Industrial fabric with laser-induced structure

Abstract

An industrial fabric formed from a continuous substrate or a substrate having ends joined to form a tape having a first surface, and which may include an MD yarn system joined to a CD yarn system, a film, or a nonwoven. At least a portion of the substrate at the first surface includes: a first internal material formed of a first polymer mixed with a laser absorbing material; a first outer material formed of a second polymer; and a first blowing agent in at least one of the first inner material or the first outer material. And a protrusion extending from the first surface at a selected location, the protrusion including an expanded portion of the first outer material, the expanded portion having a foam or cellular structure resulting from activation of the first foaming agent in or adjacent to the first inner material.

Description

[0001] Cross-reference of related patent applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 468,296, filed May 23, 2023, the contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates to industrial fabrics, and more particularly to papermaking fabrics used in papermaking processes. The invention especially relates to through-air dryer (TAD) fabrics, wherein raised structures and / or patterns formed by such raised structures are disposed on a paper support surface. Background Technology

[0004] Paper fabrics, particularly TAD fabrics, are known for their non-compression dewatering operation on TAD machines during the TAD process. Dewatering of the nascent fiber web for forming paper products is accomplished by vacuuming the formed fabric in a known manner, followed by through-drying the TAD fabric in a through-flow hot air dryer. Products with improved properties obtained using non-compression dewatering technology are particularly useful for tissue and paper towel products. These properties include improved bulk, CD stretch, and absorbency. In North America, the percentage of tissue production currently performed on TAD machines is increasing.

[0005] To enhance the bulk and absorbency of paper products, it is known to provide a paper support profile for TAD fabrics, which includes protrusions and / or pockets transferred to the paper product. These protrusions and / or pockets may be formed by a weaving pattern of CD (transverse) and MD (machine direction) yarns in the fabric, or by a material laminated onto the surface of a base fabric.

[0006] While satisfactory in many respects, improvements are still needed in the production of TAD fabrics and in the variety of different surface patterns on the paper support side formed by protrusions and / or holes.

[0007] There is also a need for improvements in other areas of papermaking to provide watermarks and / or increase bulk and / or absorbency more efficiently and / or at a lower cost.

[0008] This invention aims to address these and other needs. Summary of the Invention

[0009] In brief, an industrial fabric is provided, comprising a continuously formed substrate or a substrate having ends connected to form a strip having a first surface and a second surface. At least a portion of the substrate at the first surface comprises a first inner material formed of a first polymer mixed with a laser-absorbing material (e.g., carbon black or other laser-absorbing dye); and a first outer material formed of a second polymer. A first foaming agent is located in at least one of the first inner material or the first outer material. Protrusions extend from the first surface at selected locations, and the protrusions include expanded portions of the first outer material having a foam or cellular structure, the foam or cellular structure being generated by activation of the first foaming agent in the first inner material or in a region adjacent to the first inner material. These protrusions form a protrusion morphology pattern on the first surface in a simple and easily arrangable manner to provide different morphological patterns.

[0010] In one embodiment, the protrusion is encapsulated between a solid portion of the first outer material (excluding foam or porous structures) and the first inner material. When the foaming agent is in the first outer material, this can be part of the first outer material in which the foaming agent has not yet been activated. When the foaming agent is located in the first inner material, it can also be encapsulated separately by the first outer material.

[0011] In another embodiment, at least a portion of the substrate being treated comprises a second inner material formed of a third polymer mixed with a laser-absorbing material and a second outer material formed of a fourth polymer, and a second foaming agent is located in at least one of the second inner material or the second outer material. A second protrusion extends from a second surface at a selected second surface location, and the second protrusion includes an expanded portion of the second outer material having a foam or porous structure, the foam or porous structure being generated by activation of the second foaming agent in or adjacent to the second inner material.

[0012] In one embodiment, the second protrusion is encapsulated between a solid portion of the second outer material (excluding foam or porous structures) and the first inner material. When the second foaming agent is in the second outer material, this can be a portion of the second outer material in which the second foaming agent has not yet been activated. When the second foaming agent is located in the second inner material, it can also be encapsulated separately by the second outer material. This allows the protrusion to form on both support surfaces. Here, the first and third polymers can be the same polymer, and the second and fourth polymers can also be the same polymer, and the first and second foaming agents can be the same foaming agent.

[0013] The substrate may also have a second protrusion extending from the second surface at a selected location, and the second protrusion includes an expanded portion of the first outer material having a foam or porous structure, the foam or porous structure being generated by activation of a first foaming agent in or adjacent to the first inner material at the second surface.

[0014] The second protrusion forms a protrusion morphology pattern on the second surface in a simple and easy-to-arrange manner to provide different morphology patterns.

[0015] In one embodiment, the first blowing agent is a chemical blowing agent. Here, the chemical blowing agent can be thermally activated. In a preferred arrangement, the chemical blowing agent is thermally activated at an activation temperature in the range of 160°C to 350°C. The blowing agent can also be a physical blowing agent.

[0016] In one embodiment, the substrate is a fabric comprising an MD yarn system connected (e.g., interlaced) to a CD yarn system and continuously formed or having ends connected to form a band, and at least one of the CD yarns or MD yarns comprises: a core formed of a first polymer mixed with a laser-absorbing material to form a first inner material; and a skin or layer formed of a first outer material by a second polymer and a first foaming agent.

[0017] In one embodiment, at least some of the CD yarns include a core formed of a first polymer mixed with a laser-absorbing material and a sheath or layer formed of a second polymer and a first foaming agent. Here, the MD yarn does not contain any foaming agent and is not activated to form protrusions. Some or all of the CD yarns may include a core formed of a first polymer mixed with a laser-absorbing material and a sheath or layer formed of a second polymer and a first foaming agent.

[0018] In one embodiment, the fabric or layer comprises an inner portion formed of a second polymer and a first foaming agent, and an outer portion formed of a polymer without any foaming agent. This ensures an impermeable polymer layer on the foam or porous structure created by the first foaming agent.

[0019] In one embodiment, the second polymer is a thermoplastic elastomer (TPE) synthesized from a homopolymer, copolymer, or blend, and includes, for example, thermoplastic polyurethane (TPU), thermoplastic olefins, thermoplastic copolyesters, thermoplastic polyamides, and thermoplastic vulcanates. Examples are PEBA, TPEE, or COPE. Other suitable polymers may also be used.

[0020] The first polymer can be any suitable homopolymer, copolymer or blend thereof, and can be, for example, PET.

[0021] In one embodiment, the substrate is a thin film having a first inner material as a first layer formed of a first polymer mixed with the laser-absorbing material; and a first outer material as a second layer formed of a second polymer and a first foaming agent, the second layer being situated on the first layer. The substrate may also be formed of a nonwoven fabric, wherein at least some of the filaments are formed of a first outer material consisting of a first polymer mixed with the laser-absorbing material as the first inner material, and a second layer or yarn layer formed of a second polymer and a first foaming agent situated on the first inner material.

[0022] Preferred applications for industrial fabrics are as papermaking fabrics and / or as fabrics for through-type hot air dryers.

[0023] In one embodiment, the protrusions are arranged in a repeating pattern on the first surface forming the support surface. Here, the protrusions may be arranged in a repeating pattern on the first surface forming the machine side surface.

[0024] In another aspect, an industrial fabric is provided having a continuously formed or end-jointed substrate, the ends being connected to form a strip having a first surface and a second surface. At least a portion of the substrate at the first surface comprises a first material formed of a first polymer and a first foaming agent. Protrusions extend from the first surface at selected locations, and the protrusions include expanded portions of the first material having a foam or porous structure generated by the activation of the first foaming agent in the first material.

[0025] In one arrangement, the protrusion is completely enclosed within a solid portion of the first material, excluding foam or porous structures.

[0026] In one embodiment, the first surface includes a first monofilament formed of a first polymer mixed with a first blowing agent, and the protrusion includes an expanded portion of the monofilament having a foam or porous structure generated by the activation of the first blowing agent within the monofilament.

