Discretized Pattern Belts for Tissue, Towels, and Nonwovens

Abstract

The present invention relates to industrial fabrics such as patterned belts used to generate three-dimensional structures in products produced thereon, for example in the papermaking field, for textile products, and in nonwoven processing. The present invention relates to patterned belts that can be provided with endless, various, complex patterns using discretization, for example, where the individual subunits comprising the pattern elements are not connected and therefore do not act as stress-bearing members of the patterned belt.

Description

[Technical field]

[0001] The present invention relates to industrial fabrics such as patterned belts used in the papermaking field, for textile products, and in nonwoven processing to create three-dimensional structure in products produced thereon. [Background technology]

[0002] Patterned belts are used to produce three-dimensional products, e.g., sheet products such as paper, tissue, towels, and sheets of synthetic nonwoven fabrics. These patterned belts are typically employed in parts of processes where variations in thickness of the belting can directly impart thickness, bulk, and three-dimensional patterns to the rolled goods being produced. This type of patterned belt construction typically includes an underfabric, such as a woven understructure for dimensional stability and load-bearing properties, and an upper surface that is added to specifically impart texture, pattern, and bulk. The upper surface material can be thermoplastic or thermosetting in nature and can be applied directly in the form of a liquid resin. Bonding can be chemical or thermal, or a combination of both.

[0003] In tissue and towel production, through-dryer equipment utilizes patterned belting to create sheet products with bulk and softness while simultaneously reducing material costs and providing recognizable patterns for branding purposes. Previous belting constructions and belting processing methods have been able to provide (i) simple patterns in sheet products using discrete macro deposition, and (ii) complex patterns in sheet products using film lamination to create a continuous lattice on the surface of the belt.

[0004] However, previous and existing technologies have challenges. For example, there is a limit to the pattern complexity of film lamination. Film lamination can only produce a continuous grid since discrete portions of the pattern are removed to produce the pattern. Additionally, there is a limit to the pattern complexity due to the reduction in the permeability of the belt. As the pattern complexity increases, a significant portion of the belt surface is covered with additional material to produce the pattern. The blocked open area on the bottom fabric directly reduces the air and water permeability. Since vacuum devices are used in the manufacture of rolled goods to attract the fibers to the patterned surface and release them in place during the drying process, the reduction in permeability typically leads to reduced water removal from the sheet and poorer control of the sheet during formation. At lower permeabilities, the two options available for production of rolled goods are (i) slowing down the belt speed to avoid disturbances and keep the sheet in place, which results in reduced efficiency and higher production costs, and / or (ii) increasing the vacuum significantly, which typically results in more fiber loss through the belt, increasing machine side wear on the first layer, and increasing energy costs.

[0005] Additionally, as patterns become more complex, dimensional stability of the top surface becomes very important to maintain a controlled impression on the sheet being produced. Elasticity of the top material is often required to withstand the tension and compression forces present as the forming sheet moves through the forming portion of the manufacturing process. However, variations in thickness, width, and length of the top pattern surface due to the required elasticity create reduced control and variability in the formed pattern.

[0006] Another problem with the prior art is that there are limitations to structural strength when pattern complexity is increased; that is, stress failure (e.g., cracking), delamination, and durability challenges exist. In general, complex patterns typically require continuous lattices of various thicknesses, widths, and lengths to produce the desired final attributes of the sheet product. Continuous sections of top lamination or stacking create stress concentrations at both the edges and the body of the top surface material when the belt is repeatedly flexed, resulting in both delamination and stress cracking. Either delamination or stress cracking can result in premature belt failure.

[0007] Challenges also arise with respect to durability. More specifically, trade-offs in material durability and abrasion resistance are made by the need to accommodate the heat, tension, and compression requirements as the belt runs through its processing loop in producing a sheet product. Generally, softer, more flexible materials are less durable and abrasion resistant than harder, more dimensionally stable materials. Summary of the Invention [Means for solving the problem]

[0008] The present invention relates to an industrial fabric for producing a patterned product. The industrial fabric comprises a first layer having a length and a width and a second layer covering at least a portion of a top surface of the first layer. The second layer comprises two or more non-adjacent subunits deposited on the top surface of the first layer.

[0009] In some embodiments, two or more non-adjacent subunits form a pattern element.

[0010] In other embodiments, two or more non-adjacent subunits each have a three-dimensional shape.

[0011] In yet other embodiments, the first layer and second layer of the industrial fabric are chemically, thermally, or mechanically bonded together.

[0012] In some embodiments, the pattern elements form a complex pattern.

[0013] In certain embodiments, the first layer is a woven, nonwoven, laminate, or composite.

[0014] In yet other embodiments, the first layer is a nonwoven fabric selected from a machine direction yarn arrangement, a cross machine direction yarn arrangement, a braid, a series of independent links, spiral link fabrics, extruded mesh, knitted structures, foils, films, spunbond fabrics, carded fibers, needled fibers, airlaid fibers, meltblown fibers, and / or wet laid fiber structures.

[0015] In some embodiments, the non-adjacent subunits of the industrial fabric comprise an industrial polymer, a thermoplastic, a thermoplastic polyurethane, a polyamide, a polyester, a copolyester, an ethylene vinyl acetate (EVA), a thermoset, and / or a combination thereof. In select embodiments, the thermoset is a catalyzed, moisture-cured, heat-activated, or light-activated polymer system. In further embodiments, the thermoset is a catalyzed, moisture-cured, heat-activated, or light-activated polymer system polyurethane, urethane acrylate, or silicone.

[0016] In certain embodiments, the permeability of the industrial fabric is increased by about 10% to 90% as compared to an industrial fabric having continuous pattern elements.

[0017] In other embodiments, the non-adjacent subunits of the second layer of the industrial fabric extend across the entire length and / or width of the first layer.

[0018] In some embodiments, the top surface of the first layer is the top surface of the forming side of the lower fabric.

[0019] In certain embodiments, the pattern elements are selected from round shapes, polygonal shapes, lines, curves, letters, numbers, words, logos, trademarks, animals, plants, foods, people, landforms, and / or combinations thereof. In certain embodiments, the round shapes are circles or ellipses. In yet other embodiments, the polygonal shapes are selected from triangles, squares, rectangles, pentagons, hexagons, heptagons, octagons, rhombus, diamonds, and / or stars.

[0020] In some embodiments, the three-dimensional shape of the non-adjacent subunits is selected from a cube, a cylinder, a pyramid, a cone, a prism, a sphere, an ellipsoid, a regular tetrahedron, and / or combinations thereof, hi other embodiments, the shape of the cylinder is round or rectangular.

[0021] In a particular embodiment, the industrial fabric is a patterned or textured belt.

[0022] In some embodiments, the inter-subunit spacing of non-adjacent subunits of the pattern element minimizes substantial fiber intrusion of the patterned product into the areas between the non-adjacent subunits of the pattern element, while in yet other embodiments, fibers of the patterned product bridge the non-adjacent subunits of the pattern element.

[0023] In certain embodiments, the non-adjacent subunits do not act as stress-bearing members of the industrial fabric. In some embodiments, the industrial fabric reduces stress in the second layer. In certain embodiments, the industrial fabric reduces cracking and / or delamination in the second layer. In still other embodiments, the industrial fabric reduces one or more of bending, flex fatigue, or compressive stress in the second layer.

[0024] In some embodiments, one or more of the non-adjacent subunits of the second layer are coplanar with the first layer.

[0025] In certain embodiments, the industrial fabric comprises a third layer or more layers. In some embodiments, the third layer or more layers are selected from woven fabrics, nonwoven fabrics, laminates, and / or composites. In other embodiments, the third layer or more layers are nonwoven fabrics selected from machine direction yarn arrangement, cross machine direction yarn arrangement, braid, series of independent links, spiral link fabric, extruded mesh, knitted structure, foil, film, spunbond fabric, carded fiber, needled fiber, airlaid fiber, meltblown fiber, and / or wetlaid fiber structures.

[0026] In some embodiments, the industrial fabric comprises a third layer that is a bottom fabric, with the first layer covering at least a portion of the top surface of the third layer.

