Extrusion-molded reinforced industrial belt

Abstract

The present disclosure relates to non-woven extruded industrial fabrics. The method of manufacturing the industrial fabric is to crosshead extrude a polymeric matrix material together with linear components. The linear components crosshead extruded together with the polymeric matrix material can be a longitudinally oriented continuous system. The polymeric resin matrix at least partially encompasses one or more of the linear components. Additionally, the resin matrix can be further strengthened by the inclusion of nanoparticles, nanomaterials, and / or short fibers. The front side of the industrial belt may be smooth or may include a surface pattern or texture.

Description

Technical Field

[0001]

[0001] This disclosure relates to industrial fabrics for nonwoven extrusion molding. Industrial fabrics such as belts are produced by co-extruding a polymeric matrix material with linearly configured elements oriented in the machine direction. The front side of the industrial fabric may be smooth or may include surface patterns or textures.

Background Art

[0002]

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

[0003]

[0003] The newly formed web of cellulose fibers proceeds from the forming section to a pressing section that includes a series of press nips. The web of cellulose fibers passes through a press nip supported by a press fabric or, in most cases, between two such press fabrics. The web of cellulose fibers is subjected to a compressive force in the press nip, which squeezes out water therefrom and causes the cellulose fibers in the web to adhere to each other, converting the web of cellulose fibers into a paper sheet. The water is received by one or more press fabrics and ideally does not return to the paper sheet.

[0004]

[0004] Finally, the paper sheet proceeds to a dryer section, which includes at least a series of rotatable dryer drums or cylinders that are internally heated by steam. The newly formed paper sheet is guided by a dryer fabric that holds the paper sheet in proximity to the surface of the drums in a continuous serpentine path surrounding each of the series of drums. The heated drums reduce the water content of the paper sheet by evaporation to a desired level.

[0005] It should be understood that the forming fabric, press fabric, and dryer fabric all take the form of an endless loop on the paper machine and function like a conveyor. Further, it should be understood that papermaking is a continuous process that proceeds at a significant speed. That is, the fibrous slurry is continuously deposited on the forming fabric in the forming section, and the newly produced paper sheet is continuously wound onto a roll after exiting the dryer section.

[0006]

[0006] Patterned belts in the papermaking and nonwoven fields are used to create three-dimensional nonwoven, tissue, or towel structures. Typically, these belts are employed, for example, in the forming and press sections of the papermaking process, where an increase in the thickness of the belts can directly impart thickness, bulk, and three-dimensional patterning to the produced patterned products such as roll goods. For this type of patterned belt, there is usually a base fabric, for example, for dimensional stability and load-bearing characteristics. These belts often have an upper surface of a second layer added to the base fabric, especially to impart thickness, surface pattern, pattern, and bulk. This upper surface can be made from a thermoplastic or thermosetting material and is either applied directly in a molten or liquid form or first produced as a sheet and subsequently joined to the surface of the base fabric of the belt. The joining can be by any of chemical, thermal, or a combination thereof.

Summary of the Invention

Problems to be Solved by the Invention

[0007]

[0007] The present disclosure relates to an extruded nonwoven industrial fabric with linear components disposed in the machine direction (MD) of the fabric, and an extruded polymeric matrix material that at least partially encapsulates one or more of the linear components. The present disclosure further provides a method for forming an extruded nonwoven industrial fabric with linear components disposed in the machine direction of the fabric, and an extruded polymeric matrix material that at least partially encapsulates one or more of the linear components.

Means for Solving the Problems

[0008]

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

[0009]

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

[0010]

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

[0011]

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

[0012]

[0012] In certain embodiments, the linear components are extruded with the polymeric matrix material. In certain embodiments, this can be done by cross - head extrusion and can be done in a helical configuration.

[0013]

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

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

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

[0016] In certain embodiments, the extruded polymeric matrix material includes nanoparticles, nanomaterials, fibrous materials, glass, carbon, inorganic fillers, and / or polymeric materials. In some embodiments, the nanoparticles, nanomaterials, fibrous materials, glass, carbon, inorganic fillers, and / or polymeric materials are incorporated throughout or in part of the extruded polymeric matrix material. In still other embodiments, the extruded polymeric matrix material can include thermoplastics, polyurethanes, polyesters, polyamides, copolyesters, copolyamides, hot melt adhesives, copolymers of thermoplastic polyurethane (TPU) and acrylic acid, copolymers of polyester elastomers and TPU, and copolymers of polyamide elastomers and TPU.

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

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

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

[0020]

[0020] In certain embodiments, the nonwoven industrial fabric is a conveyor belt and a paper-making fabric ("PMC") that is a forming fabric, press fabric, dryer fabric, shoe press belt, transfer belt, wind-up belt, through-air drying ("TAD") fabric, creping fabric, high energy efficiency technology advanced drying ("eTAD") fabric, advanced tissue forming system ("ATMOS") fabric or belt, new tissue technology ("NTT") fabric or belt, or a structured fabric PMC, a double nip thickener ("DNT") fabric, a belt filter, a pulp washer, a belt, fabric, or sleeve for the production of airlaid, spunbond, meltblown, hydroentangled nonwoven materials, a belt for producing building materials, a belt for producing oriented strand board ("OSB"), a corrugator belt, a fiber product finishing belt, a shrink-proofing belt, a leather finishing belt, or a leather finishing sleeve, and is selected from the group consisting of.

