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EP-4735242-A1 - EXTRUDED REINFORCED INDUSTRIAL BELT WITH EMBEDDED LAYER

EP4735242A1EP 4735242 A1EP4735242 A1EP 4735242A1EP-4735242-A1

Abstract

The present disclosure relates to an extruded industrial fabric. A method of manufacture of the industrial fabric is crosshead extruding a first layer polymeric matrix material with linear components. The linear components crosshead extruded with the polymeric matrix material may be continuous systems oriented in the machine direction. A nonwoven layer of material is provided on a surface of the first layer of polymeric matrix material and a second layer of polymeric matrix material is extruded onto the nonwoven layer of material. The first layer of polymeric matrix material at least partially encompasses the linear components. A faceside of the industrial fabric may be smooth or may include a texture or pattern. A backside may be smooth (planar), have a variable roughness, or include needled fibers that are incorporated into the structure of the fabric.

Inventors

  • LEVINE, MARK J.
  • HANSEN, ROBERT
  • GOEL, VIVEK
  • CAMPONESCHI BROTHERSON, ERIN LYNN

Assignees

  • Albany International Corp.

Dates

Publication Date
20260506
Application Date
20230630

Claims (20)

  1. 1. An industrial fabric comprising: linear components disposed in a machine direction of the fabric; a first layer of extruded polymeric matrix material encapsulating one or more of the linear components thereby forming a first layer with a first external side and a first internal side; a second layer of extruded polymeric matrix material including a second external side and a second internal side; and a third layer that is an internal nonwoven layer situated between the first internal side of the first layer and the second internal side of the second layer.
  2. 2. The industrial fabric of claim 1 , wherein the industrial fabric is impermeable.
  3. 3. The industrial fabric of claim 1, wherein the industrial fabric is permeable.
  4. 4. The industrial fabric of any of claims 1-3, wherein the internal nonwoven layer is selected from the group consisting of: batt fiber, needled fiber, needled batt fiber, spunlaid (spunbond) material, airlaid nonwoven material, meltblown material, spunlace material (hydroentangled), spunmelt/SMS material, and wetlaid material.
  5. 5. The industrial fabric of any of claims 1-4, wherein the extruded polymeric matrix matenal of the first and/or second layer impregnates the internal nonwoven layer.
  6. 6. The industrial fabric of any of claims 1-5, wherein the first layer of extruded polymeric matrix material partially encapsulates one or more of the linear components.
  7. 7. The industrial fabric any of claims 1 -6, wherein the first layer of extruded polymeric matrix material fully encapsulates one or more of the linear components.
  8. 8. The industrial fabric of any of claims 1-7, wherein the first layer of extruded polymeric matrix material fully encapsulates all of the linear components.
  9. 9. The industrial fabric of any of claims 1-8, wherein the linear components are yams.
  10. 10. The industrial fabric of any of claims 1-9, wherein the linear components are selected from the group consisting of: multifilaments, monofilament yams, cords, spun yams, tapes, twisted tow yams, and untwisted tow yams.
  11. 11. The industrial fabric of any of claims 1-10, wherein the linear components are substantially parallel to one another.
  12. 12. The industrial fabric of any of claims 1-11, wherein the linear components are substantially in the same plane.
  13. 13. The industrial fabric of any of claims 1-11, wherein the linear components are in a plurality of planes.
  14. 14. The industrial fabric of any of claims 1-13, wherein the linear components have a sufficient modulus to be load-bearing.
  15. 15. The industrial fabric of any of claims 1-14, wherein the linear components are crosshead extruded with the first layer of polymeric matrix material.
  16. 16. The industrial fabric of any of claims 1-15, wherein the linear components comprise a material selected from the group consisting of: thermoset plastics, carbon, glass, polyesters, and polyamides.
  17. 17. The industrial fabric of any of claims 1-16, wherein all of the linear components are of the same size and material.
  18. 18. The industrial fabric of any of claims 1-16, wherein the linear components comprise first linear components and second linear components, wherein the first linear components are of a first size and/or a first material and the second linear components are of a second size and/or a second material.
  19. 19. The industrial fabric of any of claims 1-16, wherein the linear components comprise first linear components and second linear components, wherein a portion of the first and second linear components are of the same size and/or material.
  20. 20. The industrial fabric of any of claims 1 -19, wherein at least one of the first and second extruded polymeric layers comprises a material selected from the group consisting of: fibers, nanoparticles, nanomaterials, fiber materials, glass, carbon, inorganic fillers, polymeric material, and combinations thereof.

