JP2015516034A - Industrial fabric comprising a spirally wound material strip with reinforcement - Google Patents

Abstract

Disclosed are industrial fabrics, such as endless belts or sleeves, for use in the manufacture of nonwovens, and methods of making the same. Industrial fabrics are manufactured by spirally winding strips of polymer material such as industrial straps or ribbons and joining adjacent sides of the strips using ultrasonic or laser welding techniques. The The fabric may then be perforated using a suitable technique to make it permeable to air and / or water.

Description

[Cross-reference of related applications]
This application is based on US Provisional Patent Application No. 61 / 246,812 filed on September 29, 2009, US Provisional Patent Application No. 61 / 246,801 filed on September 29, 2009, 2009. Claims priority of US Provisional Patent Application No. 61 / 147,637 filed Jan. 27 and US Provisional Patent Application No. 61 / 121,998 filed Dec. 12, 2008, This is a continuation-in-part of U.S. Patent Application Publication No. 12 / 635,367 filed on Dec. 10, 2000.

[Incorporation by reference]
All patents, patent applications, documents, references, manufacturer's instructions, instructions, product specifications, and product sheets for any product referred to herein are hereby incorporated by reference herein. Can be used in the implementation.

  The present invention is directed to endless fabrics, and in particular to industrial fabrics used in the manufacture of nonwoven products. More particularly, the present invention is directed to support members such as belts or sleeves used in the manufacture of patterned or marked nonwoven products. Furthermore, the present invention can be used as a belt and / or sleeve used in the production of nonwoven fabrics such as airlaid, meltblown, spunbond, and hydroentangled methods.

  The process of making nonwoven products has been known for many years. In one process, fiber bats or webs are treated with a stream of water or a water jet to entangle the fibers together and improve physical properties such as web strength. Techniques for such treatment with water jets have been known for decades, and are described in US Pat. No. 3,214,819, US Pat. No. 3,508,308, and US Pat. No. 3,485,706. You can know from the disclosure.

  In general, this method involves entanglement of the base fibers by the action of a pressurized water jet, which acts like a needle on the fiber structure and causes a portion of the fibers to form a web in the thickness direction. Allows reorientation.

  Such techniques are still widely developed at the present time, especially for applications in the medical field and healthcare facilities, for wiping, for filtering, and for the use of textiles, such as for the packaging of tea bags. It is not only used to produce what is known as a "spunlace" structure or "hydroentangled" structure, and the resulting article is known from the disclosure of US Pat. No. 3,508,308. Including a design that is as uniform and uniform as possible, and provides fiber reorientation as needed, which is very important for aesthetic purposes as known from the disclosure of US Pat. No. 3,485,706. Is important to.

  For the production of “spunlace” or “hydroentangled” molds, by producing a mixture of materials, a plurality of webs of different types of fibers, for example made of natural fibers, artificial fibers or synthetic fibers, Or a flat web premixed with fibers (such as a “spunbond” type web) can be combined with a reinforcement that can be incorporated into a nonwoven structure to match the final properties of the product. Known since before.

  French patent FR-A-2 730 246 and French patent FR-A-2 734 285, corresponding to US Pat. No. 5,718,022 and US Pat. No. 5,768,756, respectively, are hydrophobic Describes a solution that makes it possible to successfully treat a natural fiber or a mixture of these fibers with a flat web of other hydrophilic fibers or completely natural fibers by means of a water jet.

  According to the teachings of these documents, processing generally involves treating a base web composed of the same or different types of base fibers, compressing and moistening the base web, and then the high pressure acting on the base web. Interweaving the fibers with at least one rack of continuous jets of water.

  For this purpose, the base web is actively advanced on a moving endless porous support and carried on the surface of a perforated rotating cylindrical drum in which a partial vacuum is applied. The base web is mechanically compressed between a porous support and a rotating drum, both of which advance at substantially the same speed. Immediately downstream of the compression zone, a water curtain is directed over the web, which continuously penetrates the porous support, the compressed base web, and the supporting perforated drum, where the vacuum source Remove excess water.

  The base fibers are still interwoven continuously on the rotating cylindrical drum by the compressed and wet web being subjected to the action of at least one rack of high pressure water jets. In general, the coupling is performed by a plurality of consecutive racks of water jets acting on the same side of the web or alternately on two sides, the pressure in the rack and the speed of the jet being ejected from one rack. Change to the next rack, and the change is usually gradual.