[0027] In certain embodiments, the first layer of the industrial fabric is selected from spunbond fabrics, carded fibers, needled fibers, airlaid fibers, meltblown fibers, and / or wetlaid fiber constructions.

[0028] In yet another embodiment, the industrial fabric comprises a third layer that is a bottom fabric, and the first layer is a layer of batting fibers covering at least a portion of the top surface of the third layer. In an optional embodiment, the batting fibers of the first layer are attached to the third layer using needling.

[0029] The present invention further relates to a method of producing a patterned product, the method comprising the steps of patterning the product with an industrial fabric, the industrial fabric comprising a first layer having a length and a width, and a second layer covering at least a portion of a top surface of the first layer. The second layer comprises two or more non-adjacent subunits deposited on the top surface of the first layer. In some embodiments, the two or more non-adjacent subunits each have a three-dimensional shape. In some embodiments, the non-adjacent subunits of the second layer of the industrial fabric do not act as stress-bearing members of the fabric.

[0030] In some embodiments, the industrial fabric used in the method comprises two or more non-adjacent subunits forming a pattern element. In certain embodiments, the pattern element is selected from round shapes, polygonal shapes, lines, curves, letters, numbers, words, logos, trademarks, animals, plants, foods, people, landforms, and / or combinations thereof. In still other embodiments, the pattern elements form a complex pattern.

[0031] In another embodiment, the permeability of the industrial fabric used in the present method is increased by about 10% to 90% as compared to fabrics having continuous pattern elements. [Brief description of the drawings]

[0032] [Figure 1] FIG 1A shows an example of a general discretization strategy of the present invention, illustrating a standard sequential deposition on a belt; FIG 1B shows an example of a general discretization strategy of the present invention, illustrating a deposition of non-adjacent subunits on a belt according to an embodiment of the present invention; and FIG 1C shows an example of a general discretization strategy of the present invention, illustrating a deposition of non-adjacent subunits on a belt according to an embodiment of the present invention. [Diagram 2] FIG. 2 shows multiple pattern elements of FIG. 1B or FIG. 1C on a belt to generate a pattern. The pattern in FIG. 2 represents a total area of ​​40 mm×40 mm with 300 μm discretized subunits making up the pattern elements. FIG. 2 shows how non-adjacent subunits can generate both pattern elements at one scale, and the overall pattern at a larger scale. [Figure 3A] FIG. 3A is a diagram (three-dimensional, i.e., 3D) showing an example of a bending stress finite element analysis (FEA) of a belt in a standard continuous deposition. As shown by the accompanying color-coded bar graph shown in FIG. 3A, areas that are medium gray represent areas of high stress, areas that are light gray represent areas of intermediate stress, and areas that are dark gray or black represent areas of low stress. The color-coded bar graphs are also applicable to FIG. 3B and FIGS. 4-8 discussed below. [Figure 3B]FIG. 2 shows an example (two-dimensional or 2D) of a bending stress finite element analysis (FEA) of a belt in a standard continuous deposition. [Figure 4A] FIG. 13 shows an example (in 3D) of bending stress FEA of a belt with a stack of non-adjacent subunits, where the high and intermediate stress regions are located in a first layer or substructure and not in the second layer of non-adjacent subunit stacks. [Figure 4B] FIG. 13 shows an example (in 2D) of bending stress FEA of a belt with a stack of non-adjacent subunits. The high and intermediate stress regions are located in a first layer or substructure and not in a second layer of non-adjacent subunit stacks. [Figure 5A] FIG. 4D shows a belt with FEA of continuous lines of resin in the inverse pattern to that of FIG. 4A and FIG. 4B, and associated bending stress FEA representing a lattice, e.g., holes in the continuous layer of resin. The high stress areas are located at the surface of the second layer (continuous lines of resin). [Figure 5B] FIG. 4D shows a belt with FEA of continuous lines of resin in the inverse pattern to that of FIG. 4A and FIG. 4B, and associated bending stress FEA representing a lattice, e.g., holes in the continuous layer of resin. The high stress areas are located at the surface of the second layer (continuous lines of resin). [Figure 6A] FIG. 13 is a diagram (in 3D) showing the bending stress FEA of a belt with a standard continuous stack of the letter "A" shape. The higher stress areas of the standard continuous stack of the letter "A" are located on the surface of the second layer. [Figure 6B] 1 is a diagram (in 3D) showing bending stress FEA of a belt with a letter "A" shaped stack of non-adjacent subunits. The higher stress areas of the belt with the letter "A" non-adjacent subunit stack are located at the surface of the first layer. [Figure 7A] FIG. 13 shows (in 3D) the bending stress FEA of a belt for a standard continuous stack of spiral flower shapes. [Figure 7B] FIG. 13 shows (in 3D) the bending stress FEA of a belt with a spiral flower-shaped stack of non-adjacent subunits. [Figure 8]FIG. 7B is a (2D) enlarged view of FIG. 7B from above. [Figure 9] FIG. 9A shows an exemplary sheet product produced on a belt of the present invention having a patterned surface utilizing the general discretization strategy disclosed herein, and illustrates the resulting sheet product. FIG. 9B shows the stacking structure used to create the resulting sheet product of FIG. 9A. FIG. 9C shows an exemplary sheet product produced on a belt of the present invention having a patterned surface utilizing the general discretization strategy disclosed herein, and illustrates a 3D height map of the resulting sheet product. The light to medium gray areas in the color-coded height map of FIG. 9C indicate areas of higher elevation, while the white and dark gray to black areas indicate areas of lower elevation. The color coding of the height map in FIG. 9C is also applicable to FIGS. 11-15 and 17. FIG. 9D shows the stacking structure used to create the resulting sheet product of FIG. 9C. [Figure 10A] FIG. 10C shows a discrete stack with increased belt permeability compared to the belt with an uninterrupted stack in FIGS. 10D. [Figure 10B] FIG. 10C shows a discrete stack with increased belt permeability compared to the belt with an uninterrupted stack in FIGS. 10D. [Figure 10C] FIG. 2 shows a belt having an unbroken stack. [Figure 10D] FIG. 2 shows a belt having an unbroken stack. [Figure 11] Figure 11A shows a discretized hexagonal shape (pattern element) with round subunits. Figure 11B shows a discretized hexagonal shape (pattern element) with square subunits. Figure 11C shows an uninterrupted hexagonal shape (pattern element) with round holes or voids. Figure 11D shows an uninterrupted hexagonal shape (pattern element) with square holes or voids. [Figure 12A]FIG. 2 illustrates a belt having uninterrupted hexagonal shapes (pattern elements) with round holes before being subjected to a flex test. [Figure 12B] FIG. 1 shows a belt with continuous hexagonal features (pattern elements) with round holes after flex testing. [Figure 12C] FIG. 12C is a magnified portion of FIG. 12B showing a belt with continuous hexagonal shapes (pattern elements) with round holes after bending testing. [Figure 12D] FIG. 12C is a magnified portion of FIG. 12B showing a belt with continuous hexagonal shapes (pattern elements) with round holes after bending testing. [Figure 12E] FIG. 12C is a magnified portion of FIG. 12B showing a belt with continuous hexagonal shapes (pattern elements) with round holes after bending testing. [Figure 12F] A color-coded 3D height map image with colors that help you see damage, e.g., stress fractures (cracking), in the structure after flex testing. To show an example of a resin crack, a thin dark gray line indicating a crack is surrounded by a black oval. [Figure 13A] FIG. 2 illustrates a belt with uninterrupted hexagonal shapes (pattern elements) with square holes before being subjected to flex testing. [Figure 13B] FIG. 1 shows a belt with continuous hexagonal features (pattern elements) with square holes after flex testing. [Figure 13C] FIG. 13C is a magnified portion of FIG. 13B showing a belt with uninterrupted hexagonal features (pattern elements) with square holes after flex testing. [Figure 13D] FIG. 13C is a magnified portion of FIG. 13B showing a belt with uninterrupted hexagonal features (pattern elements) with square holes after flex testing. [Figure 13E] A color-coded 3D height map image with colors that help to see damage, e.g., stress fractures (cracks), in the structure after flex testing. The dark gray lines indicate cracks in the resin. [Figure 14A]FIG. 2 illustrates a belt with discretized hexagonal shapes (pattern elements) with rounded subunits before being subjected to flex testing. [Figure 14B] FIG. 2 illustrates a belt with discretized hexagonal shapes (pattern elements) with rounded subunits before being subjected to flex testing. [Figure 14C] FIG. 1 shows a belt with discretized hexagonal shapes (pattern elements) with rounded subunits after flex testing. [Figure 14D] FIG. 1 is a color-coded 3D height map image of the tested belt showing no detectable cracks or damage. [Figure 15A] FIG. 2 illustrates a belt with discretized hexagonal shapes (pattern elements) with square subunits before being subjected to a flex test. [Figure 15B] FIG. 2 illustrates a belt with discretized hexagonal shapes (pattern elements) with square subunits before being subjected to a flex test. [Figure 15C] FIG. 1 shows a belt with discretized hexagonal shapes (pattern elements) with square subunits after flex testing. [Figure 15D] FIG. 1 is a color-coded 3D height map image of the tested belt showing no detectable cracks or damage. [Figure 15E] FIG. 1 is a color-coded 3D height map image of the tested belt showing no detectable cracks or damage. [Figure 16A] FIG. 1 illustrates a belt with discretized hexagonal shapes (pattern elements) with closely spaced rounded subunits before being subjected to flex testing. [Figure 16B] FIG. 1 shows a belt with discretized hexagonal shapes (pattern elements) with closely spaced rounded subunits after flex testing. [Figure 17A] FIG. 1 illustrates a belt with discretized hexagonal shapes (pattern elements) with coarsely spaced rounded subunits before being subjected to flex testing. [Figure 17B]FIG. 1 shows a belt with discretized hexagonal shapes (pattern elements) with coarsely spaced rounded subunits after flex testing. [Figure 17C] FIG. 1 is a color-coded 3D height map image of the tested belt showing no detectable cracks or damage. [Figure 18A] A top view of the belt, using a scanning electron microscope (SEM) for imaging, shows that the continuous hexagonal pattern elements (solid lines bordering the open hexagonal spaces) combine to form a lattice pattern on the belt, with the belt containing hexagonal shaped voids in a continuous lattice. [Figure 18B] Cross-sectional image of the belt, using a scanning electron microscope (SEM) for imaging, showing that the continuous hexagonal pattern elements (solid lines bordering the open hexagonal spaces) combine to form a lattice pattern on the belt, with the belt containing hexagonal shaped voids in a continuous lattice. [Figure 18C] Cross-sectional image of the belt, using a scanning electron microscope (SEM) for imaging, showing that the continuous hexagonal pattern elements (solid lines bordering the open hexagonal spaces) combine to form a lattice pattern on the belt, with the belt containing hexagonal shaped voids in a continuous lattice. [Figure 18D] Cross-sectional image of the belt, using a scanning electron microscope (SEM) for imaging, showing that the continuous hexagonal pattern elements (solid lines bordering the open hexagonal spaces) combine to form a lattice pattern on the belt, with the belt containing hexagonal shaped voids in a continuous lattice. [Figure 18E] Cross-sectional image of the belt, using a scanning electron microscope (SEM) for imaging, showing that the continuous hexagonal pattern elements (solid lines bordering the open hexagonal spaces) combine to form a lattice pattern on the belt, with the belt containing hexagonal shaped voids in a continuous lattice. [Figure 18F] Cross-sectional image of the belt, using a scanning electron microscope (SEM) for imaging, showing that the continuous hexagonal pattern elements (solid lines bordering the open hexagonal spaces) combine to form a lattice pattern on the belt, with the belt containing hexagonal shaped voids in a continuous lattice. [Figure 19A] 1 is a top view image of the belt using a scanning electron microscope (SEM) for imaging, showing the discretized hexagonal shaped pattern elements on the belt. [Figure 19B] 1 is a cross-sectional image of a belt using a scanning electron microscope (SEM) for imaging, showing discretized hexagonal shaped pattern elements on the belt. [Figure 19C] 1 is a cross-sectional image of a belt using a scanning electron microscope (SEM) for imaging, showing discretized hexagonal shaped pattern elements on the belt. [Figure 19D] 1 is a cross-sectional image of a belt using a scanning electron microscope (SEM) for imaging, showing discretized hexagonal shaped pattern elements on the belt. [Figure 19E] 1 is a cross-sectional image of a belt using a scanning electron microscope (SEM) for imaging, showing discretized hexagonal shaped pattern elements on the belt. [Figure 19F] 1 is a cross-sectional image of a belt using a scanning electron microscope (SEM) for imaging, showing discretized hexagonal shaped pattern elements on the belt. [Figure 19G] 1 is a cross-sectional image of a belt using a scanning electron microscope (SEM) for imaging, showing discretized hexagonal shaped pattern elements on the belt. [Figure 20A] FIG. 1 is a top view of the belt using a scanning electron microscope (SEM) for imaging, showing continuous (unbroken) hexagonal pattern elements on the belt. [Figure 20B] 1 is a cross-sectional image of a belt using a scanning electron microscope (SEM) for imaging, showing continuous (unbroken) hexagonal pattern elements on the belt. [Figure 20C] 1 is a cross-sectional image of a belt using a scanning electron microscope (SEM) for imaging, showing continuous (unbroken) hexagonal pattern elements on the belt. [Figure 20D] 1 is a cross-sectional image of a belt using a scanning electron microscope (SEM) for imaging, showing continuous (unbroken) hexagonal pattern elements on the belt. [Figure 20E]1 is a cross-sectional image of a belt using a scanning electron microscope (SEM) for imaging, showing continuous (unbroken) hexagonal pattern elements on the belt. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] The term "comprising" in this disclosure may mean "including" or may have the meaning commonly given to the term "comprising" in U.S. patent law. The term "consisting essentially of," when used in the claims, has the meaning given to it in U.S. patent law. Other aspects of the invention are described in or are apparent from the following disclosure (and within the scope of the invention).

