초록 ▼

A structure for use in industrial fabrics such as paper machine clothing and engineered fabrics is disclosed. The structure includes one or more layers of an elastic nonwoven extruded film or sheet, which is elastic, resilient, and compressible in a thickness direction, and extensible, bendable, and

A structure for use in industrial fabrics such as paper machine clothing and engineered fabrics is disclosed. The structure includes one or more layers of an elastic nonwoven extruded film or sheet, which is elastic, resilient, and compressible in a thickness direction, and extensible, bendable, and resilient in its length and transverse directions, and one or more layers of a plurality of substantially parallel machine direction (MD) yarns in various patterns. The structure can also include one or more layers of a plurality of substantially parallel cross-machine direction (CD) yarns attached on top of or under the MD yarns. The structure has a high degree of both compressibility under an applied normal load and excellent recovery (resiliency or spring back) upon removal of that load.

대표청구항 ▼

1. A compressible resilient industrial fabric comprising: one or more layers of a nonwoven extruded film or sheet, wherein the nonwoven extruded film or sheet is elastic, resilient, and compressible in a thickness direction, and extensible, bendable and resilient in its length and transverse directi

1. A compressible resilient industrial fabric comprising: one or more layers of a nonwoven extruded film or sheet, wherein the nonwoven extruded film or sheet is elastic, resilient, and compressible in a thickness direction, and extensible, bendable and resilient in its length and transverse directions; andtwo or more layers of a plurality of substantially parallel machine direction (MD) yarns, wherein the fabric comprises:a first layer of the parallel yarns running in MD;a second layer of the elastic nonwoven extruded film or sheet on one side of the first layer;a third layer of the parallel yarns on the opposite of the second layer as the first layer and running in the same direction as those of the first layer, andwherein the parallel yarns of the third layer are aligned such that they nest between the spaces created between the parallel yarns of the first layer. 2. The fabric as claimed in claim 1, wherein the number of yarns in the third layer is less than the number of yarns in the first layer or vice versa. 3. The fabric as claimed in claim 1, further comprising: a fourth layer of the elastic nonwoven extruded film or sheet on the opposite of the third layer as the second layer; anda fifth layer of parallel yarns in the same direction as the first layer, wherein the yarns of the fifth layer are aligned in the same vertical plane in a through thickness direction as that of the first layer. 4. The fabric as claimed in claim 1, wherein the elastic nonwoven extruded film or sheet comprises a polymeric material. 5. The fabric as claimed in claim 4, wherein the polymeric material is selected from the group consisting of: a polyurethane, a rubber, silicone, Lycra®, Estane®, and a high temperature polyester. 6. The fabric as claimed in claim 1, wherein the elastic nonwoven extruded film or sheet is perforated with a plurality of through holes. 7. The fabric as claimed in claim 6, wherein the through holes have a shape selected from the group consisting of circular, non-circular, square, rectangular, triangular, elliptical, trapezoidal, polygonal, and lobate. 8. The fabric as claimed in claim 1, wherein the fabric is a paper machine clothing;a forming fabric;a press fabric;a dryer fabric;a through air dryer fabric;a shoe press belt base;a calendar belt base;an engineered fabric base;a transfer belt base;a belt used in the production of nonwovens by processes such as airlaid, melt blowing, spunbonding, and hydroentangling; oran industrial process belt such as a textile finishing belt or tanning belt. 9. The fabric as claimed in claim 1, wherein the fabric is a laminate base for a dryer fabric, whereby the dryer fabric further includes; a backside or a non-sheet contact side of the fabric, the backside including angled components. 10. The fabric as claimed in claim 1, wherein the fabric is an endless or an on-machine seamable fabric. 11. The fabric as claimed in claim 1, wherein strips of the fabric are spiral wound to form a desired width and desired length of the final base structure. 12. The fabric as claimed in claim 1, further comprising: one or more layers of a fibrous batt material. 13. The fabric as claimed in claim 12, wherein the fibrous batt material is needled into the fabric. 