[0027] In another aspect, the industrial fabric may have at least a portion of the substrate on the second surface comprising a second material formed of a third polymer mixed with a second foaming agent, and a second protrusion extending from the second surface at a selected location on the second surface. The second protrusion includes an expanded portion of the second material having a foam or porous structure generated by activation of the second foaming agent in the second material. The first and third polymers may be the same polymer, and the first and second foaming agents may be the same foaming agent. Alternatively, the second protrusion may be formed solely by activating the first foaming agent at a desired location on the second surface of the substrate.

[0028] In this embodiment, the first foaming agent can be a chemical foaming agent. The first foaming agent can also be a physical foaming agent. The second foaming agent can be the same as or different from the first foaming agent.

[0029] In another aspect, a method is provided for forming an industrial fabric having a positive morphological form. The method includes: (a) providing a substrate continuously formed or having ends, the ends being joined to form a strip having a first surface and a second surface, at least a portion of the substrate at the first surface comprising a first inner material formed of a first polymer mixed with a laser-absorbing material and a first outer material formed of a second polymer and a first foaming agent located in at least one of the first inner material or the first outer material; and (b) applying energy at a selected location on the first surface of the substrate to activate the first foaming agent in an adjacent region, thereby forming a protrusion extending from the first surface, the protrusion comprising an expanded portion of the first outer material having a foam or porous structure formed by the foaming agent.

[0030] The method may also optionally include encapsulating the protrusion between a solid portion of the first outer material (excluding foam or porous structures) and the first inner material.

[0031] The method can also be carried out substantially as described herein for a substrate having a first surface having a first material formed of a first polymer mixed with a first foaming agent, wherein the first polymer is itself laser-absorbing and heat-generating, and the protrusions include expanded portions of the first polymer having a foam or porous structure generated by the foaming agent.

[0032] In one aspect, applying energy includes applying a laser at a selected location and absorbing the laser energy through a first internal material to generate heat. Optionally, the laser may be activated based on a lacquer pattern to apply energy at the selected location, thereby forming at least one of a protruding shape or a connecting contour.

[0033] In one embodiment of the method, the laser may include a high-power near-infrared (NIR) laser with digital light processing (DLP) technology, and the method further includes irradiating a two-dimensional region of a first surface with laser in a single laser application, and controlling the height of the protrusion via grayscale imaging control of the laser energy applied to the first surface. This allows for the formation of complex protrusion patterns in a faster manner than with point-by-point laser steering systems.

[0034] In one embodiment, the foaming agent is a thermally activated chemical foaming agent activated at an activation temperature in the range of 160°C to 350°C, and heat is generated in this range at the interface between the first internal material and / or the first external material in the region between the first internal material and the first external material.

[0035] The preferred application of this method is in the manufacture of papermaking fabrics.

[0036] In one embodiment of the method, the substrate is a fabric comprising an MD yarn system connected (e.g., interlaced) to a CD yarn system and continuously formed or having ends connected to form a strip, and at least one of the CD yarns or MD yarns comprises: a core formed of a first polymer mixed with a laser-absorbing material to form an inner material; and a skin or layer formed of a second polymer and a first foaming agent to form an outer material.

[0037] In all embodiments of industrial fabrics, the first surface can be a machine-side surface, where the protrusions provide enhanced abrasion resistance; or a support-side surface, where the protrusions can be used for various functions, such as for conveying applications, for example, adjusting the gripping and release properties of the industrial fabric. Particular attention is also paid to industrial fabrics for papermaking where the protrusions are used to form patterns in the paper products being carried or formed to provide watermarking and / or increase bulk and / or absorbency. The use of industrial fabrics with this type of protrusion allows for more efficient and / or lower cost formation of a wide array of patterns.

[0038] In embodiments with CD and MD yarn systems, the base fabric can be woven or nonwoven.

[0039] In one embodiment, the industrial fabric is a papermaking fabric. More preferably, the fabric is a TAD fabric, and the morphological pattern enhances the bulk and absorbency of the tissue paper or paper towel product carried on the support surface. Using such a fabric, bulk and absorbency can be increased without incurring significant capital costs to rebuild existing wet crepe machines. Furthermore, this allows bulk to be generated in the forming section without having to press it in (using felting and suction pressure rollers), avoiding the disadvantages of pressing that densifies the paper, eliminates bulk, and reduces absorbency. Using the industrial fabric of the present invention as a forming fabric allows for imparting a paper morphology while still maintaining other key performance characteristics of the forming wire (fiber support, good drainage, etc.).

[0040] Additionally, the industrial fabric of the present invention, when used as a forming fabric, can be used to produce drainage marks. After the foil section on the forming table, in many cases, the forming fabric passes through a series of vacuum chambers and then through a dandy roll. A dandy roll is located on top of the forming fabric above the absorbent chamber. This is a lightweight, open-structured roll covered with a wire mesh fabric, gently resting on the surface of the paper. Its function is to flatten the top surface of the paper and improve its smoothness. The pattern on the dandy roll can leave a semi-transparent pattern in the form of a name, badge, or graphic on the wet paper, called a watermark. Using the industrial fabric of the present invention, watermark patterns can be produced using the forming fabric.

[0041] Another application of the industrial fabric according to the invention is as a conveyor belt. Here, the surface morphology can be used to adjust the gripping and releasing properties of the conveyor belt. In applications such as forming spunbond and meltblown nonwoven materials, the morphology of the support side of the industrial fabric can be adjusted to obtain gripping and releasing properties most comparable to the nonwoven product being formed and conveyed.

[0042] Preferably, the second polymer is a thermoplastic elastomer (TPE) synthesized from homopolymers, copolymers, or blends, and includes, for example, thermoplastic polyurethane (TPU), thermoplastic olefins, thermoplastic copolyesters, thermoplastic polyamides, and thermoplastic vulcanized rubbers. Other materials such as PEBA, TPEE, or COPE may also be used.

[0043] The base fabric can also be formed from spunbond and meltblown nonwoven materials comprising yarns having the core / sheath structure described above.

[0044] Alternatively, the substrate may preferably be provided in the form of a biaxially stretched film. Here, the substrate is continuously formed or has ends connected to form a strip having a first surface and a second surface, and at least a portion of the substrate includes: a first inner material, which may be a first film layer formed of a first polymer; and a first outer material, which may be a second film layer or coating formed of a second polymer and a first foaming agent located on the first inner material. The substrate may be structured, for example, punched or otherwise having pores defined therein, to provide desired permeability. Protrusions extend from the first surface at selected locations, and the protrusions include expanded portions of the first outer material having a foam or porous structure generated by the activation of the first foaming agent in a region adjacent to the first inner material and completely encapsulated by the first inner material and the solid portion of the first outer material (excluding foam or porous structure).

[0045] In a preferred embodiment, the protrusions are arranged on the support surface in one or more repeating patterns. Here, the repeating pattern includes a pattern that can vary depending on where specific features (e.g., knots, if the substrate is a woven fabric) appear on the first and / or second surfaces of the substrate, or where spaces appear between the CD yarns and / or MD yarns. Variations also occur for spunbond or meltblown nonwovens, depending on the location of the chopped fibers or yarns. Variations may also occur due to providing structure for the film used as a substrate. All these variations are encompassed within the meaning of the term "repeating pattern" as used herein.

[0046] In one embodiment, the substrate is formed of a fabric having an MD yarn system connected to the CD yarn system, at least some of the CD yarns include a core formed of a first polymer mixed with a laser-absorbing material such as carbon black, and the sheath is formed of thermoplastic polyurethane (TPE) and a chemical foaming agent, and the MD yarns do not include TPU and may be, for example, monofilaments.

[0047] In one embodiment, the first foaming agent and / or the second foaming agent is a chemical foaming agent, and preferably thermally activated using laser energy, the laser energy being absorbed by a first internal material in the yarn core of the yarn arrangement or a first film layer in the film arrangement to reach the activation temperature of the chemical foaming agent in the region of the yarn skin adjacent to the yarn core of the yarn arrangement or in the second external material of the second film layer or coating in the film arrangement.

[0048] In a preferred arrangement, the first blowing agent is a chemical blowing agent and is thermally activated at an activation temperature in the range of 160°C to 350°C. Alternatively, the first blowing agent may be a physical blowing agent, such as a trapped liquid particle, which may also be thermally activated.