[0034] The term "yarn" in the following disclosure can refer to monofilament, multifilament yarn, twisted yarn, textured yarn, coated yarn, composite yarn, and yarn made from elastically broken fibers of any material known to those skilled in the art. The yarn can be made of carbon, polyamide, rayon, fiberglass, cotton, ceramic, aramid, polyester, metal, polyethylene, polypropylene, and / or other materials exhibiting desired physical, thermal, chemical, or other properties. Further examples of suitable materials include, for example, polycyclohexylene dimethylene terephthalate (PCT), cyclohexane dimethanol terephthalate (PCTA), polyphenylene sulfide (PPS), polyether ether ketone (PEEK), polyether ketone ketone (PEKK), polyethylene terephthalate (PET), polyethylene naphthalate (PEN). In general, any yarn of a bottom layer, such as a first layer of the industrial fabric of the present invention, can be made from any commercially available material suitable for bonding to a discretized second (e.g., top) layer, or can be made suitable.

[0035] "Pattern element" as used in the following disclosure refers to a deposition of material, such as resin, in a desired shape or design. Pattern elements are typically macroscopic in size (e.g., greater than 1 mm in diameter). Pattern elements may consist of continuous depositions of material or discretized subunit depositions of material.

[0036] Unless the context indicates otherwise, a "subunit" as used in the following disclosure is a micro-sized (e.g., diameter less than 1 mm) deposit of material (e.g., resin), two or more of which may make up a pattern element.

[0037] Unless the context indicates otherwise, a "pattern" as used in the following disclosure refers to two or more pattern elements.

[0038] The terms "machine direction" (MD) and "cross-machine direction" (CD) as used in the following disclosure are used with respect to their well-understood meanings in the art, i.e., 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 fabric making process, while the CD refers to the direction perpendicular to the MD of the industrial fabric.