14. The fabric as claimed in claim 12, wherein the fibrous batt material is applied on a top and/or bottom surface of the fabric, and needled therethrough. 15. The fabric as claimed in claim 1, wherein a top and/or bottom surface of the fabric is coated with a polymeric resin. 16. The fabric as claimed in claim 15, wherein the polymeric resin at least partially impregnates the fabric. 17. The fabric as claimed in claim 1, wherein the nonwoven extruded layer has continuous grooves formed on one or both its surfaces. 18. The fabric as claimed in claim 17, wherein the grooves have a cross-sectional shape selected from the group consisting of semi-circle, square, rectangular, triangular, elliptical, trapezoidal, hexagonal and other polygonal shapes. 19. A compressible resilient industrial fabric comprising: one or more layers of a nonwoven extruded film or sheet, wherein the nonwoven extruded film or sheet is elastic, resilient, and compressible in a thickness direction, and extensible, bendable and resilient in its length and transverse directions;two or more layer of a plurality of substantially parallel machine direction (MD) yarns; andone or more layers of a plurality of substantially parallel cross-machine direction (CD) yarns attached on top of or under the one of the two or more layers or parallel machine direction (MD) yarns;wherein the parallel yarns of at least two of the two or more layers of parallel machine direction (MD) yarns are aligned such that one layer of parallel machine direction (MD) yarns nests between the spaces created between the parallel yarns of the other of the two or more layers. 20. The fabric as claimed in claim 19, wherein the MD and CD yarns are selected from the group consisting of monofilaments, multifilaments, plied monofilaments or muitifilaments, wrapped members comprising different materials, knitted members, twisted members, multicomponent members, and braided members. 21. The fabric as claimed in claim 19, wherein the MD and CD yarns have a cross-section selected from the group consisting of: circular, non-circular, square, rectangular, triangular, elliptical, polygonal, trapezoidal and lobate. 22. The fabric as claimed in claim 19, wherein the MD yarns and CD yarns have a yarn diameter in the range of 0.08-2.0 mm. 23. The fabric as claimed in claim 19, wherein the one or more layers of MD and/or CD yarns are thermally welded or glued to the one or more layers of nonwoven extruded film or sheet. 24. The fabric as claimed in claim 19, wherein the one or more layers of MD and/or CD yarns are attached to the one or more layers of elastic nonwoven extruded film or sheet by needling one or more layers of a fibrous batt material. 25. A compressible resilient industrial fabric comprising: (a) a first layer of a plurality of substantially parallel machine direction (MD) yarns, (b) a second layer of an elastic nonwoven extruded film or sheet, wherein the elastic nonwoven extruded film or sheet is elastic, resilient, and compressible in a thickness direction, and extensible, bendable, and resilient in its length and transverse directions, (c) a third layer of a plurality of substantially parallel machine direction (MD) yarns, (d) a fourth layer of a plurality of substantially parallel cross-machine direction (CD) yarns, (e) a fifth layer of the elastic nonwoven extruded film or sheet, (f) a sixth layer of a plurality of substantially parallel cross-machine direction (CD) yarns, and (g) a seventh layer of the elastic nonwoven extruded film or sheet,wherein the parallel yarns of at least two of the layers of parallel machine direction (MD) yarns are aligned such that one of the layers of parallel machine direction (MD) yarns nests between the spaces created between the parallel yarns of the other layer of parallel machine direction (MD) yarns. 26. The fabric as claimed in claim 25, wherein the first layer is on a machine side of the fabric, and the seventh layer is on a sheet side of the fabric. 27. The fabric as claimed in claim 25, wherein the fabric is a press fabric, and the press fabric increases a press nip width by up to 5 mm when compared to a press nip width created by a conventional press fabric of the same initial thickness under the same normal load. 28. The fabric as claimed in claim 25, wherein the layers of the fabric are needled together using one or more layers of a fibrous batt material. 29. The fabric as claimed in claim 25, wherein the layers of the fabric are attached together by needling therethrough one or more layers of a fibrous batt material, and at least partially melting the batt material. 30. The fabric as claimed in claim 25, wherein a top and/or bottom surface of the fabric is coated with a polymeric resin material. 