[0049] In an alternative embodiment, the yarn sheet (or second film layer or coating) comprises: an inner portion formed of a second polymer and a first foaming agent; and an outer portion formed of a second polymer or another polymer without any chemical foaming agent. The second polymer is also preferably TPU.

[0050] In a preferred embodiment where the substrate is a fabric, the CD yarns are arranged in monofilaments. However, multifilament arrangements can also be used.

[0051] In another aspect, a method is provided for forming an industrial fabric with a positive morphological form. The method includes: (a) A substrate continuously formed or having ends, the ends being connected to form a strip having a first surface and a second surface, at least a portion of the substrate at the first surface comprising a first inner material formed of a first polymer mixed with an energy-absorbing material, and a first outer material formed of a second polymer and a first foaming agent located on the first inner material; and (b) Applying energy to a selected location on a first surface of a substrate to activate a first foaming agent in a region adjacent to a first inner material, thereby forming a protrusion extending from the first surface, the protrusion including an expanded portion of a first outer material having a foam or porous structure generated by the first foaming agent in a region adjacent to the first inner material, a solid portion of the first outer material excluding a foam or porous structure, and a region completely enclosed by the first inner material.

[0052] In one embodiment of the method, applying energy includes applying a laser at a selected location and generating heat by absorbing the laser energy through a first internal material, which may be a yarn core when the substrate is formed from a yarn system or a nonwoven fabric made of yarn or filament, or may be a first film layer of the substrate formed as a film.

[0053] The method can also be carried out substantially as described herein for a substrate having a first surface comprising a first material formed of a first polymer mixed with a first foaming agent, wherein the first polymer is itself laser-absorbing and heat-generating, and the protrusion comprises an expanded portion of the first polymer having a foam or porous structure generated by the foaming agent.

[0054] Laser energy can be applied by one or more lasers moving along one or more paths, with intermittent or constant energy applied. Alternatively, as discussed above, industrial systems employing high-power near-infrared (NIR) lasers with digital light processing (DLP) technology can be used, where a 2D region is exposed to a single laser irradiation. This makes complex image printing faster than point-by-point laser movement control systems. DLP technology also enables multi-bit depth / height differentiated grayscale imaging by programming the on and off times of micromirrors. This can be used to set and / or control the height of protrusions to provide different profiles on a substrate.

[0055] In one embodiment, the foaming agent is a chemically activated foaming agent that is thermally activated at an activation temperature in the range of 160°C to 350°C, and in embodiments where the substrate is a fabric having one or more yarn systems, heat is generated in the region of the yarn skin adjacent to the yarn core within this range.

[0056] In a preferred arrangement, lasers are activated based on a woven pattern to apply energy at selected locations, thereby forming at least one of a protruding shape or a connecting profile. For example, one or more lasers may be mounted on a linear actuator that can move across the width of the fabric on the CD, be indexed to different CD locations, and be activated to form one or more protrusions before forward indexing the fabric on the MD, and repeat the process at desired locations to produce the desired morphological pattern of the protrusions. This avoids the need for complex weaving patterns on the MD and CD yarn systems, so that protrusions and pits can be produced solely based on the weaving pattern or by laminating additional material with a specific morphology onto the top of the base fabric.

[0057] In one application, the method is used to manufacture paper fabrics, and more preferably to manufacture TAD fabrics.

[0058] In one arrangement, the yarn skin includes an inner portion formed of TPE and a chemical foaming agent, and an outer portion formed of a second polymer (which may also be TPE) without a chemical foaming agent, and energy is applied to a selected location on the support surface of the base fabric to activate the chemical foaming agent of the inner portion to form protrusions.

[0059] In another aspect, an industrial fabric is provided, wherein a substrate is continuously formed or has ends connected to form a strip having a first surface and a second surface. At least a portion of the substrate comprises a first inner material formed of a first polymer and a first outer material formed of a second polymer and a first foaming agent located on the first inner material. The first inner material and the first outer material may be structured as described above, either formed from one or more yarn systems or as a thin film layer. However, the yarn core or the first thin film layer is not used to generate heat; for example, by adding carbon black, the first outer material is energy-absorbing, such that the first foaming agent can be activated by directly absorbing heat via the first outer material. Protrusions extend from the first surface at selected locations, and the protrusions include expanded portions of the first outer material having a foam or porous structure resulting from the activation of the first foaming agent. In this case, the first inner material is used for the mechanical properties of the industrial fabric.

[0060] According to this disclosure, as noted above, the blowing agent can be a chemical blowing agent (CBA) or a physical blowing agent (PBA), such as N2, CO2, butane, water, etc. The solubility and diffusivity of the blowing agent in the polymer determine whether this is possible and the effectiveness of PBA as a blowing agent. For example, some studies have shown that TPU can be foamed with water or water + CO2 to provide ultraporous foam. PBA can also be used to foam polyamides.

[0061] Aromatic TPU or other types of TPU, or even water, can be used as a foaming agent. The TPU is chosen to absorb water rapidly, allowing it to absorb a certain amount of water in the yarn or first outer layer. This allows localized areas to be exposed to heat, and the absorbed water evaporates, thus acting as a physical foaming agent. Here, the portions that have absorbed water but are not exposed to the laser do not foam.

[0062] One anticipated benefit of this disclosure is the ability to maintain high permeability after using a foaming agent to structure the substrate to create encapsulated foam zones or areas. No additional material needs to be added to the substrate (i.e., the surface) to produce the desired morphological protrusions.

[0063] A particular advantage of TAD and other papermaking fabrics is the reduced resistance to air and steam mass flow in the z-direction (thickness direction) and xy-plane, which will increase the drying rate.

[0064] While certain features are indicated in conjunction with the disclosed embodiments, one or more of these features can be combined to provide industrial fabrics, particularly TAD fabrics, that have a morphological form on a support surface (as a first surface), which offer greater flexibility in defining a particular morphology. Attached Figure Description

[0065] When reading in conjunction with the accompanying drawings, it is best to understand the foregoing description of the invention and the following detailed description. In the accompanying drawings: Figure 1 This is a cross-sectional view of a first embodiment of yarn used in industrial fabrics according to the present disclosure.

[0066] Figure 2 This is a cross-sectional view of a second embodiment of yarn used in industrial fabrics according to the present disclosure.

[0067] Figure 3 Is Figure 1 The enlarged detail shown in the indicated area shows a portion of the first outer material (shown here as the yarn skin) and the first inner material (shown here as the yarn core) at the selected location, and when laser energy is applied to the yarn at the selected location, a superimposed temperature distribution can be achieved through the portion of the yarn skin and the yarn core, and the laser energy is absorbed by the yarn core to generate peak heat at the area where the yarn core contacts the yarn skin.

[0068] Figure 4 Is with Figure 3 A similar magnified view shows that the foaming agent in the first outer material (here, the gauze) is preferably activated by laser-generated heat to form a cross-section of the yarn after the expansion of the first outer material, the activated foaming agent generating a foam or porous structure in the region adjacent to the first inner material, and the expansion is preferably completely encapsulated by the surface of the gauze material, which does not contain a foam or porous structure.

[0069] Figure 5 This is a schematic diagram showing a portion of the support surface of an industrial fabric formed from MD yarns and CD yarns, wherein protrusions are formed in the form of a morphological pattern (two different exemplary patterns are shown) on at least some of the CD or MD yarns, and the morphological pattern can be arranged by selecting the activation sites of the foaming agent at selected locations, wherein energy is applied to the support surface of the base fabric to activate the foaming agent in the yarn skin to form the protrusion arrangement.

[0070] Figure 6 This is a schematic diagram showing a base fabric that is continuously formed or has ends connected to form a continuous strip with a support surface.

[0071] Figure 7This is a cross-sectional view of a third embodiment of a cut yarn having a rectangular cross-section and including a first inner material formed of a first polymer mixed with a laser-absorbing material, and a first outer material formed of a second polymer and a first foaming agent located in (or mixed with) a second outer material, the yarn being used in an industrial fabric according to the present disclosure.