[0039] The present invention relates to industrial fabrics, such as belts, for producing patterned products, such as patterned nonwoven products. In certain embodiments, the patterned products are made from natural or synthetic fibers, or some combination of both. In certain embodiments, the present invention relates to industrial fabrics, such as belts, for producing three-dimensional structures in the manufacturing process of paper, tissue, towels, and / or nonwoven products. The product (which may be in the form of a sheet) is formed against the belt, thus producing the patterned product, e.g., a patterned sheet product.

[0040] The present invention solves the problems in the art and provides a solution to the limitations of current and previously practiced belt technology, for example, for patterned tissue and towel products. The present invention relates to a patterned belt that can utilize discretization to provide an endless variety of complex patterns. In "discretization," individual subunits constitute pattern elements, such as specific shapes (e.g., circles, squares, hexagons) or designs (e.g., corporate logos), that are not connected and therefore do not act as stress-bearing members of an industrial fabric, such as a belt. Moreover, the present invention solves the complexity and conformance of belt patterns, independent of belt permeability and durability, among other things, by achieving continuous patterns without significant reduction in permeability and processing speed for the end user of the belt. Advantages of the present invention further include that belts can be produced that allow for differentiation of patterns and bulk of sheet products without sacrificing the processing efficiency of the sheet products.

[0041] The industrial fabric of the present invention comprises at least a first layer and a second layer. The second layer comprises, for example, non-adjacent subunits. The second layer comprises a sheet-contacting or forming side surface that contacts the fiber-based product produced thereon. The first layer also typically comprises a sheet-contacting or forming side surface that contacts the fiber-based product produced thereon. In some embodiments, the first layer further comprises a machine side surface. In other embodiments, the industrial fabric comprises not only the first and second layers, but also, for example, a third layer or more layers. In certain embodiments, the first layer can be a batting layer attached to the forming side of the third layer, and the non-adjacent subunits of the second layer are deposited on the batting layer. For example, the third layer can be a load-bearing layer and comprise the machine side surface of the fabric, and the first (batting) layer and the second (non-adjacent subunit deposition) layer both comprise the forming side surface of the fabric and contact the fiber-based product produced thereon.

[0042] The first layer of the industrial fabric may be woven or non-woven. In embodiments where the first layer is a woven fabric, the woven fabric may be woven in a variety of weave patterns, such as complex or simple, single layer or multi-layer, such as a plain weave pattern or a satin weave pattern. The woven fabric may be woven from monofilament, twisted monofilament, multifilament, twisted multifilament yarns, and may be single layer, multi-layer, or laminated. The yarns for the woven fabric may be extruded from any of a number of synthetic polymeric resins, such as polyamide or polyester resins, used for this purpose by those skilled in the art of machine clothing.

[0043] In other embodiments, the first layer of the industrial fabric is a nonwoven, such as a permeable nonwoven. In certain embodiments, the nonwoven is selected from an extruded mesh, a knitted structure, an MD and / or CD yarn arrangement, a braid, a series of separate links, a spiral link fabric, or other nonwoven products such as foils, films, spunbonds, or carded, airlaid, meltblown, or wetlaid materials.

[0044] The second layer comprises subunits that make up the discretized pattern. The subunits of the discretized pattern may comprise any suitable material. Examples of suitable materials include engineered polymers, thermoplastics, thermoplastic polyurethanes, polyamides, polyesters, copolyesters, ethylene vinyl acetate (EVA), and thermosets including catalyzed, moisture cured, heat activated, or light activated polymeric polyurethanes, urethane acrylates, or silicones, and combinations thereof, to name a few.

[0045] The discretized patterned belt of the present invention leads to a longer life of the second layer in bending, flexural fatigue, and normal tensile / compressive stresses, since areas of high stress concentration in the discretized second layer are avoided. Thus, a technical advantage of the present invention is the reduction of stress on the material of the second layer at the upper surface of the industrial fabric of the present invention. In some embodiments, the industrial fabric of the present invention reduces any critical stress that would lead to cracking in the discretized second layer, for example as a function of the material, flex angle, speed, and / or temperature to which the fabric is subjected.

[0046] Discretized pattern element subunits are typically deposited using a deposition nozzle onto a first layer with a length and width, such as a nonwoven or woven substrate. In some embodiments, the subunits may be deposited in droplet sizes approaching 1 mm, while in other embodiments, the deposition may total, for example, 20 pl (picoliter) droplets to form larger pattern elements. In other embodiments, the subunits may be deposited at a temperature of 30° C., including in the range of 0° C. to 350° C. The subunits may be deposited in any shape, for example, by assembling smaller units to produce sharp depictions, such as shapes with sharp edges and / or distinct lines. For example, FIG. 8 shows diamond- and triangular-shaped subunits in a complex flower pattern element that result in a sharp edge as the two petals meet, depicting two distinct petals, which would not be the case with deposition that is amorphous or unstructured.

[0047] Physically, the dimensional proportions of the resulting subunits are not limited to any particular three-dimensional shape. The subunits may be any suitable shape, including three-dimensional shapes such as pillars, cubes, cylinders, pyramids, cones, cuboids, spheres, prisms, hemispheres, etc. The subunits may be deposited on any suitable first layer, such as a woven belt, a nonwoven belt, or a composite substructure. The subunits often have a depth, but no minimum depth is required. The aspect ratio of the height to width and length of the subunits can be modified to meet specific design requirements, and often may determine the stress loading in the structure (especially the discretized pattern elements) based on multiple factors such as the bulk and thickness of the sheet. Additionally, the subunit shapes of the second (e.g., top) layer of the industrial fabric of the present invention can be uniform or a mixture of shapes. For example, some subunits may be pyramidal, while others on the same belt may be cylindrical.

[0048] The individual non-adjacent subunits of the second layer (e.g., the top forming layer) of the industrial fabric of the invention collectively comprise discretized pattern elements. A discretized form of pattern element is an uninterrupted pattern element that has been subdivided into constituent non-adjacent subunits that together make up or mimic the uninterrupted pattern element, for example, in a sheet product produced thereon. The pattern elements, whether uninterrupted or discretized, are components of the overall pattern that the second layer provides for patterning a product, such as a fiber-based product, produced thereon.

[0049] In certain embodiments, the overall pattern comprises two or more pattern elements (e.g., two or more squares). In other embodiments, the overall pattern comprises only one pattern element (e.g., one square) that is repeated throughout the entire second layer (e.g., the top forming layer) of the industrial fabric (and thus throughout the fiber-based product produced thereon). In certain embodiments, the pattern elements are repeated uniformly. For example, a repeating square pattern element can result in an overall pattern that is a net. In other embodiments, the pattern elements are repeated randomly. In yet other embodiments, the pattern elements are repeated uniformly in one portion of the second layer of the industrial fabric and randomly in another portion of the second layer. In some embodiments, the overall pattern comprises multiple pattern elements. In certain embodiments, the pattern elements are the same shape but of various sizes. For example, in some embodiments, the pattern elements are large squares and small squares. In other embodiments, the pattern elements are different. For example, in some embodiments, the pattern elements are squares and circles of the same size or of various sizes. In yet other embodiments, the pattern elements are a mixture of different pattern elements that are uniformly and / or randomly repeated, hi some embodiments, the pattern elements are a mixture of different pattern elements that are not repeated.

[0050] The pattern elements may be of any desired shape or design. The pattern elements may be rounded, angular, or any combination thereof. Examples of pattern elements include round shapes, such as circles or ovals, and polygonal shapes, such as triangles, squares, rectangles, pentagons, hexagons, heptagons, octagons, rhombus, diamonds, and stars. The pattern elements may also be lines, curves, letters, numbers, words, logos, trademarks, animals, plants, foods, people, landforms, and / or combinations thereof.

[0051] The top surface layer (e.g., forming surface layer) of an industrial fabric, such as a patterned belt of the present invention, comprises one or more pattern elements in discretized form. The pattern elements are typically produced in discretized form by deposition of two or more non-adjacent subunits onto an underlying structure, such as a first layer that is a woven fabric.