31. The fabric as claimed in claim 25, wherein the nonwoven extruded layer has continuous grooves formed on one or both its surfaces. 32. The fabric as claimed in claim 31, wherein the grooves have a cross-sectional shape selected from the group consisting of semi-circle, square, rectangular, triangular, elliptical, trapezoidal, hexagonal and other polygonal shapes. 33. A method of forming a compressible resilient industrial fabric, the method comprising the steps of; providing one or more layers of an elastic nonwoven extruded film or sheet, wherein the nonwoven extruded film or sheet is elastic, resilient, and compressible in a thickness direction, and extensible, bendable, and resilient in its length and transverse directions; andattaching one or more layers of a plurality of substantially parallel machine direction (MD) yarns to a top and/or bottom surface of the nonwoven extruded film or sheet, wherein the method comprises;providing a first layer of the parallel yarns running in MD;attaching a second layer of the elastic nonwoven extruded film or sheet on one side of the first layer; andattaching a third layer of the parallel yarns on the opposite of the second layer as the first layer and running the same direction as those of the first layer,wherein the parallel yarns of the third layer are aligned such that they nest between the spaces created between the parallel yarns of the first layer. 34. The method as claimed in claim 33, wherein the number of yarns in the third layer is less than the number of yarns in the first layer or vice versa. 35. The method as claimed in claim 33, further comprising the steps of: applying a fourth layer of the elastic nonwoven extruded film or sheet on the opposite of the third layer as the second layer; andattaching a fifth layer of parallel yarns in the same direction as the first layer, wherein the yarns of the fifth layer are aligned in the same vertical plane in a through thickness direction as that of the first layer. 36. The method as claimed in claim 33, wherein the elastic nonwoven extruded film or sheet comprises a polymeric material. 37. The method as claimed in claim 36, wherein the polymeric material is selected from the group consisting of a polyurethane, a rubber, silicone, Lycra®, Estane®, and a high temperature polyester. 38. The method as claimed in claim 33, wherein the elastic nonwoven extruded film or sheet is perforated with a plurality of through holes. 39. The method as claimed in claim 38, wherein the through holes have a shape selected from the group consisting of circular, non-circular, square, rectangular, triangular, elliptical, trapezoidal, polygonal, and lobate. 40. The method as claimed in claim 33, wherein the fabric is a paper machine clothing;a forming fabric;a press fabric;a dryer fabric;a through air dryer fabric;a shoe press belt base;a calendar belt base;an engineered fabric base;a transfer belt base;a belt used in the production of nonwovens by processes such as airlaid, melt blowing, spunbonding, and hydroentangling; oran industrial process belt such as a textile finishing belt or tanning belt. 41. The method as claimed in claim 33, wherein the fabric is a laminate base for a dryer fabric, whereby a backside or a non-sheet contact side of the fabric is provided with angled components. 42. The method as claimed in claim 33, wherein the fabric is an endless or an on-machine seamable fabric. 43. The method as claimed in claim 33, further comprising the step of: spiral winding a strip of the fabric to form a final base structure of the desired width and length. 44. The method as claimed in claim 33, further comprising the step of: applying one or more layers of a fibrous batt material to a top and/or bottom surface of the fabric. 45. The method as claimed in claim 44, further comprising the step of: needling therethrough the fibrous batt material into the fabric. 46. The method as claimed in claim 45, further comprising the step of: coating a top and/or bottom surface of the fabric with a polymeric resin. 47. The method as claimed in claim 46, wherein the polymeric resin at least partially impregnates the fabric. 48. The method as claimed in claim 33, wherein the nonwoven extruded layer has continuous grooves formed on one or both its surfaces. 49. The method as claimed in claim 48, wherein the grooves have a cross-sectional shape selected from the group consisting of semi-circle, square, rectangular, triangular, elliptical, trapezoidal, hexagonal and other polygonal shapes. 