Brief Description of the Drawings

[0021]

Figure 1

[0021] FIG. 10 is a partial cutaway perspective view of one embodiment of the fabric of the present disclosure, including the patterned front side.

Figure 2

[0022] FIG. 11 is a partial cutaway perspective view of one embodiment of the fabric of the present disclosure, including the smooth front side.

Figure 3

[0023] FIG. 12 is a cross-sectional view of one embodiment of the fabric of the present disclosure along the transverse direction (width direction (CD)).

Figure 4

[0024] FIG. 13 is a cross-sectional view of another embodiment of the fabric of the present disclosure along the transverse direction (CD), with linear components partially exposed.

Figure 5

[0025] FIG. 14 is a cross-sectional view of one embodiment of the fabric of the present disclosure along the transverse direction (CD), where the openings through the fabric provide a permeable structure.

Figure 6

[0026] FIG. 15 is a cross-sectional view of one embodiment of the fabric of the present disclosure along the transverse direction (CD), with first and second types of linear components.

Figure 7

[0027] Cross-sectional view along the cross direction (CD) of one embodiment of the fabric of the present disclosure, in which the linear components are configured and arranged in a first parallel plane and a second parallel plane.

Figure 8

[0028] Cross-sectional view along the cross direction (CD) of one embodiment of the fabric of the present disclosure, including an upper coating layer or film.

Figure 9

[0029] Cross-sectional view along the cross direction (CD) of one embodiment of the fabric of the present disclosure, showing additional patterning that can be achieved by deposition of resin on the front side of the fabric.

Figure 10

[0030] Regarding FIG. 9, it is a diagram showing a continuous additional pattern (the dark regions are the addition) that can be achieved by deposition of resin on the front side of the fabric of the present disclosure. Similarly, FIG. 10 shows a continuous subtractive pattern (the white regions are the removal) regarding FIG. 12.

Figure 11

[0031] Regarding FIG. 9, it is a diagram showing a discretized additional pattern (the dark regions are the addition) that can be achieved by deposition of resin on the front side of the fabric of the present disclosure. Similarly, FIG. 11 shows a discretized subtractive pattern (the white regions are the removal) regarding FIG. 12.

Figure 12

[0032] Cross-sectional view along the cross direction (CD) of one embodiment of the fabric of the present disclosure, showing subtractive or removal patterning that can be achieved on the front side of the fabric.

Figure 13

[0033] Diagram showing equipment for producing one of the spiral configurations of an embodiment of the fabric of the present disclosure.

Figure 14

[0034] Cross-sectional view along the longitudinal direction of one embodiment of the fabric of the present disclosure.

Figure 15

[0035] Plan view of a subtractive surface formed on the front side of one embodiment of the fabric of the present disclosure.

Figure 16

[0036] Plan view of an additional surface formed on the front side of one embodiment of the fabric of the present disclosure, including perforations in the additional material.

Figure 17

[0037] A plan view of the back side of the fabric embodiment shown in FIG. 16, further showing the perforations passing through the fabric.

Figure 18

[0038] A cross-sectional view in the transverse direction (CD) of the perforations of the fabric embodiment shown in FIGS. 16 and 17.

Figure 19

[0039] A plan view of an additional surface without through holes, with an additional material forming an element similar to a bicycle chain link, formed on the front side of an embodiment of the fabric of the present disclosure.

Figure 20

[0040] A plan view of an additional surface without through holes, with an additional material forming a dumbbell-shaped form, formed on the front side of an embodiment of the fabric of the present disclosure.

Figure 21

[0041] A further plan view of an additional surface without through holes, with an additional material forming a dumbbell-shaped form, formed on the front side of an embodiment of the fabric of the present disclosure.

Figure 22

[0042] A cross-sectional view of an embodiment of the fabric of the present disclosure showing filler particles within a resin matrix.

DETAILED DESCRIPTION OF THE INVENTION

[0022]

[0043] The term "comprising" in the present disclosure may mean "including" or may have the meaning generally ascribed to the term "comprising" in United States patent law. The term "consisting essentially of" has the meaning ascribed to it in United States patent law when used in the claims. Other aspects of the present disclosure are described in the present disclosure or will be known to those skilled in the art after consideration of the present disclosure.

[0023]

[0044] The terms "yarn" or "fiber" are used interchangeably in the following disclosure and can refer to monofilaments, multifilament yarns, twisted yarns, textured yarns, covered yarns, otherwise spoolable materials, and yarns made from stretch-break fibers known to those skilled in the art. Yarns can be made in the form of multifilaments, monofilaments, cords, spun yarns, tapes, tow yarns, untwisted tow yarns, of carbon, rayon, fiberglass, cotton, ceramic, aramid, polyester, polyolefin, metal, polyethylene, glass, polyamide, polyphenylene sulfide (PPS), and / or polyether ether ketone (PEEK) materials, and / or other materials and forms exhibiting desired physical, thermal, chemical, or other properties. Yarns can further be thermoplastic, thermosetting elastomeric materials (elastomers), highly elastic elastic materials (e.g., with sufficient load-bearing properties), and / or inelastic materials, and can further be fusible sheath / core yarns having a core with a higher melting point than the surrounding sheath.