[0072] Figure 8 yes Figure 7 The third embodiment of the yarn shown is a cross-sectional view of the first outer material in which the foaming agent in the first outer material is preferably activated by laser-generated heat to form a protrusion. The protrusion comprises an expanded first outer material with a foam or porous structure, the foam or porous structure being generated by the activation of the foaming agent in a region adjacent to the first inner material. Moreover, at least the upper surface of the protrusion is preferably encapsulated with a solid material surface of the first outer material that does not contain a foam or porous structure.

[0073] Figure 9 It is a cross-sectional view of a fourth embodiment of cutting yarn, having a circular cross-section and including a first material formed of a first polymer mixed with a first foaming agent, and the yarn is used in an industrial fabric according to the present disclosure.

[0074] Figure 10 yes Figure 9 The fourth embodiment of the yarn shown is a cross-sectional view taken after the foaming agent in the first material is preferably activated by laser-generated heat to form a protrusion, the protrusion comprising an expanded first material with a foam or porous structure, the foam or porous structure being generated by the activation of the foaming agent.

[0075] Figure 11 This is a cross-sectional view of a fifth embodiment of cutting yarn, having a rectangular cross-section and including a first material formed from a first polymer mixed with a first foaming agent, the yarn being used in an industrial fabric according to the present disclosure.

[0076] Figure 12 yes Figure 11 The fifth embodiment of the yarn shown is a cross-sectional view after the foaming agent in the first material is preferably activated by laser-generated heat to form a protrusion, the protrusion comprising an expanded first material with a foam or porous structure, the foam or porous structure being generated by the activation of the foaming agent.

[0077] Figure 13 This is a cross-sectional view of a sixth embodiment of a yarn, having a circular cross-section and including a first material formed of a first polymer mixed with a first foaming agent and a first outer material formed of a second polymer, the yarn being used in an industrial fabric according to this disclosure.

[0078] Figure 14 yes Figure 13The sixth embodiment of the yarn shown is a cross-sectional view after the foaming agent in the first material is preferably activated by laser-generated heat to form a protrusion. The protrusion comprises an expanded first material with a foam or porous structure, which is generated by the activation of the foaming agent in a region adjacent to the first inner material. The protrusion is preferably encapsulated at least on the upper surface by the solid material surface of the first outer material.

[0079] Figure 15 This is a view of the first surface of an industrial fabric made from an interlacing system of MD and CD yarns, showing a pattern applied by a laser to form protrusions on the first surface in the form of a morphological pattern by a foaming agent in a first outer material used to thermally activate the CD yarns.

[0080] Figure 16 yes Figure 15 An enlarged view of the first surface of the industrial fabric shown illustrates some changes in the morphological pattern of the protrusions formed by laser thermal activation of the foaming agent in the CD yarn sheath, due to the position of the yarn, compared to the pattern used for activation.

[0081] Figure 17 This is an enlarged view of a portion of the end of an industrial fabric, including separately attached seam components.

[0082] Figure 18 Is with Figure 17 A similar view shows protrusions formed in a patterned manner on the seam component by applying a layer of second polymer mixed with a foaming agent as an outer layer on the seam component and by activating the foaming agent, for example, by activating it through thermal activation via applying a laser in a desired pattern.

[0083] Figure 19 This is a perspective view of a portion of an industrial fabric formed from a structured nonwoven film, for example, made from biaxially-oriented polyethylene terephthalate (BoPET).

[0084] Figure 20 yes Figure 19 A cross-sectional view of a structured nonwoven film, showing a coating or co-extruded layer formed by a second polymer mixed with a foaming agent as an outer layer.

[0085] Figure 21 Is with Figure 19 A similar perspective view shows, for example, the generation of protrusions from protrusions formed in a pattern on a first surface of a structured nonwoven film by activating a foaming agent through thermal activation via applying a laser to a desired pattern.

[0086] Figure 22 yes Figure 21A cross-sectional view of a structured nonwoven film, showing protrusions formed in the outer layer.

[0087] Figure 23 This is a view of the first surface of an industrial fabric made from an interlacing system of MD and CD yarns, showing another pattern applied by a laser to form protrusions in the form of a morphological pattern on the first surface by a foaming agent in a first outer material used to thermally activate the CD yarns.

[0088] Figure 24 This is a view of the first surface of an industrial fabric made from an interlacing system of MD and CD yarns, showing an additional pattern applied by a laser to form protrusions on the first surface in the form of a morphological pattern by a foaming agent in a first outer material used to thermally activate the CD yarns.

[0089] Figure 25 It is a cross-sectional view of a portion of a base fabric formed by a system of MD and CD yarns having protrusions formed on a first surface and a second surface.

[0090] Figure 26 It is a cross-sectional view of a rectangular monofilament, in which the first and second surfaces each have their own protrusions. Detailed Implementation

[0091] The specific terms used in the following description are for convenience only and are not restrictive. The fabric according to the invention is an industrial textile, preferably a papermaking fabric, and more preferably a TAD fabric. However, in some embodiments, it may have many industrial applications, such as conveyor belts, belts for pulp and filtration applications, etc. The fabric may be woven or nonwoven or formed of a structured film, and this term is used in a broad sense. The terms “support side” and “machine side” are used relative to their use in a preferred application in conveying applications to refer to the surface of the fabric; however, these terms only refer to the first and second surfaces or upper and lower surfaces of a planar fabric. “Yarn” is used generally to refer to monofilament or multifilament fibers. “Warp” and “Weft” are used to refer to yarns or monofilaments that extend in orthogonal directions in the fabric based on their position in the loom and, once mounted on a device, can be either machine-direction (MD) yarns or cross-direction (CD) yarns in the fabric, depending on whether the fabric is, for example, plain or continuous weave. In a preferred arrangement, the fabric may be plain-woven and sewn at the warp ends to form a continuous strip, such that the warp yarns are MD yarns and the weft yarns are CD yarns. The base fabric may also be continuously woven, in which case the weft yarns extend on the MD and the warp yarns extend on the CD. The base fabric may also be a multiaxial fabric assembled from a narrow strip of fabric wound at an angle to the MD around two spaced-apart rollers, its longitudinal edges joined together to form a wider strip of fabric. This strip may be woven or nonwoven. For the multiaxial arrangement, the MD and CD yarns are inclined at approximately 1° to 7° relative to the true MD and true CD. However, for the purposes of this disclosure, this will be referred to when referring to the MD and CD yarns. Regardless of how the base fabric is manufactured, the designations of warp, weft, and / or MD and CD as used in the following description are interchangeable. Furthermore, for nonwoven fabrics, these may be formed from spunbond or meltblown chopped fibers without a specific orientation. In addition, the base fabric can be a film, preferably a BOPET film, which can be foldable and laminated to provide more body and punched openings to regulate permeability.

[0092] Foaming agents are defined as compounds that are thermally unstable at the intended polymer processing temperature and decompose to produce gas or expand in other ways (e.g., water turns into steam). An example of a chemical foaming agent is azodicarbonamide (ADC), a known industrial foaming agent. Pure ADC decomposes between 200°C and 210°C. Specific activators can be added to ADC to lower its decomposition temperature to 150°C or even lower. Physical foaming agents are water, which can be absorbed or dispersed in materials that expand because water turns into steam when heated.

[0093] A positive topographic form refers to a protrusion formed on the surface of a fabric that extends beyond the nominal surface area created by interlacing or otherwise connecting MD and CD yarns (e.g., Figure 4 The distance H shown is the distance to the nominal surface of the nonwoven fabric or film.

[0094] When describing different implementations of fabric components, the same element number is used for elements that have the same function, even if there are slight differences in shape, such as yarns with different cross-sections.

[0095] Reference Figure 5 and Figure 6 An industrial fabric 10 according to a first embodiment is provided. The industrial fabric 10 includes a system of MD yarns 12 connected to a system of CD yarns 14 to form a base fabric 20 as a substrate 18. The base fabric 20 is continuously formed or has ends joined to form a belt 23, the belt 23 having a first surface 24 that may be a support surface and a second surface 26 that may be a machine-side surface. The MD yarns 12 and CD yarns 14 may be interwoven or otherwise joined (e.g., using an adhesive) to form the base fabric 20. Because the MD yarns 12 and CD yarns 14 are woven continuously, no seams are required. Alternatively, if the MD yarns 12 and CD yarns 14 are plain-woven, seams are required, as is known to those skilled in the art. The base fabric 20 may also be formed using the MD yarns 12 and CD yarns 14 as a spiral-wound fabric as defined above.