Description

EXTRUDED REINFORCED INDUSTRIAL BELT WITH EMBEDDED LAYER FIELD OF THE DISCLOSURE [0001] The present disclosure relates to an extruded industrial fabric. The industrial fabric, such as a belt, is produced by crosshead extruding a first layer polymeric matrix material with linear components oriented in the machine direction. An internal nonwoven layer is embedded between the first layer of polymeric matrix material and a second layer of polymeric matrix material. BACKGROUND [0002] During the papermaking process, a cellulosic fibrous web is formed by depositing a fibrous slurry', that is, an aqueous dispersion of cellulose fibers, onto a moving forming fabric in the forming section of a paper machine. A large amount of water is drained from the slurry through the forming fabric, leaving the cellulosic fibrous web on the surface of the forming fabric. [0003] The newly formed cellulosic fibrous web proceeds from the forming section to a press section, which includes a series of press nips. The cellulosic fibrous web passes through the press nips supported by a press fabric, or, as is often the case, between two such press fabrics. In the press nips, the cellulosic fibrous web is subjected to compressive forces that squeeze water therefrom, and that adhere the cellulosic fibers in the web to one another to turn the cellulosic fibrous web into a paper sheet. The water is accepted by the press fabric or fabrics and, ideally, does not return to the paper sheet. [0004] The paper sheet finally proceeds to a dryer section, which includes at least one series of rotatable dryer drums or cylinders, which are internally heated by steam. The newly formed paper sheet is directed in a serpentine path sequentially around each in the series of dmms by a dryer fabric, which holds the paper sheet closely against the surfaces of the drums. The heated drums reduce the water content of the paper sheet to a desirable level through evaporation. [0005] It should be appreciated that the forming, press, and dryer fabrics all take the form of endless loops on the paper machine and function in the manner of conveyors. It should further be appreciated that paper manufacture is a continuous process that proceeds at considerable speeds. That is to say, the fibrous slurry is continuously deposited onto the forming fabric in the forming section, while a newly manufactured paper sheet is continuously wound onto rolls after it exits from the dryer section. [0006] Texturing belts in the papermaking and nonwovens fields are used to make three- dimensional nonwoven and tissue and towel structures. Typically, these belts are employed prior to or during the drying step of e.g., a papermaking process, where an increase in variation of the caliper of the belting can directly impart caliper, bulk, and three-dimensional patterning in the textured products produced, such as rolled goods. For this type of texturing belt, there usually exists a base weave for, e.g., dimensional stability and load bearing properties. Often, these belts have a second layer top surface added to the base weave specifically to impart caliper, texture, pattern, and bulk. This top surface can be made from a thermoplastic or thermoset material and is either applied directly in a melted or liquid form, or first produced as a sheet and then subsequently bonded to the surface of the base fabric of the belt. Bonding can either be chemical or thermal, or a combination thereof. SUMMARY OF THE DISCLOSURE [0007] Embodiments of the present disclosure relate to an industrial fabric. The industrial fabric comprises a first and second layer of extruded polymeric matrix material and further comprises an internal nonwoven layer between the first and second layers of extruded polymeric material. The first layer of extruded polymeric matrix material encapsulates linear components disposed in a machine direction (MD) of the fabric. [0008] In some embodiments, the industrial fabric is impermeable. In other embodiments, the industrial fabric is permeable. [0009] In certain embodiments, the internal nonwoven layer is selected from the group consisting of batt fiber, needled fiber, needled batt fiber, spunlaid (spunbond) material, airlaid nonwoven material, meltblown material, spunlace material (hydroentangled), spunmelt/SMS material, and wetlaid material. [0010] In some embodiments, the extruded polymenc material of the first and/or second layer impregnates the internal nonwoven layer. [0011] In certain embodiments, the first layer of polymeric material partially encapsulates one or more of the linear components. In certain other embodiments, the first layer of polymeric material fully encapsulates one or more of the linear components, or all of the linear components. [0012] In some embodiments, the linear components are yarns. [0013] In yet other embodiments, the linear components are selected from the group consisting of: multifilaments, monofilament yams, cords, spun yams, tapes, twisted tow yams