  It is important to note that a perforated roller / drum can contain randomly distributed micropores, as known from FR2734285. If desired, after the first bonding process, the porous nonwoven structure may be subjected to a second process applied to the opposite side.

  In the process of manufacturing spunlace nonwoven products or hydroentangled nonwoven products, it is often desirable to apply a pattern or mark on the finished product, thereby creating the desired design on the product. This pattern or mark is typically developed using a secondary process that is separate from the nonwoven sheet forming and winding process, in which case an embossed / patterned calendar roll is used. These rolls are usually expensive and work on the principle of compressing specific areas of the porous web to produce the required pattern or mark. However, there are several disadvantages of using a separate process to create a pattern or mark on the nonwoven product. For example, a high initial investment in calendar rolls may be required, which may limit the length of production operation that a manufacturer can economically justify. Secondly, higher processing costs may occur due to the separate patterning or mark formation stage. Third, in order to maintain the caliper (thickness) of the product after compression in the calendaring step, it is possible that the final product has a material content that is greater than necessary. Finally, it is conceivable that the volume of the finished product is smaller than desired due to the two-stage process due to high pressure compression during calendaring. Prior art nonwoven fabrics made using these known patterning processes do not have clear and well-defined raised portions and are therefore difficult to see the desired pattern. Furthermore, the raised portions of the prior art embossed nonwoven products are not dimensionally stable and these raised portions lose their three-dimensional structure when stressed after some time depending on the application. There is a tendency.

  U.S. Pat. No. 5,098,764 and U.S. Pat. No. 5,244,711 disclose the use of support members in more recent methods for making nonwoven webs or articles. The support member has a topographical feature configuration and an array of apertures. In this process, the starting fiber web is positioned on a topographic support member. The support member has a porous web on its surface and is passed under a jet of high pressure fluid, typically water. The water jet causes the fibers to intertwine and entangle with each other in a specific pattern based on the topographical configuration of the support member.

  The topographical features of the support member and the pattern of openings are critical to the structure of the resulting nonwoven product. In addition, the support member is structural integrity sufficient to support the porous web while the fluid jet repositions the fibers and entangles them with their new configuration to provide a stable fabric. And must have strength. The support member should not undergo any substantial distortion under the force of the fluid jet. The support member also has means for removing a relatively large amount of entangled water to prevent “flooding” of the porous web which would prevent effective entanglement. Must be. Typically, the support member includes a discharge opening that must be sufficiently small in order to maintain the integrity of the porous web and prevent loss of fibers through the forming surface. Further, the support member should be substantially free of burrs, ridges, or similar irregularities that can interfere with removal of the entangled porous nonwoven from there. At the same time, the support member must be such that the fibers of the porous web processed on its surface are not washed away under the influence of the fluid jet (ie good fiber retention and support).

  One of the major problems that arise during the manufacture of nonwovens is to maintain or impart specific physical properties such as volume, texture, appearance, etc. to give the nonwoven product the strength properties depending on the intended application. However, it is a problem of realizing the binding of the fibers constituting the nonwoven fabric.

  Volume, water absorption, strength, flexibility, and aesthetic appearance properties are truly important for many products when used for their intended purpose. In order to produce a nonwoven product having these properties, the support member will often be constructed such that the sheet contact surface exhibits a topographical change.

  It should be appreciated that these support members (fabrics, belts, sleeves) may take the form of endless loops and function in the manner of a conveyor. It should be further appreciated that the production of nonwovens is a continuous process that proceeds at a significant rate. That is, the base fibers or webs are continuously disposed on the forming fabric / belt in the forming section while the newly entangled nonwoven fabric is continuously transferred from the support member to the subsequent process. ing.

  The present invention provides an alternative solution to the problem addressed by the prior art patents / patent applications discussed above.

  The present invention provides an improved belt or sleeve that functions in place of a conventional belt or sleeve, and the nonwoven product produced thereon has a desired volume, appearance, texture, water absorption, strength and texture, etc. Give physical properties.

  Accordingly, a principal object of the present invention is to provide a support member for spunlace or hydroentanglement, such as a belt or sleeve having a through-hole in a desired pattern.

  A further object is to apply topography or textures created using any of the means known in the art, such as sanding, graving, embossing, or etching, to one or both surfaces. It is to provide a belt or sleeve that can be included. These and other objects and advantages are provided by the present invention. Without limitation, improved fiber support and removal (no leftover) and prior ease of cleaning as a result of no yarn crossing to catch the base fiber over prior art woven fabrics Other advantages are provided.