[0052] The optimal size, shape, and distribution of the subunits may depend, for example, on the size of the overall stack, the transferable complexity of the desired pattern, and the deposited material. For example, some parameters that may affect the size and shape of the subunits of the second layer include (i) the deposition technique (e.g., nozzle spacing, print resolution), (ii) the physical interaction of the subunit material with the first layer, such as the bottom layer (e.g., the "lubricity" of the deposited material), (iii) the structural influence of the first layer, such as the bottom layer, on creating the pattern (e.g., monofilament size, and mesh / count / open area in woven structures, and monoplanar properties in continuous structures), and (iv) the interaction of the stack with the final fiber-based (e.g., sheet) product (e.g., fiber length, basis weight, and / or sheet tensile properties on the ability of the stack to functionally create a pattern / impression in the sheet).

[0053] The pattern elements of the surface layer (e.g., forming surface layer) of the industrial fabric of the present invention may comprise two or more non-adjacent subunits that together make up the pattern element in a discretized form. The discretized form of the pattern element results in the same or substantially the same pattern element in an uninterrupted form in a product, such as a fiber-based product, produced thereon. For example, a pattern element that is hexagonal may comprise a series of resin depositions of columnar non-adjacent subunits that collectively make up a hexagonal pattern in a discretized form. In this embodiment, the discretized hexagonal pattern element produces or mimics an uninterrupted hexagonal shape in a fiber-based product produced thereon.

[0054] The spacing between the discrete non-adjacent subunits of a discretized pattern element is the inter-subunit spacing. Often the minimum degree of spacing between subunits depends in part on the first layer, e.g., substrate or underfabric, on which the subunits are deposited. For example, in certain embodiments, if the first layer is a woven substrate, the minimum spacing between subunits in the second layer may be, e.g., 1-2 thread diameters (regardless of the mesh / count of the woven substrate), to prevent the materials of the subunits from flowing together. In other embodiments, e.g., for a monoplanar continuous sheet product, the subunits in the second layer may be closer together. Typically, the inter-subunit spacing is wide enough to allow water to pass through. In some embodiments, the subunits may be spaced far apart, without any particular limit, long enough that their interaction with the fibers forming the fiber-based (e.g., sheet) product results in the satisfaction of the desired macroscopic pattern in the sheet product produced.

[0055] In further embodiments, the fibers of a fiber-based product (e.g., sheet product) produced on an industrial fabric, such as a patterned belt of the present invention, do not substantially significantly press or stretch into the inter-subunit spaces of the discrete pattern elements. Rather, in certain embodiments, the product fibers (e.g., sheet product fibers) bridge the areas between non-adjacent subunits of the discrete pattern elements.

[0056] The deposited subunits form a stacked structure on the first layer of the industrial fabric of the present invention. The subunits can be, for example, a resin, e.g., photocurable, that is deposited on the first layer and subsequently cured. The stacked structure of the second (e.g., top) layer can form a top patterned surface, such as a complex patterned surface, e.g., on the forming side of a patterned belt. Examples of complex patterns include logos, images, and repeatable pattern elements, e.g., in a large number of subunits. A complex pattern can be a pattern of potentially diverse elements that do not necessarily repeat geometrically. In contrast, a simple pattern can be a geometric X×Y repeating pattern of identical common elements (e.g., a checkerboard of dots).

[0057] In some embodiments, one or more portions of the industrial fabric of the present invention comprise discretized pattern elements and one or more portions of the same fabric comprise a continuous deposition, e.g., an uninterrupted line of resin.

[0058] The deposited subunits of the second (e.g., top) layer can form a discrete layer in relation to the first layer (e.g., woven bottom fabric), or one or more portions of the deposited subunits of the second layer can be impregnated into the first layer. The deposition of the second layer can have a height above the top plane of the first layer of the industrial fabric of the present invention, but no minimum height is required. Rather, the subunit deposition of the second layer, regardless of height, is typically designed to create a blockage in the first layer (e.g., bottom layer) that inhibits permeability and contributes to the pattern of the resulting fiber-based (e.g., sheet) product. For example, in certain embodiments, the first layer is a nonwoven fabric, and the subunit deposition of the second layer is flush with the nonwoven fabric of the first layer, creating a pattern in the sheet product produced thereon.

[0059] By employing the discretization described herein, the stack structure of the second layer is partially decoupled from the macroscopic effects of bending and tensile forces in the first layer, thereby allowing the first layer to continue to withstand a majority of the total stresses applied to the industrial fabric (e.g., belt) for a longer life of the stack structure of the second layer. The discretization utilized in the second (e.g., top) layer of the industrial fabric of the present invention also provides the opportunity to use a stack material with different tensile and bending properties (e.g., different tensile strength, stiffness, and / or modulus) than those of the first layer.

[0060] As a result of discretization, industrial fabrics such as patterned belts with discretized patterns of the present invention exhibit many benefits, such as fewer limitations on pattern complexity, less reduction in air permeability, and less impact on the structural strength of industrial fabrics. As an example, the permeability of discretized pattern elements can be 50% more permeable than continuous (uninterrupted) pattern elements on the same substrate (e.g., an underlying fabric such as a woven or nonwoven fabric), and can form a bulky patterned sheet of paper. The permeability of discretized pattern elements can depend on factors such as the physical open area of ​​the underlying fabric, the area of ​​the stacked subunits of the pattern elements, and / or the interaction of the pattern elements with the void volume of the underlying fabric. In some embodiments, the air permeability can be scaled directly and therefore / proportionately to the ratio of the stacked area of ​​the subunits per unit area.

[0061] Additionally, control of the surface pattern of the industrial fabric is generally achieved by primarily decoupling the physical properties of the surface material of the second layer from the dimensional stresses at the surface of the industrial fabric. Furthermore, stress concentrations are primarily transferred to the load-bearing substructure, such as the first layer being a woven fabric, thereby greatly reducing the tendency for stress fracture or delamination of the discrete pattern elements (e.g., the upper patterned surface) of the subunits of the second layer of the industrial fabric of the present invention. Additionally, the durability and abrasion resistance of the second layer (e.g., the upper patterned surface) can be optimized without the constraints of high elasticity and compression required of a continuous matrix. Thus, in some embodiments, a stiffer and more dimensionally stable material can be used to generate the non-adjacent subunits of the top layer of the industrial fabric of the present invention.

[0062] 1A-1C show an example of a general element discretization strategy of the present invention. FIG. 1A shows a larger individual uninterrupted pattern element (101). With discretization, the pattern element can be subdivided to generate discrete non-adjacent subunits that mimic the uninterrupted pattern (101). The dimensions of the discrete subunits can be varied to provide a wide range of sizes from coarse to fine while still retaining the overall shape of the individual pattern element. For example, FIG. 1B shows a subunit (102) that is larger than the subunit (103) in FIG. 1C, but each of the subunits (102) in FIG. 1B and the subunits (103) in FIG. 1C form the overall shape of the individual hexagonal pattern element (101) in FIG. 1A. The spacing between the discrete non-adjacent subunits in each of FIG. 1B and FIG. 1C is the inter-subunit spacing (104) where the spacing between the non-adjacent subunits is.

[0063] Figure 1A shows the 4 mm (14.5 mm 2 FIG. 1B shows an uninterrupted pattern element with a basic dimension of 0.3 mm subunits per side, which individually are 0.62% of the total pattern element area. FIG. 1C shows a discretized pattern element with 0.15 mm subunits per side, which individually are 0.15% of the total pattern element area. Additionally, the subunits and inter-subunit spacing (i.e., the spacing between any two individual subunits) need not be of uniform size, height, distribution, or material to produce a surface layer of an industrial fabric, such as a belt of the present invention. The dimensions of the deposited subunits and their inter-subunit spacing can result, for example, from the size of the deposition nozzle, the properties of the material being deposited, and / or the structure (e.g., weave pattern or material composition) of one or more layers underlying the surface layer comprising the subunits.