[0024]

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

[0025]

[0046] The present disclosure relates to nonwoven industrial fabrics such as belts that can be used in a fairly large number of industrial processes including papermaking processes. The fabric or belt comprises linear components disposed in the MD and a matrix material that at least partially encapsulates one or more of the linear components. The fabric or belt can be produced in various ways that relatively simplify its production, such as, for example, by forming a matrix to encapsulate the linear components and form the first and second sides of the fabric or belt, such as a spiraling technique in coextruded polymers.

[0026]

[0047] The linear component can be a continuous system such as a thread, a string, a tape, or a similar thread-windable material. The linear component can be tension-resistant and / or flexible. In certain embodiments, the linear component has an elastic modulus high enough to be load-bearing. The linear components of the present invention can comprise any suitable material, such as in the form of multifilament, monofilament, string, spun yarn, tape, twisted tow yarn, untwisted tow yarn, elastic or inelastic thermosetting plastics, thermoplastics, carbon, rayon, fiberglass, cotton, ceramic, aramid, polyester, metal, polyethylene, glass, polyamide, polyphenylene sulfide (PPS), and / or polyether ether ketone (PEEK) materials, as well as other materials and forms exhibiting desired physical, thermal, chemical, or other properties. Further embodiments of the linear component include linear components with coatings, and embodiments where the linear component comprises a core and a fusible sheath, for example, embodiments where the melting point of the core material is higher than that of the fusible sheath material.

[0027]

[0048] Linear components such as threads are arranged in the MD of the industrial fabric of the present invention. The linear components are arranged in the MD adjacent to each other and can be spaced apart from each other by a specific distance. In some embodiments, the linear components are arranged in the MD in a substantially parallel array. In further embodiments, the linear components are in substantially the same plane. In other embodiments, the linear components are in different planes. In yet a further embodiment, the industrial fabric includes multiple planes of linear components, and the planes are not entirely or partially parallel to each other. In still other embodiments, at least two linear components are in a plane parallel to each other, while other linear components in the industrial fabric are in a plane not parallel to the plane of the at least two linear components.

[0028]

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

[0029]

[0050] The linear components may vary in number, material composition, and / or size (e.g., yarn diameter) within the industrial fabric of the present invention. In certain embodiments, the linear components each comprise the same material and are of the same size (e.g., diameter).

[0030]

[0051] When making the industrial fabric of the present invention, typically, pieces of a polymeric matrix material (e.g., a resin) are extruded longitudinally of the fabric or belt together with the linear components. This extrusion of the polymeric matrix material and the linear components may be characterized as co-extrusion, i.e., simultaneous extrusion or extrusion at the same time. Crosshead extrusion may be utilized for this operation, where the polymeric matrix material is melted and extruded together with pre-manufactured linear components. Some embodiments may use extrusion that is only a few inches (about 5 - 8 cm) wide.

[0031]

[0052] The industrial fabric of the present invention is envisioned to be produced in the form of an endless belt, although some embodiments may be produced in a flat form.

[0032]

[0053] A polymeric matrix material, such as a resin, encapsulates one or more of the linear components. Encapsulating one or more linear components with a polymeric matrix material joins the linear components to make the nonwoven industrial fabric of the present invention. In some embodiments, one or more linear components are partially encapsulated by the matrix material. In other embodiments, one or more linear components are entirely encapsulated by the matrix material. In certain embodiments, all of the linear components in the industrial fabric of the present invention are entirely encapsulated by the polymeric matrix material.

[0033]

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

[0034]

[0055] In addition, the polymeric matrix material can be further strengthened by the inclusion of comminutable fibers such as carbon, glass, spunbond polyethylene, polyamide, polyester, or similar materials such as polymeric fibers, airlaid, nonwoven fabric, etc. The polymeric matrix material can further include a spunbond, spunlace, meltblown, or needlepunched fiber structure or fabric to enhance the integrity and overall strength of the fabric. Similarly, the polymeric matrix material can be further strengthened by the inclusion of fiber materials such as nanoparticles, nanomaterials, inorganic filler particles (e.g., clay, SiO2), and / or, without limitation, glass, carbon, inorganic fillers, or polymeric materials that enhance the physical properties of the resulting matrix. Reinforcing materials such as nanoparticles or nanomaterials can be incorporated throughout the polymeric matrix material or into one or more portions of the polymeric matrix material. In certain embodiments, reinforcing materials such as nanoparticles or nanomaterials are uniformly incorporated throughout the polymeric matrix material.