[0096] Now refer to Figures 1 to 4 At least some of the CD yarns 14 and / or MD yarns 12 include a core 30 (more generally, a first inner material 21), which is formed of a first polymer mixed with carbon black or any other suitable laser-absorbing material, such as PET or any other suitable polymer, which absorbs heat when exposed to some type of energy (e.g., laser). A sheath or layer 32 (more generally, a first outer material 22) is formed of a second polymer (e.g., thermoplastic polyurethane (TPU), homopolymer, block copolymer, or blend (e.g., PEBA, TPEE, or COPE)), and a foaming agent 34 is formed, for example, by co-extrusion onto or at least partially around the core 30. While TPU is preferred, other polymers may also be used.

[0097] The blowing agent 34 can be a chemical blowing agent as discussed above. However, other chemical blowing agents, including physical blowing agents, can also be used, which, when incorporated into the polymer material, form a foam or porous structure, for example, when activated by heat. In a preferred embodiment, the chemical blowing agent 34 is used and thermally activated, and more preferably, the chemical blowing agent 34 is thermally activated at an activation temperature T in the range of 160°C to 350°C.

[0098] like Figure 1 As shown, the yarn sheet or layer 32 can be formed as a single layer with the mixture of the second polymer and the foaming agent 34. Alternatively, as... Figure 2 As shown, the yarn sheet or layer 32 may include: an inner portion 32a formed of a second polymer and a foaming agent 34, and an outer portion 32b formed of a second polymer (or another polymer) without a foaming agent. In a preferred arrangement, the same second polymer is used. The inner portion 32a and the outer portion 32b may be co-extruded onto the yarn core 30.

[0099] like Figure 4 As shown in detail, protrusions 40 formed by activating the foaming agent 34 at selected locations 42 extend from at least some CD yarns 14 and / or MD yarns 12 on the first surface 24 (such as...). Figure 5 (As indicated) Extension. Activation of foaming agent 34 can be achieved by applying laser energy and accumulating heat, such as... Figure 3 The superimposed temperature distribution in the diagram shows that the energy absorbed by the yarn core 30 can be used to achieve an activation temperature, for example, above 160°C, at selected locations on the yarn through a portion of the yarn skin or layer 32, so as to generate peak heat in the region where the yarn core 30 contacts the yarn skin or layer 32.

[0100] like Figure 4 As shown, these protrusions 40 include an expanded first outer or gauze material 33 having a foam or porous structure 36, the foam or porous structure 36 being generated by the activation of a chemical foaming agent 34 in a region of the gauze 32, 32a adjacent to the yarn core 30, said region preferably being completely encapsulated by the solid gauze material surface 38 of the gauze 32, 32b, excluding the foam or porous structure 36. As shown, for example, in Figure 15 , Figure 23 and Figure 24 In the middle, these protrusions 40 are arranged in a repeating pattern on the support surface 24. Figure 5 Two different exemplary patterns are shown. One pattern forms a hexagonal raised shape across a group 15 of five CD yarns 14, with a not-protruding center forming a dimple. The other pattern consists of enlarged protrusions formed on three adjacent CD yarns. However, the size, shape, and spacing of the patterns are not limited to the examples shown and can take various forms, including graphics, shapes, characters, or pictures, such as... Figure 23 and Figure 24 As shown. Additionally, protrusions may be present on the first surface 24 and / or the second surface 26. If the first surface 24 is a support surface, the pit can be used for bulk enhancement during tissue formation. If the first surface is a machine-side surface, the protrusion 40 can be used for wear protection.

[0101] In a preferred arrangement, only some of the CD yarns 14 include a core 30 formed of a first polymer mixed with carbon black or other laser-absorbing material, and a skin or layer 32 or its internal portion 32a formed of a second polymer and a chemical foaming agent 34. Here, the CD yarns 14 are preferably arranged as monofilaments rather than multifilaments. This arrangement is useful in providing papermaking fabrics 10 (especially TAD fabrics) with protrusions 40 arranged in shapes, patterns, or contours, thereby forming repeating morphologies that can be easily changed by simply arranging different patterns at selected locations 42, preferably by applying energy to the selected locations 42 in the form of a laser beam to activate the chemical foaming agent 34 and form the protrusions 40.

[0102] Alternative constructions of CD and / or MD yarns 12', 14'; 12', 14' in Figures 7 to 14 As shown in the diagram. Alternative constructions of CD and / or MD yarns 12, 14; 12', 14' have the same type of protrusions 40, 40' formed by the activation of a foam or porous structure 36 produced by the chemical foaming agent 34 present in the yarn core 30, 30' and / or the yarn skin or layer 32, 32' on it. CD and / or MD yarns 12', 14' have rectangular cross-sections, while CD and / or MD yarns 12, 14 have circular cross-sections. Other cross-sections are also possible. Further differences in the additional embodiments are described below. These embodiments, as well as those described above, can also be used in nonwoven materials, since some or all of the filaments are used to form the nonwoven fabric.

[0103] Figure 7 and Figure 8A third embodiment is shown, which may be monofilament yarns of CD and / or MD yarns 12', 14' having a rectangular cross-section and including a first inner material 21' formed of a first polymer, which may be, for example, PET or any other suitable polymer, mixed with any other suitable laser-absorbing material or carbon black that absorbs heat when exposed to a specific type of energy, such as a laser. A first outer material 22' in layer form is formed of a second polymer (e.g., a thermoplastic elastomer (TPE) synthesized from homopolymers, copolymers, or blends) and includes, for example, thermoplastic polyurethane (TPU), thermoplastic olefins, thermoplastic copolyesters, thermoplastic polyamides, and thermoplastic vulcanizates (e.g., PEBA, TPEE, or COPE), and the foaming agent 34' described above is formed, for example, on or at least partially around the inner material 21' by co-extrusion. In the illustrated embodiment, the first outer material 22' exists only on the upper surface of the first inner material 21'; however, it may surround the entire first inner material 21'. While TPU is preferred for the first outer material 22', other polymers may also be used.

[0104] like Figure 8 As shown, a laser 50 is applied at a selected location, and the laser energy is absorbed by the first internal material 21' based on carbon black or other laser-absorbing materials, thereby generating heat to produce an activated foaming agent 34', thus forming a foam or porous structure 36. The foam or porous structure 36' and the expanding first external material 33' produce one or more protrusions 40'. The one or more protrusions 40' may be in the pattern form described above.

[0105] Figure 9 and Figure 10 The fourth embodiment is shown as a monofilament yarn that may be CD and / or MD yarns 12, 14, which may have a circular cross-section and include a first internal material 21 formed of a first polymer and a foaming agent 34. The first polymer may be any suitable polymer and may be mixed with any other suitable laser absorbing material or carbon black that absorbs heat when exposed to a particular type of energy, such as a laser.

[0106] like Figure 10 As shown, laser 50 is applied at a selected location, and the laser energy is absorbed by the first internal material 21 based on carbon black or other laser-absorbing materials, thereby generating heat to produce an activated foaming agent 34, thereby forming a foam or porous structure 36 in the first internal material that produces one or more protrusions 40. The foam or porous structure 36 of the one or more protrusions 40 may be completely encapsulated in the solid portion of the first material 21 that does not contain the foam or porous structure 36.

[0107] One or more protrusions 40 may be in the pattern form described above.

[0108] Figure 11 and Figure 12 A fifth embodiment is shown, which may be a monofilament yarn 12', 14' of CD and / or MD yarns, having a rectangular cross-section and including a first internal material 21' formed of a first polymer and a foaming agent 34'. The first polymer may be any suitable polymer and is mixed with any other suitable laser-absorbing material or carbon black that absorbs heat when exposed to a particular type of energy, such as a laser.

[0109] like Figure 12 As shown, laser 50 is applied at a selected location, and the laser energy is absorbed by the first internal material 21' based on carbon black or other laser-absorbing materials, thereby generating heat to produce an activated foaming agent 34', which in turn forms a foam or porous structure 36' in the first internal material that produces one or more protrusions 40'. The one or more protrusions 40' may be in the pattern form described above.