[0064] FIG. 2 shows a pattern with discretized pattern elements similar to those in FIG. 1B and FIG. 1C. In FIG. 2, each pattern element (105) is 15 mm (97 mm 2The subunits have a basic size of 0.3 mm each, thereby each contributing 0.092% of the total pattern element area.

[0065] 3A and 3B and 4A and 4B show stress distribution in bending stress analysis simulation, where the object (107, 108) is a second layer with a single individual pattern element bonded to the first layer, which is the flexible first layer (106). The stress analysis simulation serves the purpose of showing the stress distribution as a result of bending. Generally, in such simulation, (i) the pattern element has a boundary condition fixed midway under the bottom (machine side) of the first layer of the fabric structure (physically simulating bending around a roll), and (ii) a downward (from the product sheet side to the machine side) displacement is applied to the first layer with respect to a plane perpendicular to the machine direction. In this case, the applied displacement length is equal to 100% of the size (width) of the pattern element.

[0066] 3A (3D view) and 3B (2D view) depict uninterrupted stacked structure pattern elements (107) of the second layer, whereas FIG. 4A (3D view) and FIG. 4B (2D view) depict discrete, non-adjacent subunit structure (of the present invention) pattern elements (108) of the second layer.

[0067] In Figures 3A and 3B, there is a large stress concentration (109) at the outer edge of the unbroken stack where it joins with the first layer, with an intermediate uniform level of stress propagating throughout the entire stack. This is further illustrated by the color-coded bar graphs in Figure 3A (medium gray for high stress, light gray for intermediate stress, dark gray / black for low stress). In this case, failure involves delamination of the stack in the area of ​​high stress concentration at the stack-first layer interface. Depending on the elastic modulus of the material, there could also be cracking of the stack in the center. Both of these failure modes of delamination and cracking were verified by bending tests of physical stack samples, e.g., flexural fatigue tests. See, e.g., Figures 12 and 13.

[0068] In Figures 4A and 4B, the discrete pattern element stacks (subunits) of the second layer are subjected to much lower stress than the uninterrupted stack pattern elements because the subunits are not connected to transfer stress, which shifts the neutral axis of the bending region toward the lower fabric of the first layer. In the lower fabric of the first layer, there are high stresses (110) between some of the individual subunits, which may cause some local delamination between the individual subunits depending on the material modulus and the degree of bending. However, as demonstrated in Figures 4A and 4B, through the use of individual discrete pattern element subunits, the areas of high stress are minimized.

[0069] The permeability of any one belt with the discretization of the present invention may depend on a variety of factors, such as the size of the pattern and pattern elements, and the interaction of the discretized pattern element subunits with any void volume of the underlying layer on which they are deposited. In the belt of Figure 4, the permeability of the belt of Figures 4A and 4B with discretized pattern elements is approximately 50% greater than the belt of Figures 3A and 3B with uninterrupted pattern elements.

[0070] The present invention supports greater permeability of industrial fabrics such as patterned belts compared to prior art patterned industrial fabrics having a continuous build-up on the forming (sheeting) surface, the greater permeability of the fabrics of the present invention ranging from about 10% to 90%, including, for example, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, and 85%, and fractions therebetween.

[0071] 5A (3D view) and 5B (2D view) show an FEA of a pattern element (111) that is the inverse of the pattern element (108) shown in FIG. 4A and FIG. 4B, and the resulting bending stress when bent in the same manner as was done for the belts of FIG. 3A and FIG. 3B and FIG. 4A and FIG. 4B. The inverse pattern element was produced with successive depositions, and shows a continuous lattice framework. Comparison of FIG. 5A and FIG. 5B with FIG. 4A and FIG. 4B demonstrates the advantage of using discretization in producing non-adjacent discrete subunits, as in FIG. 4A and FIG. 4B, for example, resulting in lower bending stresses (108) in the deposited second layer structure, compared to the high bending stress concentration (112) shown in the deposited second layer in FIG. 5A and FIG. 5B. The stresses shown in FIG. 5 would likely cause localized cracking of the deposited structure and failure of the deposit to adhere to the substructure (106) of the first layer. Creating a connected grid pattern in the manner of Figures 5A and 5B does not confer the functional benefits of non-adjacent discrete patterning methods applied to industrial fabrics, such as those illustrated by Figures 4A and 4B.

[0072] 6A-6B and 7A-7B show similar bending stress analyses performed using simulations of an uninterrupted deposition layer (FIGS. 6A-7A) compared to a deposition layer of the present invention using discretization (FIGS. 6B-7B), where the underlying deposition has a non-uniform shape.

[0073] For example, some subunits may be rounded pillar shapes, while other subunits may be three-dimensional polygons such as cubes or rectangular pillars, or a combination of rounded and angular three-dimensional shapes, with different distributions. As another example, some subunits may be pyramids in addition to cones that together form the letters of a hexagonal pattern element logo and / or trademark. In general, discretized pattern element subunits can be generated in any shape and size distribution. There is no limit to standard geometric shapes for subunits or uniform subunits. Furthermore, the size and shape of the subunits can be randomized.

[0074] Figures 6A and 7A show conventional contiguous stacks (113, 114, respectively), while Figures 6B and 7B show non-adjacent subunits of the present invention (115, 116, respectively). The pattern in Figures 6A and 6B is in the shape of the letter "A," while the pattern in Figures 7A and 7B is in the shape of a spiral flower.

[0075] Figure 8 shows a subdivision strategy whereby the discrete deposited subunits (117) are of various sizes, shapes, and distributions while still mimicking the overall pattern element shape of the spiral flower. Figure 8 is an enlargement of Figure 7B shown in plan view.

[0076] 9A and 9C each show an exemplary sheet product produced on a belt of the present invention having a patterned surface utilizing the general discretization strategy disclosed herein. The fiber length and / or interconnected nature of the web produced on an industrial fabric such as the patterned belt of the present invention will still allow for sharp pattern definition in the web without the need for continuous filling in a grid pattern deposition. FIG. 9A shows the resulting sheet product, and FIG. 9B shows the stacking structure used to make the resulting sheet product of FIG. 9A. FIG. 9C shows a 3D height map of the resulting sheet product, and FIG. 9D shows the stacking structure used to make the resulting sheet product of FIG. 9C.

[0077] 10A, 10B, 10C, and 10D show resin deposits on fabric surfaces where the discontinuous rectangular black deposits (119) are more porous than the continuous rectangular white deposits (126), and the same end effect is created in the sheet products formed on each of these surfaces. That is, the same texture is effectively created in the sheet products produced on each belt. As specifically noted, both deposits, the rectangular patterns in this example, functionally create the same overall impression or texture in the sheet products. The more open black structure of FIG. 10A and FIG. 10B increases the permeability by 50 CFM over the belt with the white continuous pattern elements of FIG. 10C and FIG. 10D. The open black structure is formed of discrete non-adjacent subunits (119).

[0078] 11-17 show belts of the present invention with exemplary discretized resin pattern elements compared to belts without discretized resin pattern elements. The patterned belts of FIGS. 11-17 were subjected to flex tests. A photocurable resin that was approximately 0.50 mm high was used for the belts. The resin was applied to the belts in a single layer with 18 / cm mesh x 23 / cm count, 0.30 mm shoot, 0.30 mm warp, and 500 CFM air permeability. The flex tests were run for 1,256,000 cycles (48 hours run time) under dry conditions. For each flex test, the sample belt width was 4.75 inches (0.12 m), the belt length was 2.3 m, the belt tension was 30 PSI set point (5.4 kN / m belt tension), and the belt speed was 519.4 m / min. In the embodiment of FIGS. 11-17, heat was applied to the belt being tested via a heat gun that can be attached to an air chamber. The belt surface was heated to .about.150°C. A heat gun was employed to simulate the temperatures the belt would experience in a commercial machine. Photographs were taken using a digital microscope for analysis of material behavior over time. Photographs can be taken at intermittent intervals during the flex test to show, for example, surface wear, cracks, and delamination, potentially indicating when the belt may begin to fail and highlighting differences in life span between materials. Furthermore, an optional additional use of measurement equipment can measure the surface temperature of the belt using an infrared laser temperature sensor, which also allows for design comparison of surface wear, cracks, and delamination between prior art belts and the belts of the present invention.