[0035]

[0056] The polymeric matrix material in which the MD linear component is at least partially encapsulated provides sufficient reinforcement in the CD of the extruded industrial fabric of the present invention such that a linear component extending in the cross direction (CD) is not required. Thus, in various embodiments of the present invention, all linear components are arranged in the MD of the extruded industrial fabric. In these embodiments, there are no linear components arranged in the CD of the extruded industrial fabric. Additionally, in further embodiments, the polymeric matrix material of the industrial fabric of the present invention provides sufficient CD reinforcement such that a fabric cloth layer having woven-in cross (CD) yarns, such as a fabric bottom cloth having woven-in warp and weft yarns, is not required. Thus, in various embodiments, the industrial fabric of the present invention comprises only an extruded polymeric matrix material in which the MD linear component is at least partially encapsulated therein, and the fabric optionally comprises a coated coating or film on its front or machine side surface and / or is patterned on its front or machine side surface. In certain of these embodiments, the extruded polymeric matrix comprises additional reinforcement as described above, such as short fibers, nanoparticles, nanomaterials, organic fillers, etc., which are incorporated randomly, either wholly or partially, throughout the polymeric matrix material, e.g., not aligned with the CD of the fabric.

[0036]

[0057] The industrial fabrics of the present invention, such as belts, can be used in a fairly large number of industrial processes including the papermaking process. In some embodiments, the industrial fabrics of the present invention are forming fabrics, press fabrics, dryer fabrics, shoe press belts, conveyor belts, wind-up belts, through air drying (「TAD」) fabrics, impression fabrics, energy efficient technologically advanced drying (「eTAD」) fabrics, advanced tissue molding system (「ATMOS」) fabrics or belts, new tissue technology (「NTT」) fabrics or belts, papermachine clothing such as structured fabrics, as well as double nip thickener (「DNT」) fabrics, belt filters, pulp washer fabrics, belts / cloths / sleeves for the production of nonwovens (e.g., airlaid, spunbonded, meltblown, hydroentangled), belts for the production of building materials (e.g., oriented strand board (「OSB」)), coater belts, textile finishing belts (e.g., shrink-proofing belts), or are suitable for use as leather buffing belts or sleeves.

[0037]

[0058] Various embodiments of the present invention include a cloth with a plain, patterned (opaque), perforated patterned (permeable), both patterned and perforated patterned, or additional or removed patterned front (or paper side) surface. These embodiments can be used, for example, in applications such as conveyor belts, NTT belts, PMCs, or conveyor belts. For optimizing the cloth (e.g., belt) for use in dehydration processes such as forming sections, press sections, or dryer sections, and for use as a conveyor belt or conveyor belt in paper machines or tissue production machines, the surface should enable a uniform pressure distribution and / or include a pattern on the front side to be imprinted on the paper, board, tissue, or other materials produced thereon. In certain embodiments, the cloth or belt of the present invention including a patterned or unpatterned front side can be used in industrial applications such as the production of non-woven fabrics, spunlace, building materials, tissues, towels, boards, felt boards, medium density fiberboards (MDF), and similar products. The cloth or belt can be configured to include a front side and a back side formed from a polymer matrix so as to be impermeable to gases and / or liquids such as water. However, in other specific embodiments, the cloth or belt can include perforations formed therethrough by mechanical methods, lasers, or similar methods to provide permeability to gases and / or liquids. Industrial cloths of other embodiments can include both permeable sections or parts and impermeable sections or parts.

[0038]

[0059] In certain embodiments, the patterning on the front side (or “paper side”), by way of example and not limitation, if patterned by methods such as laser, etching, or other types of surface removal techniques (similar to gravure or negative relief), can vary in depth up to the maximum thickness of the final product (e.g., tissue or towel) produced thereon. The patterning can be provided by techniques such as embossing techniques (e.g., from a patterned roll, belt, or other patterned media), or can be patterned by resin deposition onto the surface (similar to letterpress or positive relief). The resin deposition can be applied by three-dimensional printing techniques such as inkjet printing techniques or other resin injection molding techniques. A wide variety of patterns can be produced, by way of example and not limitation, such as continuous or discontinuous lines, dots, logos, figures, images, handwritten characters, text, etc. Further possibilities for pattern elements include shapes such as, by way of example and not limitation, circular, polygonal, curved, characters, numbers, words, waveforms, slits, pictures, trademarks, or any desired shape, or combinations of shapes that produce any random or aligned desired pattern. In certain embodiments, circular is round or oval. These patterns are typically realized on the front side of the fabric of the present invention, for example, in a reverse, turned-over, or negative relief configuration, whereby the corresponding desired image will be imprinted onto paper, board, tissue, or other product materials produced on industrial fabrics such as the belt of the present invention.

[0039]

[0060] In certain embodiments, the spiral winding technique can provide channels on the vented backside of an industrial fabric (e.g., a belt) that aid in induction and stability. In certain embodiments, the channels on the vented backside prevent the hydroplaning phenomenon on a wet rotating roll. In yet further embodiments, the industrial fabric can be vented by perforated openings that completely pass through the fabric, thereby rendering it permeable. In other embodiments, the backside may be smooth (planar) or may have a variable roughness depending on the needs of the application (including, but not limited to, polishing, added fibers, or patterning), or may include batt fibers incorporated into the structure of the fabric (e.g., belt). Other specific embodiments may include perforated openings or may vent through the industrial fabric or belt.