[0110] Figure 13 and Figure 14 A sixth embodiment is shown, which may be a monofilament yarn, such as CD and / or MD yarns 12, 14, having a circular cross-section and comprising a first inner material 21 formed of a first polymer and a foaming agent 34. The first polymer may be, for example, PET or any suitable polymer, and may be mixed with any other suitable laser-absorbing material or carbon black that absorbs heat when exposed to a specific type of energy, such as a laser. Depending on the first polymer, if the first polymer itself is a laser energy absorber to generate heat, then carbon black or other laser-absorbing material additives may be omitted. The first outer material 22, in the form of a layer, is formed of a second polymer (e.g., a thermoplastic elastomer (TPE) synthesized from homopolymers, copolymers, or blends) and includes, for example, thermoplastic polyurethane (TPU), thermoplastic olefins, thermoplastic copolyesters, thermoplastic polyamides, and thermoplastic vulcanizates (e.g., PEBA, TPEE, or COPE), and is formed, for example, on or at least partially around the inner material 21 by co-extrusion. In the illustrated embodiment, the first outer material 22 is in the form of a gauze sheet and surrounds the first inner material 21 in the form of a yarn core 30. However, it is also possible to provide only the upper surface of the first inner material 21 having a single layer of the first inner material 21.

[0111] like Figure 14As shown, a laser 50 is applied at a selected location, and the heat generated by the absorption of laser energy by the first internal material 21 based on the properties of the laser, including carbon black or other lasers, or based on the properties of the first polymer itself, generates heat to produce an activated foaming agent 34, forming a foam or porous structure 36 (in this case, in the first internal material 21). The foam or porous structure 36, together with the expanding first external material 33, produces one or more protrusions 40. The one or more protrusions 40 may be in the pattern form described above.

[0112] Reference Figure 15 and Figure 16 , Figure 15 The first surface 24 of the industrial fabric 10 is shown, which has a hexagonal pattern (labeled 44) ​​for activating the foaming agent 34, 34' in the CD yarns 14, 14' using a laser to repeat the pattern. Figure 16 The repetitive pattern of protrusions 40, 40' may vary depending on how the hexagonal pattern 44 intersects with CD yarns 14, 14'; however, it is still referred to as the repetitive pattern of protrusions 40, and these variations are covered in this disclosure. This also applies to the arrangement of MD yarns 12, 12' or CD yarns 14, 14' and MD yarns 12, 12' both comprising a first inner material 21, 21' formed of a first polymer mixed with carbon black and a first outer material 22, 22' / outer skin 32 or its inner portion 32a formed of a second polymer and foaming agent 34 and / or yarns 12, 12'; 14, 14' being formed solely of the first inner material 21, 21' comprising foaming agent 34.

[0113] Reference Figure 17 and Figure 18 A layer 32” formed of a second polymer mixed with foaming agent 34 is applied to seam member 46, which is used to join the ends of industrial fabric 10 together to form an endless loop. Figure 10 As shown, when activated, for example by thermal activation through the application of a laser to a desired pattern, the protrusions 40” are formed in a patterned form on the seam component. This allows a desired morphology to be added to the seam component 46.

[0114] For industrial fabrics formed as spunbond or meltblown nonwoven webs, some or all of the fibers used can be formed from a first inner material 21, 21' and a first outer material 22, 22'. The first inner material 21, 21' is formed from a first polymer mixed with carbon black or another laser-absorbing material. The first outer material 22, 22' can be in the form of a layer or outer yarn 32 or an inner portion 32a of the outer yarn 32 formed from a second polymer and a foaming agent 34, as described above. Figures 1 to 3As shown. Here, the first surface 24 and / or the second surface 26 may be activated by a laser at selected locations, for example, causing the foaming agent 34 to expand to form protrusions on one or both of the first surface 24 or the second surface 26. One or more of the other embodiments of the monofilament yarn described above can also be used to form a nonwoven web.

[0115] Now refer to Figures 19 to 22 This illustrates another embodiment of the industrial fabric 110. The industrial fabric 110 includes a substrate 120, preferably provided in the form of a biaxially stretched film. Here, the substrate 120 is continuously formed or has ends, the ends being connected to form a strip having a first surface 124 and a second surface 126. Figure 6 (Similar to band 23 in the text). If the thin film is like... Figure 19 As shown, when folded back onto itself, the film can be constructed with stamped portions defining openings and depths, wherein the folded ends define intersecting and connected rings via pivot 111. Figure 20 As shown, at least a portion of the substrate 120 includes: a first inner material 121, which may be a first thin film layer formed of a first polymer; and a first outer material 122, which may be a second thin film layer or coating formed of a second polymer and a foaming agent 134 located on the first inner material 121. Here, the first and second polymers may be those described above. The foaming agent 134 is preferably a chemical or physical foaming agent as described above.

[0116] like Figure 21 and Figure 22 As shown, the protrusion 140 extends from the first surface 124 at a selected location 142, and the protrusion 140 includes an expanded portion 133 of the first outer material 122. The expanded portion 133 has a foam or porous structure 136, which is generated by the activation of a foaming agent 134 in a region adjacent to the first inner material 121, optionally enclosed by a solid portion of the first outer material 122 that does not contain a foam or porous structure, and a region completely encapsulated by the first inner material 121. Figure 4 The structure of the protrusion 40 shown is similar.

[0117] Therefore, in a more general sense, the present invention provides an industrial fabric 10, 110 comprising a substrate 20, 120 continuously formed or having ends, the ends being connected to form a strip 23 having a first surface 24, 124 and a second surface 26, 126. At least a portion of the substrate 20, 120 at the first surface 24, 124 comprises a first inner material 21, 121 formed of a first polymer mixed with carbon black, and a first outer material 22, 122 formed of a second polymer and a first foaming agent 34, 134 located on the first inner material 21, 121. Protrusions 40 and 140 extend from the first surfaces 24 and 124 at selected locations 42 and 142, and each protrusion 40 and 140 includes an expanded portion of the first outer material 22 and 122. This expanded portion has a foam or porous structure, which is generated by the activation of a first foaming agent 34 and 134 in a region adjacent to and preferably completely encapsulated by the solid portion of the first outer material 22 and 122 (excluding the foam or porous structure) and the first inner material 21 and 121. The foaming agent 34 and 134 can be a chemical or physical foaming agent and can be thermally activated. The first surfaces 24, 124 may be machine-side surfaces, wherein the protrusions 40, 140 provide enhanced abrasion resistance, or the first surfaces 24, 124 may be support-side surfaces, wherein the protrusions 40, 140 may be used for various functions and are of particular interest in industrial fabrics 10, 110 for papermaking, and the protrusions 40, 140 are used to form patterns in the paper products that are carried or formed.

[0118] Now refer to Figure 25The protrusions 40, 40a may be disposed on both the first surface 24 and the second surface 26. Here, the base fabric 20 has CD yarns 14, 14' at the first surface 24, and is shown to have different CD yarns 15 formed in the same manner as the CD yarns 14, 14' according to one or more embodiments indicated above at the second surface 26. Here, the CD yarns 15 include: a second inner material 21a (similar to the first inner material 21), formed of a third polymer (which may be the same as or different from the first polymer) mixed with carbon black, serving as a yarn core 30a; and a second outer material 22a (similar to the first outer material 22), formed of a fourth polymer (which may be the same as or different from the second polymer) and a second foaming agent 34a (which may be the same as or different from the first foaming agents 34, 134), serving as a yarn sheath 32a located on the second inner material 21a. The second protrusions 40a (similar to 40) extend from the second surface 26 at selected locations on the second surface. The second protrusion 40a includes an expanded portion of the second outer material 22a, the expanded portion having a foam or porous structure, the foam or porous structure being generated by the activation of a second foaming agent 34a in a region adjacent to the second inner material 21a and preferably completely encapsulated by the solid portion of the second outer material 22a excluding the foam or porous structure 36a and the second inner material 22a. This provides the protrusions 40, 40a on both the first surface 24 and the second surface 26 of the substrate 20. These protrusions 40 form a protrusion morphology pattern on the first surface 24 and / or the second surface 26 in a simple and easily arranged manner to provide different morphology patterns.