  If the belt / sleeve has a surface texture, a more effective patterning / texture is transferred to the nonwoven and this also results in better physical properties such as volume / water absorption.

  The present invention relates to an endless support member for supporting and transporting natural fibers, artificial fibers, or synthetic fibers in a spunlace process or hydroentanglement process, such as a belt or a sleeve. The porous structure, belt, or sleeve of the present invention offers the following non-limiting advantages over the calendering technique. That is, the fabric sleeve is a relatively inexpensive article and does not involve a large capital investment in the fixed equipment, patterning is achieved during the entanglement process itself, eliminating the need for a separate calendaring process, A lower material content in the final product is achieved because the caliper / thickness is not degraded by compression, and the finished product can be produced in a larger volume because the finished product is not compressed in the calendaring stage. For non-woven roll product manufacturers, the advantages of these processes are further the advantages of a lower cost spunlace web or hydroentangled web with the desired pattern, mark, or texture of the final product; The advantage of being able to customize the product by reducing the size / length of the operation; higher performance products, such as products with a large volume that characterize higher water absorption that is of great value in consumer applications Leading to the advantage of manufacturing.

  In an exemplary embodiment, the endless belt or endless sleeve is formed from a strip of material that is spirally wound in a manner that abuts adjacently around two rolls. The strips are firmly attached to each other in a suitable manner to form an endless loop with the desired length and width for a particular use. In the case of a sleeve, the strip may be wound around the surface of a single roll or mandrel of the approximate diameter size and CD length of the drum on which the sleeve will be used. Strips used as material are usually produced as industrial strap materials. Straps, particularly plastic strap materials, are defined as relatively thin plastic bands that are typically used to secure or pinch objects together. Surprisingly, it has been discovered that this type of plastic material has properties suitable for becoming a material strip to form an inventive belt or sleeve.

  The definition differences between (plastic) strap material and monofilament are related to size, shape, and application. Both the strap material and the monofilament are made by an extrusion process having the same basic steps of extrusion, uniaxial orientation, and winding. Monofilaments are generally smaller in size than straps and are usually round in shape. Monofilaments are used in a wide variety of applications such as fishing line and industrial fabrics including papermaking machine fabrics. The straps are generally much larger than monofilaments and are basically always wider along the main axis and are therefore rectangular in shape for their intended purpose.

  In extrusion technology, it is well known that plastic straps are made by an extrusion process. It is also well known that this process involves uniaxial orientation of the extruded material. It is also well known that there are two basic extrusion processes that use uniaxial orientation. One process is the extrusion and orientation of wide sheets that are cut into individual straps. The other process is the extrusion of oriented individual strap materials. This second process is very similar to the process of making a monofilament, which is evident from the similar facilities for both processes.

  The advantage over the monofilament of using strapping material is the number of spiral turns required to produce the fabric. Monofilaments are usually considered yarns that do not exceed 5 mm in their maximum axis. The size of uniaxial monofilaments used for papermaking machine fabrics and other uses mentioned above rarely exceeds 1.0 mm at their maximum axis. The strap material used is typically at least 10 mm wide and may exceed 100 mm wide. It is envisaged that strap materials with a width of up to 1000 mm can also be used. Suppliers of strap materials that can be used include companies such as Signode.

  Yet another advantage is thickness against tensile modulus. For example, prior art polyester (PET) films have a tensile modulus of about 3.5 GPa in the long axis (or machine direction or MD). The PET strap (or ribbon) material has a tensile modulus in the range of 10 GPa to 12.5 GPa. In order to achieve the same coefficient for the film, the structure must be 3 to 3.6 times thicker.

  Accordingly, the present invention, according to one exemplary embodiment, is a fabric, belt, or sleeve formed from these spirally wound ribbons as a single layer or multilayer structure. The fabric, belt or sleeve has a smooth top and bottom surface on a flat surface. The belt or sleeve is also textured in some manner using any means known in the art, such as sanding, graving, embossing, or etching. The belt or sleeve can be impermeable to air and / or water. The belt or sleeve can also be perforated by any mechanical or thermal (laser) means so that it can be permeable to air and / or water.