[0040]

[0061] Further embodiments include a front side with a coating or film, for example, to increase the adhesion of the sheet. For example, in some embodiments, a thin coating such as an aqueous urethane topcoat can be applied to the front side of the fabric of the present invention to increase the surface energy for improved sheet adhesion. The coating can be spray, coated, or extruded. Other coatings, or in some embodiments films, can be applied to the industrial fabric of the present invention considering hydrophobicity or other specificities. In certain embodiments, a material is applied to the front side surface of the fabric of the present invention as a coating that improves the adhesion of the sheet. In other embodiments, the material can be applied as a laminated film. The coating or film can be applied to the fabric of the present invention that is impermeable, permeable, or has both impermeable and permeable portions.

[0041]

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

[0042]

[0063] Referring now to the drawings in detail, FIGS. 1 and 2 can be seen showing an embodiment of an industrial fabric 10, such as a belt, of the present disclosure, cut away. The linear components 12 are oriented longitudinally and typically have a high modulus of elasticity, thereby providing reinforcement and load-bearing properties to the fabric or belt 10, particularly under longitudinal tensile loads. The linear components 12 are substantially parallel to each other and can be substantially in one or more planes (see FIG. 7). The linear components 12 can be a continuous system, such as, but not limited to, yarns, cords, tapes, or similar woundable materials. The linear components 12 can also be configured as multifilaments, monofilament yarns, cords, spun yarns, or tapes.

[0043]

[0064] Typically, the linear components 12 are co-extruded with a polymeric matrix material, such as a resin, for example, by crosshead extrusion, thereby forming a resin matrix 14 with the linear components 12 encapsulated within the resin matrix 14. Many different extrudable polymeric resin systems can be utilized, including, but not limited to, thermoplastics, polyurethanes, polyesters, polyamides, copolyesters, copolyamides, hot melt adhesives, copolymers of thermoplastic polyurethane (TPU) and acrylic acid, polyester elastomers, polyamide elastomers, and similar polymeric systems. FIGS. 1 and 2 are shown cut away to expose the linear components 12, but the linear components 12 of the finished fabric or belt 10 can be fully encapsulated by the resin matrix 14, as shown in FIG. 3, or partially exposed, as shown in FIG. 4, or some combination of both.

[0044]

[0065] In addition, the resin matrix 14 can be further strengthened by inclusion of fibers that can be shredded, such as carbon, glass, spunbond polyethylene, polyamide, polyester, or similar materials such as polymer fibers, airlaid, clogged woven fabric, etc. The resin matrix 14 can further include a spunbond, spunlace, meltblown, or needled fiber structure or fabric to enhance the integrity and overall strength of the fabric of the present invention. Similarly, the resin matrix 14 can be further strengthened by inclusion of fiber materials such as nanoparticles, nanomaterials, inorganic filler particles (e.g., clay, SiO2), and / or, without limitation, glass, carbon, inorganic substances, or polymer materials that enhance the physical properties of the resulting matrix. For example, FIG. 22 shows the use of filler particles 30, typically inorganic, in the fabric of the present invention.

[0045]

[0066] In certain embodiments, the resin matrix 14 forms an impermeable front (or paper side) 16 and an impermeable back (or machine side) 18, as shown in FIG. 3, by entirely encompassing the linear component 12. In this and similar embodiments, the linear component 12 is extruded in a helical wrap on a two-roll system simultaneously with the resin matrix 14 to produce an endless belt (see apparatus 100 in FIG. 13) from a creel 104. The extrusion can be only a few inches (about 5 - 8 cm) wide at the linear component 12 passing through an extruder (see extruder 102 in FIG. 13). Embodiments include fabrics with a plain, patterned (impermeable), perforated pattern (permeable), both a pattern and a perforated pattern, or an added or removed pattern on the front (or paper side) surface. These embodiments can be used, for example, in applications such as conveyor belts, NTT belts, PMCs, or conveyor belts. In some embodiments, as shown in FIG. 3, the linear component 12 is not exposed and does not extend through or across the impermeable front side 16 or the impermeable back side 18 of the finished fabric or belt 10. In other embodiments, as shown in FIG. 4, the linear component 12 extends partially through the back side 18 of the resin matrix 14 so as to be partially exposed. Further, as shown in FIGS. 5, 9, and 12, the industrial fabric or belt 10 can include openings or vents 21 formed by perforating or other means through the resin matrix 14, thereby providing a permeable configuration. Further, as shown in FIG. 8, the impermeable front side 16 can include a thin “film” 20, such as an aqueous urethane overcoat, to increase the surface energy for improved sheet adhesion. This thin film 20 can be sprayed, coated, or extruded. Other coatings, or in some embodiments films, can be applied to the industrial fabric of the present invention with hydrophobic or other specificities considered. In certain embodiments, a material is applied to the front surface of the fabric of the present invention as a coating to improve the sheet adhesion. In other embodiments, the material can be applied as a laminated film.

[0046]

[0067] Figure 14 shows a cross-sectional view along the longitudinal direction of the fabric of the present invention, in which a linear component 12 (polyethylene terephthalate (PET) yarn fiber) is encapsulated within a resin matrix 14 (TPU extruded products above and below the linear component 12), and a resin coating 20 is present on the front side 16 to enhance the peeling of the paper sheet.