[0119] Those skilled in the art will recognize that the same CD yarns 14, 14' (or MD yarns 12, 12') may also have protrusions formed on both the first surface 24 and the second surface 26. For example, refer to Figure 26 This illustrates another embodiment of the rectangular monofilament 14', wherein both the first surface 24 and the second surface 26 have their respective protrusions 40', 40'a. The first surface of the monofilament 14' is combined with the above-described embodiment. Figure 7 and Figure 8The same as described in the third embodiment. Furthermore, a second outer material 22'a (similar to the first outer material 22'), formed of a fourth polymer (which may be the same as or different from the second polymer) and a second blowing agent 34'a (which may be the same as or different from the first blowing agent 34'), is located on the second surface 26 of the inner material 21'. A second protrusion 40'a (similar to 40') extends from the second surface 26 at a selected location on the second surface. The second protrusion 40'a includes an expanded portion of the second outer material 22'a, the expanded portion having a foam or porous structure, the foam or porous structure being generated by activation of the second blowing agent 34'a in a region adjacent to the inner material 21', preferably completely enclosed by the solid portion of the second outer material 22'a excluding the foam or porous structure 36'a and the inner material 21'. Activation is described as activation by laser irradiation 50.

[0120] Generally, when it is desired that the protrusions 40, 140 are on both the first surfaces 24, 124 and the second surfaces 26, 126, an embodiment can be provided in which at least a portion of the base fabric 20, 120 at the second surfaces 26, 126 comprises: a second inner material (similar to the first inner material 21, 121) (if the first inner material itself is required not to absorb laser irradiation), which is formed of a third polymer (which may be the same as or different from the first polymer) mixed with carbon black or another laser-absorbing material; a second outer material (similar to the first outer material 22, 122), which is formed of a fourth polymer (which may be the same as or different from the second polymer) and a second foaming agent (which may be the same as or different from the first foaming agent 34, 134) mixed with at least one of the second inner material or the second outer material, and the second protrusions 40a, 40'a (similar to 40, 140) extend from the second surfaces 26, 126 at selected second surface locations. The second protrusion includes an expanded portion of the second outer material having a foam or porous structure. This foam or porous structure is generated by the activation of a second foaming agent 34a, 34'a in a region adjacent to, and preferably completely encapsulated by, the solid portion of the second outer material (excluding the foam or porous structure) and the second inner material. This provides protrusions 40, 140 on both the first surfaces 24, 124 and the second surfaces 26, 126 of the substrates 20, 120. The fourth and / or fifth embodiments of the monofilament described above can also be adapted to the second surface, providing protrusions formed solely of the second inner material mixed with the second foaming agent, without requiring a second outer material.

[0121] In each case, these protrusions 40, 40a, 40'a, 140 form a protrusion morphology pattern on the first surface 24, 124 and / or the second surface 26, 126 in a simple and easily arranged manner, thereby providing different morphology patterns.

[0122] In another aspect, a method is provided for forming industrial fabrics 10, 110 having first surfaces 24, 124, the first surfaces 24, 124 having a positive morphological form formed by protrusions 40, 140.

[0123] The method includes providing a base fabric or substrate 20, 120, the base fabric or substrate 20, 120 being continuously formed or having ends, the ends being connected or connectable to form a strip 23 having a first surface 24, 124 and a second surface 26, 126, at least a portion of the substrate 20, 120 at the first surface 24, 124 comprising: a first inner material 21, 121 formed of a first polymer mixed with carbon black or another laser irradiation absorbing material, a first outer material 22, 122 formed of a second polymer, and a first foaming agent 34, 134 located in at least one of the first inner material 21, 121 or the first outer material 22, 122. In embodiments where the substrate is a base fabric 20, the first inner material 21 is formed as a yarn core 30, while the first outer material 22 is formed as a sheath 32 for forming the CD yarn 14 and / or MD yarn 12 of the base fabric 20.

[0124] The method further includes, preferably, applying laser energy to select locations 42, 142 on the first surfaces 24, 124 of the substrates 20, 120 to activate chemical foaming agents 34, 134 in regions adjacent to the first internal material 21, 121, thereby forming a foam extending from the first surfaces 24, 124 (e.g., at a height H above the nominal surface, such as...). Figure 4 (As shown) Protrusions 40, 140. Protrusions 40, 140 include expanded outer portions or gauze materials 33, 133, the expanded outer portions or gauze materials 33, 133 having foam or porous structures 36, 136, the foam or porous structures 36, 136 being generated by chemical foaming agents 34, 134 in at least one of the first inner materials 21, 121 or the first outer materials 22, 122 in a region of the first inner material or adjacent to the first inner material. The foam or porous structures 36, 136 are preferably completely encapsulated by the solid portion of the first outer material 122 that does not contain the foam or porous structures 36, 136.

[0125] The method can also be combined with the fourth and / or fifth embodiments of the monofilament described above for forming only protrusions of the first internal material mixed with the first foaming agent, without having a first external material. The method would thus be modified to remove the first external material.

[0126] In a preferred embodiment, applying energy includes applying laser 50 at a selected location and generating heat by the first internal materials 21, 121 based on carbon black or other laser-absorbing materials to absorb laser energy and thus generate heat. The heat is generated at the surface of the first internal materials 21, 121 where laser 50 is applied, and preferably reaches an activation temperature in the range of 160°C to 350°C in the region adjacent to the first external materials 22, 122 and the first internal materials 21, 121.

[0127] An exemplary heat distribution in Figure 3 As shown in the diagram. Here, the heat distribution is designed such that, in the first embodiment of the first outer material 22 in the form of a gauze 32, the foam or porous structure 36 does not extend to the surface 38 of the first outer material 22, as... Figure 4 As shown, surface 38 is formed as a solid gauze material surface 38. The same or similar heat distribution can be applied to other embodiments including the thin film substrate 120.

[0128] In a preferred arrangement, a controller or processor is used to position and activate the laser 50 based on an arrangement pattern that can be stored in a fixed memory. The laser 50 is activated at a selected location 42, thereby forming at least one of the shape, pattern, or connection profile of the protrusion 40. This can be achieved, for example, by providing the laser 50, which is mounted on the CD for controlled movement, while the fabric 20 is addressed in a stepwise manner on the MD to define a relative movement grid between the laser and the substrate fabric, thereby allowing the morphology, shape, pattern, or connection profile of the protrusion 40 to be formed as desired.

[0129] Laser energy can be applied by one or more lasers 50 moving along one or more paths, and the energy can be applied intermittently or constantly. Alternatively, an industrial system employing a high-power near-infrared (NIR) laser 50 with digital light processing (DLP) technology can be used, where a 2D area is exposed to laser irradiation in a single irradiation. This makes complex image printing faster than a point-by-point laser-movement control system. DLP technology also enables multi-bit depth / height differentiated grayscale imaging by programming the micromirror on and off times. This can be used to set and / or control the heights of protrusions 40, 40', 40a, 40'a, 140 to provide different profiles on substrates 20, 120.

[0130] for Figure 2The embodiments of yarns 12 and 14 shown include an outer portion 32b of a yarn skin 32 formed of a second polymer without a chemical foaming agent, where heat distribution is less critical and ensures that the foam or porous structure 36 cannot reach the surface 38 of the yarn skin 32 to reach the protrusion 40 that is expected to be completely encapsulated.

[0131] Preferably, the method is used to manufacture paper fabrics 10, 110, and more particularly TAD fabrics.

[0132] Therefore, the invention has been described in detail. It should be understood and apparent to those skilled in the art that many physical modifications can be made (while only a few modifications are exemplarily illustrated in the detailed description of the invention) without altering the inventive concept and principles of the particular embodiments therein. It should also be understood that numerous embodiments may be incorporated only into a portion of the preferred embodiments, and for those incorporated portions, this does not alter the inventive concept and principles of the particular embodiments therein. Therefore, this embodiment and, as appropriate, the selected configuration are to be regarded in all respects as exemplary and / or illustrative rather than restrictive, and the scope of the invention is indicated not by the foregoing description but by the appended claims, and thus all alternative embodiments and modifications to this embodiment falling within the equivalent meaning and scope of the claims are covered within the scope of the invention.