[0079] Results from the flex testing described above showed cracking and surface wear / flattening in the continuous pattern elements. In contrast, the discrete pattern elements showed no cracking or delamination and minimal to no apparent surface wear / flattening.

[0080] FIG. 11A shows a discretized hexagonal shape with round subunits (120) and shows the shape (top frame) and a color-coded 3D height map (bottom frame) showing the shape above the woven lower fabric. FIG. 11B shows a discretized hexagonal shape with square subunits (121) and shows the shape (top frame) and a color-coded 3D height map (bottom frame) showing the shape above the woven lower fabric. FIG. 11C shows an uninterrupted hexagonal shape with round holes (122) and shows the shape (top frame) and a color-coded 3D height map (bottom frame) showing the shape above the woven lower fabric. FIG. 11D shows an uninterrupted hexagonal shape with square holes (123) and shows the shape (top frame) and a color-coded 3D height map (bottom frame) showing the shape above the woven lower fabric. Overall, the air permeability of the lower fabric is 472 CFM. The air permeability of discrete square subunits on a bottom fabric (Figure 11B) is 295 CFM. The air permeability of unbroken (or filled) hexagons with square holes on a bottom fabric (Figure 11D) is 127 CFM.

[0081] FIG. 12A shows an uninterrupted hexagonal shape with a round hole before bend testing. FIG. 12B shows an uninterrupted hexagonal shape with a round hole after bend testing. FIG. 12C-E show an uninterrupted hexagonal shape with a round hole (enlarged portion of FIG. 12B) after bend testing, with cracks (124) and wear from roll contact (125). FIG. 12F is a color-coded 3D height map to more easily show damage to the stack after bend testing due to the continuous nature of the stack. Dark grey lines represent damage such as cracks.

[0082] Figure 13A shows an uninterrupted hexagonal shape with a square hole before bend testing. Figure 13B shows an uninterrupted hexagonal shape with a square hole after bend testing. Figures 13C and 13D show an uninterrupted hexagonal shape with a square hole (enlarged portion of Figure 13B) after bend testing with cracks (127) and wear from roll contact (128). Figure 13E is a color-coded 3D height map to more easily show damage to the stack after bend testing due to the continuous nature of the stack. Dark grey lines represent areas of damage such as cracks.

[0083] Figures 14A and 14B show the discretized hexagonal shape with rounded subunits before bending test. Figure 14C shows the discretized hexagonal shape with rounded subunits after bending test. Figure 14D is a color-coded 3D height map. Figure 14D shows that there are no cracks or delaminations after bending test, only some wear.

[0084] Figures 15A and 15B show the discretized hexagonal shape with square subunits before bending test. Figure 15C shows the discretized hexagonal shape with square subunits after bending test. Figures 15D and 15E are color-coded 3D height maps. Figures 15D and 15E show that there are no cracks or delaminations after bending test, only some wear.

[0085] Figure 16A shows a discretized hexagonal shape with closely spaced rounded subunits before bending testing, and Figure 16B shows a discretized hexagonal shape with closely spaced rounded subunits after bending testing.

[0086] Figure 17A shows the discretized hexagonal shape with coarsely spaced rounded subunits before flex testing. Figure 17B shows the discretized hexagonal shape with coarsely spaced rounded subunits after flex testing. Figure 17C is a color-coded 3D height map. Figure 17C shows no cracks or delaminations after flex testing, only some wear.

[0087] Figures 18-20 relate to fabric samples photographed with a Scanning Electron Microscope (SEM). The samples were photographed using a BSE (Backscattered Electron) detector. Generally, the BSE detector gives the photograph atomic number contrast, with materials with higher atomic numbers (fillers, etc.) appearing brighter compared to materials with lower atomic numbers (polymers, paper fibers, etc.).

[0088] FIG. 18A shows in a top view continuous hexagonal pattern elements (solid lines outlining open hexagonal spaces) that combine to form a lattice pattern on the belt. The lattice pattern contains hexagonally shaped voids in a continuous lattice made from resin. In FIG. 18A, dashed lines (129) indicate where the belt was cut to generate the cross-sectional images using SEM shown in FIG. 18B-18F. FIG. 18B-18F show cross-sectional measurements of the hexagonal lattice resin and belt yarns at various sections along the cut belt of FIG. 18A.

[0089] Figure 18B shows cross-sectional measurements of resin thickness between the top surface of the resin on the forming surface of the belt and the MD yarns of the lower fabric at 0.19 mm, 0.17 mm, and 0.15 mm, and Figure 18B shows cross-sectional measurements of resin thickness between the top surface of the resin on the forming surface of the belt and the CD yarns of the lower fabric at 0.72 mm.

[0090] Figure 18C shows cross-sectional measurements of resin thickness between the top surface of the resin on the forming surface layer of the belt and the MD yarns of the lower fabric at 0.15 mm, 0.086 mm, 0.060 mm, and 0.32 mm, and Figure 18C shows cross-sectional measurements of resin thickness between the top surface of the resin on the forming surface layer of the belt and the CD yarns of the lower fabric at 0.70 mm.

[0091] Figure 18D shows cross-sectional measurements of resin thickness between the top surface of the resin on the forming surface of the belt and the MD yarns of the lower fabric at 0.19 mm, 0.17 mm, and 0.15 mm, and Figure 18D shows cross-sectional measurements of resin thickness between the top surface of the resin on the forming surface of the belt and the CD yarns of the lower fabric at 0.72 mm.

[0092] FIG. 18E shows cross-sectional measurements of resin thickness between the top surface of the resin on the forming surface of the belt and the MD yarns of the bottom fabric at 0.034 mm, 0.14 mm, 0.29 mm, 0.043 mm, and 0.099 mm.

[0093] Figure 18F shows cross-sectional measurements of resin thickness between the top surface of the resin on the forming surface of the belt and the MD yarns of the lower fabric at 0.051 mm and 0.35 mm, and Figure 18F shows cross-sectional measurements of resin thickness between the top surface of the resin on the forming surface of the belt and the CD yarns of the lower fabric at 0.52 mm.

[0094] FIG. 19A shows a top view of discretized hexagonal shaped pattern elements on a belt. The hexagonal shapes are discretized hexagonal pattern elements made up of subunits. In FIG. 19A, the dashed line (130) indicates where the belt was cut to generate the cross-sectional images using SEM shown in FIG. 19B-G. FIG. 19B-G show cross-sectional measurements of the hexagonal subunits and belt yarns at various sections along the cut belt of FIG. 19A.

[0095] FIG. 19B shows a cross-sectional measurement of a subunit thickness of 0.56 mm between the top surface of the subunit on the forming surface of the belt and the MD yarns of the bottom fabric.

[0096] FIG. 19C shows cross-sectional measurements of subunit thicknesses of 0.68 mm and 0.57 mm between the top surface of the subunit on the forming surface of the belt and the MD yarns of the bottom fabric.

[0097] Figure 19D shows cross-sectional measurements of subunit thicknesses of 0.58 mm and 0.70 mm between the top surface of the subunit on the forming surface of the belt and the MD yarns of the lower fabric, and Figure 19D shows cross-sectional measurements of subunit thicknesses of 1.0 mm between the top surface of the subunit on the forming surface of the belt and the CD yarns of the lower fabric.

[0098] FIG. 19E shows a cross-sectional measurement of a subunit thickness of 0.52 mm between the top surface of the subunit on the forming surface of the belt and the MD yarns of the bottom fabric.

[0099] FIG. 19F shows cross-sectional measurements of subunit thicknesses of 0.56 mm, 0.49 mm, and 0.72 mm between the top surface of the subunit on the forming surface of the belt and the MD yarns of the bottom fabric.

[0100] FIG. 19G shows a cross-sectional measurement of a subunit thickness of 0.56 mm between the top surface of the subunit on the forming surface of the belt and the MD yarns of the bottom fabric.