[0047]

[0068] As shown in Figure 6, the linear components shown as two different types of linear components 12A and 12B can be, but are not limited to, a plurality of types of linear components such as different multifilaments, monofilament yarns, cords, spun yarns, or tapes arranged in a parallel configuration. Further, as shown in Figure 7, the linear components 12C, 12D are configured on a plurality of planes. The linear component 12C in Figure 7 is shown on a first plane, and the linear component 12D in Figure 7 is shown on a second plane parallel to the first plane. A further plurality of similar parallel planes including the linear components can be realized. Still further embodiments can include linear components on a plurality of planes, and the planes can be, in whole or in part, not parallel to each other.

[0048]

[0069] When an industrial fabric or belt 10 is produced in a manner similar to that shown in Figure 13, the sequential extrusion passes of the linear component 12 and the resin matrix 14, for example by crosshead extrusion, can be joined by the weld lines 15 shown in Figures 3 - 9 and 12. This weld line 15 can be the result of the self-bonding of the resin when the resin is placed adjacent to the resin of the previous pass. Certain embodiments use materials with sufficient body joining to withstand consolidation and form one strip from many pieces. Other options for forming joints between the pieces are hot gas joining, infrared joining, and laser joining.

[0049]

[0070] For use in a dehydration process such as a forming section, a pressing section, or a dryer section, and for use as a conveyor belt or a transfer belt in a paper machine or a tissue production machine (such as Valmet's Advantage™ NTT®, or other patterned tissue production paper machines), in order to optimize a fabric (e.g., a belt), the surface of the front side 16 should be prepared to allow for a uniform pressure distribution and / or a pattern to be imprinted on the paper, board, or tissue being produced. This patterned belt can also be used in other industrial applications such as building materials, etc. In certain embodiments, the industrial fabric such as the belt of the present invention is completely impermeable to air and / or water. The industrial fabric of other embodiments can include both permeable sections or parts and impermeable sections or parts. In other embodiments, the fabric or belt 10 can be perforated by various means (e.g., laser or mechanical) to provide permeability to gases and / or liquids.

[0050]

[0071] In certain embodiments, the patterning of the front side 16, when patterned by an additional process, can vary in depth, for example, up to a maximum of the maximum thickness of the finished product produced on the fabric. As seen in FIG. 9, the front side 16 can include additional pattern elements 22, which can be formed by a process such as resin deposition into the resin matrix 14 while maintaining the impermeability of the front side 16 in embodiments without openings or vents 21. These additional pattern elements 22 can form a continuous additional pattern 22 as shown in FIG. 10 (the dark areas are the addition), or can form individual / discretized additional patterns as shown in FIG. 11 (the dark areas are the addition). A wide variety of patterns can be produced, including but not limited to continuous or discontinuous lines, dots, logos, figures, images, handwritten characters, text, etc. Further possibilities for pattern elements include, but are not limited to, shapes such as circular, polygonal, wavy, slits, pictures, trademarks, or any desired shape, or combinations of shapes that produce any random or aligned desired pattern.

[0051]

[0072] Examples of additional pattern elements on the front side 16 of the fabric 10 are shown in FIGS. 16, 19, 20, and 21. FIG. 16 shows a resin that forms an additional element 22 by being deposited on the front side 16 of the extruded fabric 10, and there are perforations 21 between the additional elements 22. FIG. 17 shows the back side 18 of the fabric 10 corresponding to FIG. 16 and further shows the perforations 21. FIG. 18 shows a cross-sectional view of the fabric 10 of FIG. 16 in the cross direction (CD) approaching the perforation 21. The perforated perforation 21 is shown together with the additional element 22 surrounding the outer periphery of the perforated perforation 21 and can be further formed by protrusions caused by drilling or forming the perforated perforation. In this figure, a circular end view of the linear component 12 in the extruded polymer matrix 14 is further shown. FIG. 19 shows an additional element 22 in a shape similar to a bicycle chain ring. Similarly, FIGS. 20 and 21 include additional elements 22 on the front side 16 that resemble dumbbells. The illustrated embodiments of FIGS. 19-21 do not include any perforations, punched openings, or vents 21. However, it is contemplated that there are embodiments of the present disclosure that include FIGS. 19-21 with perforations, openings, or punched vents 21. Note that the white lines on the additional element 22 in FIGS. 19 and 20 are due to light reflection in photo processing.

[0052]

[0073] Similarly, as shown in FIG. 12, the front side 16 may include subtractive pattern elements 24 such as voids and patterns in the resin matrix 14, and these subtractive pattern elements 24 may be formed by material removal such as, but not limited to, lasers, etching, or other types of surface removal techniques (similar to gravure printing or engraving) while maintaining the impermeability of the front side 16 in embodiments without openings or vents 21. These subtractive pattern elements 24 may form a continuous subtractive pattern as shown in FIG. 10 (where the white areas are removed), or may form individual / discretized subtractive patterns 24 as shown in FIG. 11 (where the white areas are removed). A wide variety of subtractive patterns can be produced, including, but not limited to, continuous or discontinuous lines, dots, logos, figures, images, handwritten characters, text, etc. Further possibilities for pattern elements include shapes such as, but not limited to, circular, polygonal, wavy, slits, pictures, trademarks, or any desired shape, or combinations of shapes that produce any random or aligned desired pattern. FIG. 15 shows an embodiment of the present disclosure where the front side 16 includes subtractive elements 24.