  In another exemplary embodiment, the ribbons are formed to have a profile combined with each other. A belt or sleeve is formed by spirally winding these combined strips and is considered to have greater integrity than simply abutting the parallel and / or orthogonal sides of adjacent ribbon strips. . The belt or sleeve can be impermeable to air and / or water or can be perforated to be permeable.

  While the above embodiments relate to a single layer of a spirally wound ribbon strip, the advantages of using strips with various geometries forming a belt or sleeve of two or more layers May exist. Thus, according to one exemplary embodiment, the belt or sleeve is such that two or more layers are mechanically combined or attached together by other means known to those skilled in the art. Further, it may have two or more layers on which a strip can be formed. Again, the structure can be either impermeable to air and / or water or perforated to be permeable.

  Another exemplary embodiment is a multi-layer structure formed using the concept of a “weld strip” that is used to further improve belt or sleeve integrity. The structure may be impermeable to air and / or water or perforated to make it permeable.

  Various novel features that characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the present invention, its operational advantages, and the specific objects obtained by its use, preferred but non-limiting embodiments of the present invention have the same Reference is made to the accompanying explanatory drawings, which are illustrated in the accompanying drawings identified by:

  Although the terms fabric and fabric structure are used, fabric, belt, conveyor, sleeve, support member, and fabric structure are used interchangeably to describe the structure of the present invention. Similarly, the terms strap, ribbon, strip material, and material strip are used interchangeably throughout the description.

  The terms “comprising” and “comprising” in this disclosure may mean “comprising” and “comprising”, or are commonly referred to as “comprising” or “comprising” in US patent law. Can have the meaning given. The terms “consisting essentially of” or “consisting essentially of”, when used in the claims, have the meaning assigned to them in US Patent Law. Other aspects of the invention are described in or are obvious from the following disclosure (and are within the scope of the invention).

  The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings presented herein illustrate various embodiments of the invention and, together with the description, serve to explain the principles of the invention.

1 is a perspective view of a fabric, belt, or sleeve according to one aspect of the invention. FIG. FIG. 2 illustrates a method by which a fabric, belt, or sleeve of the present invention can be constructed. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. FIG. 2 is a cross-sectional view from the width direction of some embodiments of strip material used to produce an inventive fabric, belt, or sleeve. 6 is a bar graph showing the advantages of using uniaxially oriented material (strap / ribbon) versus biaxially oriented material (film) and extruded material (molded part). FIG. 6 illustrates the steps involved in a method of constructing a fabric, belt, or sleeve of the present invention. FIG. 6 illustrates the steps involved in a method of constructing a fabric, belt, or sleeve of the present invention. FIG. 6 illustrates the steps involved in a method of constructing a fabric, belt, or sleeve of the present invention. FIG. 6 illustrates the steps involved in a method of constructing a fabric, belt, or sleeve of the present invention. 1 is a schematic diagram of an apparatus that can be used in forming a fabric, belt, or sleeve according to an aspect of the present invention. 1 is a schematic diagram of an apparatus that can be used in forming a fabric, belt, or sleeve according to an aspect of the present invention. 1 is a schematic diagram of an apparatus that can be used in forming a fabric, belt, or sleeve according to an aspect of the present invention. 1 is a cross-sectional view of a fabric, belt, or sleeve according to one aspect of the invention. 1 is a cross-sectional view of an apparatus used in the manufacture of a fabric, belt, or sleeve according to one aspect of the invention. FIG. 2 is a schematic view of different types of apparatus for producing a nonwoven web using the support member of the present invention. FIG. 2 is a schematic view of different types of apparatus for producing a nonwoven web using the support member of the present invention.

  The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. However, the invention can be implemented in many different forms and should not be construed as limited to the illustrated embodiments described in the invention. Rather, these illustrated embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

  The present invention provides a continuous support member, such as an endless belt for use in an apparatus such as that shown in FIG. The nonwoven support member functions as a replacement for conventional woven support members and imparts the desired texture, texture, and volume to the nonwoven product produced thereon. The support members of the present invention can reduce manufacturing time and costs associated with the manufacture of nonwovens.