[0101] Figure 20A shows continuous (unbroken) hexagonal pattern elements. In Figure 20A, dashed lines (131) indicate where the belt was cut to generate the cross-sectional images using SEM shown in Figures 20B-20E. Figures 20B-20E show cross-sectional measurements of hexagonal subunits and belt yarns at various sections along the cut belt of Figure 20A.

[0102] Figure 20B shows a cross-sectional measurement of 0.51 mm resin thickness between the top surface of the resin on the forming surface of the belt and the MD yarns of the lower fabric. Figure 20B shows a cross-sectional measurement of 0.94 mm resin thickness between the top surface of the resin on the forming surface of the belt and the CD yarns of the lower fabric.

[0103] FIG. 20C shows cross-sectional measurements of resin thicknesses of 0.49 mm and 0.46 mm between the top surface of the resin on the forming surface of the belt and the MD yarns of the bottom fabric.

[0104] Figure 20D shows cross-sectional measurements of resin thickness between the top surface of the resin on the forming surface of the belt and the MD yarns of the lower fabric at 0.41 mm and 0.44 mm, and Figure 20D shows cross-sectional measurements of resin thickness between the top surface of the resin on the forming surface of the belt and the CD yarns of the lower fabric at 0.91 mm.

[0105] FIG. 20E shows cross-sectional measurements of resin thickness between the top surface of the resin on the forming surface of the belt and the MD yarns of the bottom fabric at 0.55 mm, 0.50 mm, and 0.47 mm.

[0106] Modifications to the above would be obvious to one skilled in the art, but would not take the invention so modified beyond the scope of the present invention, and the following claims should be construed to cover such situations.

Claims

1. 1. An industrial fabric for producing patterned products, comprising: a first layer; and a second layer covering at least a portion of the top surface of the first layer; Equipped with the second layer includes a plurality of non-contiguous subunits deposited on the top surface of the first layer to define a pattern comprising pattern elements having discretized shapes on the top surface of the first layer; the plurality of non-adjacent subunits are disposed within a boundary of the discretized shape of the pattern element and at least partially define the boundary of the discretized shape of the pattern element. industrial fabric.

2. An industrial fabric as described in claim 1, wherein the plurality of non-adjacent subunits each have a three-dimensional shape.

3. An industrial fabric as described in claim 1, wherein the pattern is a complex pattern.

4. An industrial fabric as described in claim 1, wherein the first layer comprises at least one lower fabric selected from the group consisting of woven fabrics, nonwoven fabrics, laminates, and composites.

5. The industrial fabric of claim 1, wherein the first layer comprises a nonwoven fabric, the nonwoven fabric comprising at least one fiber structure selected from the group consisting of a machine direction yarn arrangement, a cross machine direction yarn arrangement, a braid, a series of independent rings, a spiral link fabric, an extruded mesh, a knitted structure, a foil, a film, a spunbond fabric, carded fibers, needled fibers, airlaid fibers, meltblown fibers, and a wetlaid fiber structure.

6. The industrial fabric of claim 1, wherein the plurality of non-adjacent subunits comprise at least one material selected from the group consisting of industrial polymers, thermoplastics, thermoplastic polyurethanes, polyamides, polyesters, copolyesters, ethylene vinyl acetate (EVA), and thermosets.

7. An industrial fabric as described in claim 6, wherein the at least one material has a thermosetting substance, and the thermosetting substance is a catalytic, moisture-curing, heat-activated, or light-activated polymer system.

8. An industrial fabric as described in claim 1, wherein the industrial fabric has a permeability that is 10% to 90% greater than the permeability of an industrial fabric having continuous pattern elements.

9. An industrial fabric as described in claim 1, wherein the plurality of non-adjacent subunits of the second layer extend across the length and / or width of the first layer.

10. An industrial fabric as described in claim 1, wherein the pattern elements have at least one element selected from the group consisting of round shapes, polygonal shapes, lines, curves, letters, numbers, words, logos, trademarks, animals, plants, food, people, and landforms.

11. An industrial fabric as described in claim 3, wherein the three-dimensional shape of the plurality of non-adjacent subunits has at least one shape selected from the group consisting of a cube, a pillar, a pyramid, a cone, a rectangular prism, a sphere, an ellipsoid, and a regular tetrahedron.

12. The industrial fabric according to claim 1, which is a patterned belt or a processed belt.

13. An industrial fabric as described in any one of claims 1, wherein the plurality of non-adjacent subunits have inter-subunit spacing configured to minimize substantial fiber penetration of the patterned product into areas between the plurality of non-adjacent subunits of the pattern element.

14. In the industrial fabric of claim 1, the non-adjacent subunits of the pattern element have an inter-subunit spacing that defines an area between the non-adjacent subunits, and the area between the non-adjacent subunits is dimensioned so that when the industrial fabric is used to manufacture a patterned product, fibers of the patterned product extend across the area between the non-adjacent subunits. industrial fabric.

15. An industrial fabric as described in claim 1, wherein one or more of the non-adjacent subunits of the second layer are flush with the surface of the first layer.

16. An industrial fabric as described in claim 1, wherein the industrial fabric has three or more layers, and the three or more layers include the first layer and the second layer.

17. An industrial fabric as described in claim 16, wherein the three or more layers include a third layer having at least one lower fabric selected from the group consisting of woven fabrics, nonwoven fabrics, laminates, and composites.

18. An industrial fabric as described in claim 1, further comprising a third layer, the third layer being a lower fabric, and the first layer covering at least a portion of the upper surface of the third layer.

19. 1. A method for producing a patterned product, comprising: Patterning the product with an industrial fabric, the industrial fabric comprising: a first layer; and a second layer covering at least a portion of the top surface of the first layer; the second layer includes a plurality of non-contiguous subunits deposited on the top surface of the first layer to define a pattern comprising pattern elements having discretized shapes on the top surface of the first layer; the plurality of non-adjacent subunits being disposed within a boundary of the discretized shape of the pattern element and at least partially defining the boundary of the discretized shape of the pattern element.

20. The method of claim 19, wherein the plurality of non-adjacent subunits each have a three-dimensional shape.

21. The method of claim 19, wherein the pattern elements have at least one element selected from the group consisting of round shapes, polygonal shapes, lines, curves, letters, numbers, words, logos, trademarks, animals, plants, food, people, and landforms.

22. An industrial fabric as described in claim 1, wherein the boundary of the discretized shape of the pattern element is defined at least in part by the plurality of non-adjacent subunits and the areas between the plurality of non-adjacent subunits.

23. An industrial fabric as described in claim 1, wherein the shapes of the multiple non-adjacent subunits are uniform and extend over the entire area defined by the boundaries of the discretized shapes of the pattern elements.

24. The industrial fabric of claim 23, wherein the second layer comprises: an industrial fabric comprising one or more non-adjacent subunits disposed within the boundary of the discretized shape of the pattern element, the non-adjacent subunits not adjacent to the plurality of non-adjacent subunits, and having a shape distinct from the shape of the plurality of non-adjacent subunits.

25. An industrial fabric as described in claim 24, wherein the one or more non-adjacent subunits at least partially define the boundary of the discretized shape of the pattern element.

26. The industrial fabric according to claim 1, the pattern element is a first pattern element, and the plurality of non-adjacent subunits is a first plurality of non-adjacent subunits; the second layer comprises a second plurality of non-adjacent subunits defining a second pattern element having a discretized shape on the top surface of the first layer, the second plurality of non-adjacent subunits being disposed within a boundary of the discretized shape of the second pattern element and at least partially defining the boundary of the discretized shape of the second pattern element.

27. The industrial fabric according to claim 26, The industrial fabric, wherein the discretized first pattern elements and the discretized second pattern elements are spaced apart from one another.

28. An industrial fabric as described in claim 1, wherein the length of a subunit of the plurality of non-adjacent subunits is 1 mm or less.

29. The industrial fabric according to claim 1, the first layer has a first region in which the plurality of non-adjacent subunits are distributed and a second region in which the plurality of non-adjacent subunits are not distributed, the second region surrounding the first region so as to at least partially define the discretized shape of the pattern element.

Images