[0053]

[0074] In summary, patterning can be provided by techniques such as, but not limited to, laser technology or embossing technology (e.g., from a patterned roll, belt, or other patterned media), or can be patterned by resin deposition on the surface (similar to letterpress printing or relief printing). The resin deposition can be applied by three-dimensional printing techniques such as inkjet printing technology or other resin injection molding techniques. A wide variety of patterns can be produced, including, but not limited to, continuous or discontinuous lines, dots, logos, figures, images, handwritten characters, text, etc. Further possibilities for pattern elements include shapes such as, but not limited to, circular, polygonal, wavy, slits, pictures, trademarks, or any desired shape, or combinations of shapes that produce any random or aligned desired pattern.

[0054]

[0075] These patterns are typically realized on the front side of the fabric of the present invention, for example, in a reverse, turned - inside - out, or intaglio configuration, whereby the corresponding desired image will be imprinted onto paper, board, tissue, or other product materials produced on an industrial fabric such as the belt of the present invention.

[0055]

[0076] Figure 13 shows an apparatus 100 for one method of forming an industrial fabric or industrial belt 10. A resin extruder 102 is provided to cross - head extrude a resin material of (resin matrix 14) and a material of the linear component 12 received from a yarn package 104. A strip of resin material containing the linear component is helically wound around two parallel support "head" roll 106 and "tail" roll 108 (the distance between rolls 106, 108 defines the length of the resulting industrial belt 10), and adjacent passes of the extruded material are joined together at a weld line 15 (see also FIGS. 3 and 4).

[0056]

[0077] In certain embodiments, the helical winding technique can provide channels on the vented back side that serve for dehydration, induction, and stability. In other embodiments, the back side may be smooth or planar, may have variable roughness, or may include batt fibers incorporated into the structure of the fabric (e.g., belt).

[0057]

[0078] Modifications to the above will be apparent to those skilled in the art, but do not cause the present invention to deviate from the scope of the present invention. The following claims should be construed to cover such situations.

Claims

1. A nonwoven industrial fabric, comprising: a linear component disposed in the longitudinal direction (MD) of the fabric; and an extruded polymeric matrix material that at least partially encapsulates one or more of the linear components, wherein the nonwoven industrial fabric is impermeable.

2. A nonwoven industrial fabric, comprising: a linear component disposed in the longitudinal direction (MD) of the fabric; and an extruded polymeric matrix material that at least partially encapsulates one or more of the linear components, wherein the extruded polymeric material includes a first side and a second side, the first side and the second side are planar, and one or more of the linear components extend at least partially through at least one of the first side and the second side.

3. A nonwoven industrial fabric, comprising: linear components disposed on a plurality of planes in the longitudinal direction (MD) of the fabric; and an extruded polymeric matrix material that at least partially encapsulates one or more of the linear components disposed on the plurality of planes.

4. A nonwoven industrial fabric for patterning a product, comprising: a linear component disposed in the longitudinal direction (MD) of the fabric; and an extruded polymeric matrix material that at least partially encapsulates one or more of the linear components, wherein a first side of the nonwoven industrial fabric includes a pattern formed by addition elements and / or subtraction elements for providing a desired surface pattern to the product.

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

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

7. The nonwoven industrial fabric according to any one of claims 1 to 6, wherein the linear components are crosshead extruded with the polymeric matrix material.

8. The nonwoven industrial fabric according to any one of claims 1 to 7, wherein the linear components include a material selected from the group consisting of thermosetting plastics, thermoplastics, carbon, glass, polyester, polyolefin, and polyamide.

9. ​ ​ ​ ​ ​ In the nonwoven fabric for industrial use according to any one of claims 1 to 8, the extruded polymeric matrix material optionally contains nanoparticles, nanomaterials, fiber materials, glass, carbon, inorganic fillers, and / or polymeric materials incorporated throughout or in part of the extruded polymeric matrix material. A nonwoven fabric for industrial use.

10. In the nonwoven fabric for industrial use according to any one of claims 1 to 9, the extruded polymeric matrix material is selected from the group consisting of thermoplastic substances, polyurethanes, polyesters, polyamides, copolyesters, copolyamides, hot melt adhesives, copolymers of thermoplastic polyurethane (TPU) and acrylic acid, copolymers of polyester elastomer and TPU, and copolymers of polyamide elastomer and TPU. A nonwoven fabric for industrial use.

11. In the nonwoven fabric for industrial use according to claim 1 and any one of claims 3 to 10, the extruded polymeric matrix material completely encapsulates all of the linear components. A nonwoven fabric for industrial use.

12. In the nonwoven fabric for industrial use according to claim 1 and any one of claims 3 to 10, the extruded polymeric matrix material includes a first side and a second side, the first side and the second side are planar, and the linear component does not extend through the first side or the second side. A nonwoven fabric for industrial use.

