wherein the linear component is selected from the group consisting of multifilaments, monofilaments, cords, spun yarns, and tapes.

28. The nonwoven industrial textile of any one of claims 1 to 27, wherein the linear component has sufficient modulus to bear load.

29. A method for forming a nonwoven industrial fabric according to any one of claims 1 to 28, comprising: providing a linear component disposed along a machine direction (MD) of the fabric; as well as The polymer matrix material is extruded such that the linear component is at least partially encapsulated in the polymer matrix material.

30. The method of claim 29, wherein the extruding forms a spiral configuration, the spiral configuration forming an endless belt.

31. A method according to any one of claims 29 to 30 comprising cross-head extruding the polymer matrix material together with the linear component.

32. The method of any one of claims 29 to 31, wherein the first side of the nonwoven industrial textile comprises a pattern.

33. The method of claim 32, wherein the pattern on the first side is formed by an additive process and / or a subtractive process.

34. The method of any one of claims 32 to 33, wherein the pattern on the first side is formed by a method selected from the group consisting of: laser etching, mechanical etching, embossing and resin deposition.

35. The method of any one of claims 32 to 34, wherein the pattern on the first side is formed by a resin deposition technique selected from the group consisting of: a three-dimensional printing technique and an inkjet printing technique.

36. The method of any one of claims 29 to 35, wherein the nonwoven industrial fabric is selected from the group consisting of: a conveyor belt; a paper machine clothing ("PMC"), wherein the PMC is a forming fabric, a pressure fabric, a drying fabric, a shoe pressure belt, a transfer belt, a reel belt, a through air drying ("TAD") fabric, an impression fabric, an Energy Efficient Technology Advanced Drying ("eTAD") fabric, an Advanced Tissue Forming System ("ATMOS") fabric or belt, a New Tissue Technology ("NTT") fabric or belt, or a structured fabric; a double nip thickener ("DNT") fabric; a belt filter; a pulp washer; Tapes, fabrics or sleeves for producing airlaid, spunbond, meltspun or hydroentangled nonwoven materials; belts used in the production of building products; belts used in the production of oriented strand board ("OSB"); corrugator belts; textile finishing belts; shrink-proof belts; tanning belts; and tanning sleeves.

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