Claims

1. An industrial fabric comprising: a substrate continuously formed or having ends joined to form a tape having a first surface and a second surface; at least a portion of the substrate at the first surface, the at least a portion comprising: a first interior material formed from a first polymer mixed with a laser absorbing material; and a first exterior material formed from a second polymer and a first blowing agent located in at least one of the first interior material or the first exterior material; and a protrusion extending from the first surface at a selected location, the protrusion comprising an expanded portion of the first exterior material having a foam or cellular structure produced by the first blowing agent in at least one of the first interior material or the first exterior material being activated at a region in or proximate to the first interior material.

2. The industrial fabric of claim 1, wherein the protrusion is enclosed between a solid portion of the first exterior material not including the foam or cellular structure and the first interior material.

3. The industrial fabric of claim 1, wherein the laser absorbing material is carbon black.

4. The industrial fabric of claim 1, further comprising: at least a portion of the substrate at the second surface comprising: a second interior material formed from a third polymer mixed with a laser absorbing material and a second exterior material formed from a fourth polymer and a second blowing agent located in at least one of the second interior material or second exterior material; and a second protrusion extending from the second surface at a selected second surface location, the second protrusion comprising an expanded portion of the second exterior material having a foam or cellular structure produced by the second blowing agent in at least one of the second interior material or the second exterior material being activated at a region in or proximate to the second interior material.

5. The industrial fabric of claim 4, wherein the first polymer and the third polymer are the same polymer, and the second polymer and the fourth polymer are the same polymer, and the first blowing agent and the second blowing agent are the same blowing agent.

6. The industrial fabric of claim 1, wherein the first blowing agent is a chemical blowing agent.

7. The industrial fabric of claim 6, wherein the chemical blowing agent is heat activated.

8. The industrial fabric of claim 7, wherein the chemical blowing agent is heat activated at an activation temperature in a range of 160 °C to 350 °C.

9. The industrial fabric according to claim 1, wherein the substrate is a fabric comprising a system of MD yarns connected to a system of CD yarns, and continuously formed or having ends joined to form the belt, and at least one of the CD yarns or the MD yarns comprises: a yarn core formed from the first polymer mixed with the laser absorbing material to form the first interior material; and a yarn sheath or layer formed from the second polymer and the first blowing agent forming the first exterior material.

10. The industrial fabric of claim 1, wherein, The substrate is a fabric including an MD yarn system connected to a CD yarn system, and the substrate is continuously formed or has ends joined to form the belt, and at least one of the CD yarns or the MD yarns includes a yarn core formed of the first interior material, and a first exterior material is a sheath or layer formed over the yarn core.

11. The industrial fabric of claim 10, wherein the yarn sheath or layer comprises: an interior portion formed of the second polymer and the first blowing agent; and an exterior portion formed of a polymer without any blowing agent.

12. The industrial fabric of claim 10, wherein the second polymer thermoplastic elastomer (TPE) is synthesized from a homopolymer, a copolymer, or a blend thereof.

13. The industrial fabric of claim 1, wherein the substrate is a film having the first interior material as a first layer formed of the first polymer mixed with the laser absorbing material, and the first exterior material as a second layer formed of the second polymer, the second layer being on the first layer.

14. The industrial fabric of claim 1, wherein the industrial fabric is a papermaking fabric.

15. The industrial fabric of claim 1, wherein the protrusions are arranged in a repeating pattern on the first surface forming a support surface.

16. The industrial fabric of claim 1, wherein the protrusions are arranged in a repeating pattern on the first surface forming a machine side surface.

17. The industrial fabric of claim 1, wherein the first polymer is a homopolymer, a copolymer, or a blend thereof.

18. The industrial fabric of claim 1, wherein the first blowing agent is a physical blowing agent.

19. An industrial fabric, comprising: a substrate continuously formed or having ends joined to form a belt having a first surface and a second surface; at least a portion of the substrate at the first surface including a first material formed of a first polymer and a first blowing agent; and protrusions extending from the first surface at selected locations, the protrusions including an expanded portion of the first material having a foam or cellular structure produced by the first blowing agent being activated in the first material.

20. The industrial fabric of claim 19, wherein the protrusions are completely enclosed in a solid portion of the first material that does not include the foam or cellular structure.

21. The industrial fabric of claim 19, wherein the first surface includes a first monofilament formed of the first polymer mixed with the first blowing agent, and the protrusions include an expanded portion of the monofilament having a foam or cellular structure produced by the first blowing agent being activated within the monofilament.

22. The industrial fabric of claim 19, wherein the first material further includes carbon black or another laser energy absorbing material.

23. The industrial fabric of claim 19, further comprising: at least a portion of the substrate at the second surface including a second material formed of a third polymer mixed with a second blowing agent; and a second protrusion extending from the second surface at a selected second surface location, the second protrusion including an expanded portion of the second material having a foam or porous structure resulting from activation of the second blowing agent in the second material.

24. The industrial fabric of claim 23, wherein the first polymer and the third polymer are the same polymer, and the first blowing agent and the second blowing agent are the same blowing agent.

25. The industrial fabric of claim 19, further comprising a second material formed from a second polymer located on the first material.

26. The industrial fabric of claim 19, wherein the first blowing agent is a chemical blowing agent.

27. The industrial fabric of claim 19, wherein the first blowing agent is a physical blowing agent.

28. A method of forming an industrial fabric having a surface in a positive topographical form, the method comprising: providing a substrate that is continuous or has ends that are joined to form a tape having a first surface and a second surface, at least a portion of the substrate at the first surface including a first inner material formed from a first polymer mixed with a laser absorbing material and a first outer material formed from a second polymer and a first blowing agent located in at least one of the first inner material or the first outer material; and applying energy to selected locations at the first surface of the substrate to activate the first blowing agent to form a protrusion extending from the first surface, the protrusion including an expanded portion of the first outer material having a foam or porous structure resulting from activation of the first blowing agent in at least one of the first inner material or the first outer material at a region in or proximate to the first inner material.

29. The method of claim 28, further comprising encapsulating the protrusion between a solid portion of the first outer material not including the foam or porous structure and the first inner material.

30. The method of claim 28, wherein the applying energy includes applying a laser at the selected locations and generating heat by absorption of the laser energy by the first inner material.

31. The method of claim 30, wherein the laser is activated based on a programmed pattern to apply the energy at the selected locations to form at least one of an outer shape or a connecting profile of the protrusion.

32. The method of claim 30, wherein the laser includes a high power near infrared (NIR) laser with digital light processing (DLP) technology, and the method further comprises exposing a two-dimensional area of the first surface to laser irradiation in a single laser application, and controlling a height of the protrusion via grayscale imaging control of laser energy applied to the first surface.

33. The method of claim 28, wherein the blowing agent is a heat activated chemical blowing agent that is activated at an activation temperature in the range of 160°C to 350°C, and heat is generated in this range in a region of the first interior material and / or the first exterior material at an interface between the first interior material and the first exterior material.

34. The method of claim 28, wherein the method is used to manufacture a papermaking fabric.

35. The method according to claim 28, wherein the substrate is a fabric comprising an MD yarn system joined to a CD yarn system, and continuously formed or having ends joined to form the belt, and at least one of the CD yarns or the MD yarns comprises: a core formed from the first polymer mixed with the laser absorbing material to form the interior material; and a sheath or layer formed from the second polymer and the first blowing agent to form the exterior material.

36. The method of claim 28, wherein the substrate is a film having: the first interior material as a first layer formed from the first polymer mixed with the laser absorbing material; and the first exterior material as a second layer formed from the second polymer, the second layer being on the first layer.

37. A method of forming an industrial fabric having a surface in the form of a positive topography, the method comprising: providing a substrate that is continuously formed or has ends that are joined to form a belt having a first surface and a second surface, and at least a portion of the substrate at the first surface includes a first material formed from a first polymer and a first blowing agent; and applying energy at selected locations at the first surface of the substrate to activate the first blowing agent to form protrusions extending from the first surface at the selected locations, the protrusions including an expanded portion of the first material having a foam or porous structure generated from the first blowing agent being activated in the first material.

38. The method of claim 37, wherein the first material further includes carbon black or another laser energy absorbing material.

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