13. In the nonwoven fabric for industrial use according to any one of claims 1 to 10, the extruded polymeric matrix material includes a first side and a second side, the first side and / or the second side are planar, and one or more linear components extend at least partially through at least one of the first side and the second side. A nonwoven fabric for industrial use.

14. In the nonwoven fabric for industrial use according to claim 1 or 2 and any one of claims 4 to 13, the linear components are substantially on the same plane. A nonwoven fabric for industrial use.

15. In the nonwoven fabric for industrial use according to any one of claims 1 to 13, the linear components are on a plurality of planes. A nonwoven fabric for industrial use.

16. In the nonwoven fabric for industrial use according to any one of claims 1 to 15, the first side of the nonwoven fabric for industrial use includes a pattern. A nonwoven fabric for industrial use.

17. The nonwoven fabric for industrial use according to claim 16, wherein the pattern on the first side is formed by an addition process and / or a subtraction process, the nonwoven fabric for industrial use.

18. The nonwoven fabric for industrial use according to claim 16 or 17, wherein the pattern on the first side is formed by a method selected from the group consisting of laser etching, mechanical etching, embossing, and resin deposition, the nonwoven fabric for industrial use.

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

20. The nonwoven fabric for industrial use according to any one of claims 1 to 19, a conveyor belt, a paper-making fabric ("PMC"), which is a forming fabric, a press fabric, a dryer fabric, a shoe press belt, a conveying belt, a winding belt, an air-through drying ("TAD") fabric, an indentation fabric, a high energy efficiency technology advanced drying ("eTAD") fabric, an advanced tissue forming system ("ATMOS") fabric or belt, a new tissue technology ("NTT") fabric or belt, or a structured fabric, a PMC, a double nip thickener ("DNT") fabric, a belt filter, a pulp washer, a belt, fabric, or sleeve for the production of air-laid, spunbond, meltblown, hydroentangled nonwoven materials, a belt for producing building materials, a belt for producing oriented strand board ("OSB"), a corrugator belt, a fabric finishing belt, a shrink-proofing belt, a leather finishing belt, a leather finishing sleeve, the nonwoven fabric for industrial use selected from the group consisting of.

21. The nonwoven fabric for industrial use according to any one of claims 1 to 20, which is a paper-making fabric ("PMC"), the nonwoven fabric for industrial use.

22. The nonwoven fabric for industrial use according to any one of claims 1 to 21, comprising at least two different types of linear components, the nonwoven fabric for industrial use.

23. The nonwoven fabric for industrial use according to any one of claims 1 to 22, wherein one or more of the number, material composition, or size of the linear components are different, the nonwoven fabric for industrial use.

24. In the nonwoven fabric for industrial use according to any one of claims 1 to 23, the extruded polymer matrix provides sufficient cross-direction (CD) reinforcement to the fabric, a nonwoven fabric for industrial use.

25. In the nonwoven fabric for industrial use according to any one of claims 1 to 24, all linear components are arranged in the MD, a nonwoven fabric for industrial use.

26. In the nonwoven fabric for industrial use according to any one of claims 1 to 25, the linear component is a thread, a nonwoven fabric for industrial use.

27. In the nonwoven fabric for industrial use according to any one of claims 1 to 26, the linear component is selected from the group consisting of multifilaments, monofilaments, cords, spun yarns, and tapes, a nonwoven fabric for industrial use.

28. In the nonwoven fabric for industrial use according to any one of claims 1 to 27, the linear component has an elastic modulus sufficient to be load-resistant, a nonwoven fabric for industrial use.

29. A method of forming a nonwoven fabric for industrial use according to any one of claims 1 to 28, preparing a linear component arranged in the longitudinal direction (MD) of the fabric; extruding the polymer matrix material so that the linear component is at least partially encapsulated in the polymer matrix material A method comprising.

30. The method according to claim 29, wherein the extruding step forms a helical configuration that forms an endless belt.

31. The method according to claim 29 or 30, comprising a step of crosshead extruding the polymer matrix material together with the linear component.

32. The method according to any one of claims 29 to 31, wherein the first side of the nonwoven fabric for industrial use includes a pattern.

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

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

35. The method according to any one of claims 32 to 34, wherein the pattern on the first side is formed by a resin deposition technique selected from the group consisting of three-dimensional printing technology and inkjet printing press technology. Claim 36 The method according to any one of claims 29 to 35, wherein the nonwoven industrial fabric is a conveyor belt and a paper-making fabric ("PMC"), which is a forming fabric, press fabric, dryer fabric, shoe press belt, conveying belt, winding belt, through-air drying ("TAD") fabric, indenting fabric, high energy efficiency technology advanced drying ("eTAD") fabric, advanced tissue forming system ("ATMOS") fabric or belt, new tissue technology ("NTT") fabric or belt, or a structured fabric, a double nip thickening tank ("DNT") fabric, a belt filter, a pulp washer fabric, a belt, fabric, or sleeve for the production of airlaid, spunbond, meltblown, hydroentangled nonwoven materials, a belt for producing building materials, a belt for producing oriented strand board ("OSB"), a coater belt, a fiber product finishing belt, a shrink-proofing belt, a leather finishing belt, or a leather finishing sleeve, the method being selected from the group consisting of.

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