50. A method of forming a compressible resilient industrial fabric, the method comprising the steps of: providing one or more layers of an elastic nonwoven extruded film or sheet, wherein the nonwoven extruded film or sheet is elastic, resilient, and compressible in a thickness direction, and extensible, bendable, and resilient in its length and transverse directions;attaching two or more layers of a plurality of substantially parallel machine direction (MD) yarns to a top and/or bottom surface of the nonwoven extruded film or sheet; andattaching one or more layers of a plurality of substantially parallel cross-machine direction (CD) yarns on top of or under the one or more layers of parallel machine direction (MD) yarns,wherein the parallel yarns of at least two of the two or more layers of parallel machine direction (MD) yarns are aligned such that one layer of parallel machine direction (MD) yarns nests between the spaces created between the parallel yarns of the other of the two or more layers. 51. The method as claimed in claim 50, wherein the MD and CD yams are selected from the group consisting of monofilaments, multifilaments, plied monofilaments or multifilaments, wrapped members comprising different materials, knitted members, twisted members, multicomponent members, and braided members. 52. The method as claimed in claim 50, wherein the MD and CD yarns have a cross-section selected from the group consisting of circular, non-circular, square, rectangular, triangular, elliptical, polygonal, trapezoidal and lobate. 53. The method as claimed in claim 50, wherein the MD yarns and CD yarns have a yarn diameter in the range of 0.08-2.0 mm. 54. The method as claimed in claim 50, further comprising the step of: attaching the one or more layers of MD and/or CD yarns to the one or more layers of nonwoven extruded film or sheet by thermal welding or gluing. 55. The method as claimed in claim 50, further comprising the step of: attaching the one or more layers of MD and/or CD yarns to the one or more layers of nonwoven extruded film or sheet by needling therethrough one or more layers of a fibrous batt material. 56. A method of forming a compressible resilient industrial fabric, the method comprising the steps of: (a) providing a first layer of a plurality of substantially parallel machine direction (MD) yarns, (b) attaching a second layer of an elastic nonwoven extruded film or sheet on top of the first layer, wherein the nonwoven extruded film or sheet is elastic, resilient, and compressible in a thickness direction, and extensible, bendable, and resilient in its length and transverse directions, (c) attaching a third layer of a plurality of substantially parallel machine direction (MD) yarns on top of the second layer, (d) applying a fourth layer of a plurality of substantially parallel cross-machine direction (CD) yarns on top of the third layer, (e) applying a fifth layer of the elastic nonwoven extruded film or sheet on top of the fourth layer, (f) applying a sixth layer of a plurality of substantially parallel cross-machine direction (CD) yarns on top of the fifth, and (g) applying a seventh layer of the elastic nonwoven extruded film or sheet on top of the sixth layer,wherein the parallel yarns of at least two of the layers of parallel machine direction (MD) yarns are aligned such that one of the layers of parallel machine direction (MD) yarns nests between the spaces created between the parallel yarns of the other layer of parallel machine direction (MD) yarns. 57. The method as claimed in claim 56, wherein the first layer is on a machine side of the fabric, and the seventh layer is on a sheet side of the fabric. 58. The method as claimed in claim 56, wherein the fabric is a press fabric, and the press fabric increases a press nip width by up to 5 mm when compared to a press nip width created by a conventional press fabric of the same initial thickness under the same normal load. 59. The method as claimed in claim 56, further comprising the step of: attaching the layers of the fabric together by needling therethrough one or more layers of a fibrous batt material. 60. The method as claimed in claim 56, further comprising the step of: attaching the layers of the fabric by applying one or more layers of a fibrous batt material, and at least partially melting the batt material. 61. The method as claimed in claim 56, further comprising the step of: coating a top and/or bottom surface of the fabric with a polymeric resin material. 62. The method as claimed in claim 56, wherein the nonwoven extruded layer has continuous grooves formed on one or both its surfaces. 63. The method as claimed in claim 62, wherein the grooves have a cross-sectional shape selected from the group consisting of semi-circle, square, rectangular, triangular, elliptical, trapezoidal, hexagonal and other polygonal shapes.