  FIG. 15 shows an apparatus for continuously producing a nonwoven fabric using a support member according to the present invention. The apparatus of FIG. 15 includes a conveyor belt 80 that actually serves as a topographic support member according to the present invention. As is well known in the art, the belt continuously moves around a pair of spaced rollers in a counterclockwise direction. Above the belt 80 is a fluid discharge manifold 79 that connects a plurality of lines or groups 81 of orifices. Each group has one or more rows of very fine diameter orifices, each having about 30 orifices per inch, each about 0.007 inch in diameter. The group of orifices 81 is supplied with water at a predetermined pressure, and the water is discharged from the orifices in the form of a very fine, substantially columnar, unbranched water stream or water jet. The manifold includes a pressure gauge 88 and a control valve 87 for adjusting each line or group of orifices. Below each orifice line or group is a suction box 82 to remove excess water and prevent the area from inappropriate flooding. A fibrous web 83 to be formed as a nonwoven product is fed to the topographic support member conveyor belt of the present invention. Water is sprayed onto the fibrous web through a suitable nozzle 84 to prewet the incoming web 83 and help control the fiber as it passes under the fluid discharge manifold. A suction slot 85 for removing excess water is provided below the water nozzle. The fibrous web passes under the fluid discharge manifold in a counterclockwise direction. The pressure that activates any given group 81 of orifices can be set independently of the pressure that activates any other group 81 of orifices. Ordinarily, however, the group of orifices 81 closest to the spray nozzle 84 is operated at a relatively low pressure, eg, 100 psi. This aids in placing the incoming web on the surface of the support member. As the web passes counterclockwise in FIG. 15, the pressure that actuates the group of orifices 81 is typically increased. It is not necessary to operate each group 81 of orifices at a higher pressure than the group next to its clockwise direction. For example, two or more adjacent groups 81 of orifices can be operated at the same pressure, and then the subsequent group of orifices 81 (counterclockwise direction) can be operated at different pressures. Very typically, the working pressure at the end of the conveyor belt where the web is removed is higher than the working pressure at which the web is initially fed into the conveyor belt. Although six groups 81 of orifices 81 are shown in FIG. 15, this number is not critical and will depend on the weight of the web used, speed, pressure, the number of rows of holes in each group, and the like. After passing between the fluid discharge manifold and the suction manifold, the nonwoven fabric formed at this point is passed over an additional suction slot 86 to remove excess water. The distance from the lower surface of the group of orifices 81 to the upper surface of the fibrous web 83 typically ranges from about 0.5 inches to about 2.0 inches, from about 0.75 inches to about 1.0 inches. The range of is preferable. It will be apparent that the web cannot be placed so close to the manifold that the web contacts the manifold. On the other hand, if the distance between the lower surface of the orifice and the upper surface of the web is too great, the fluid flow loses energy and the process becomes less efficient.

  A preferred apparatus for producing a nonwoven fabric using the support member of the present invention is schematically illustrated in FIG. In this device, the topographic support member is a rotatable drum sleeve 91. The drum below the drum sleeve 91 rotates counterclockwise. The outer surface of the drum sleeve 91 includes the desired topographic support configuration. Arranged around a portion of the periphery of the drum is connected to a plurality of orifice strips 92 for applying water or other fluid to a fibrous web 93 placed on the outer surface of the curved plate. Manifold 89. Each orifice strip may include one or more rows of fine diameter holes or apertures as previously described herein. Usually, the nominal diameter of the opening is, for example, approximately 0.005 inches to 0.01 inches. Other sizes, shapes, and orientations are of course available if appropriate for the purpose. Also, for example, there may be as many as 50 or 60 holes per inch, or more if desired. Water or other fluid is directed through the row of orifices. In general, and as explained above, the pressure in each orifice group typically increases from the first group to the last group through which the fibrous web passes. The pressure is controlled by a suitable control valve 97 and monitored by a pressure gauge 98. The drum is connected to a water collection hole 94, but a vacuum may be applied to the water collection hole 94 to help remove the water and prevent the area from flooding. As seen in FIG. 16, the fibrous web 93 is placed on the upper surface of the topographic support member in front of the water discharge manifold 89 in operation. The fibrous web passes under the orifice strip and the formed nonwoven formed as a nonwoven product then passes over the section 95 of the device 95 without the orifice strip, but the vacuum is continuously applied. The fabric is removed from the drum after dewatering and passed around a series of drying cylinders 96 to dry the fabric.

  Turning now to the structure of the support member, belt, or sleeve, the support member can have a pattern of cavities therethrough. The penetrating cavities may include, among other things, geometric features that improve the topography and volume of the nonwoven product or web, for example when manufactured on a support member, belt, or sleeve. Other advantages of the support member of the present invention include easier web removal, improved contamination resistance, and reduced fiber strandedness. Yet another advantage is that this support member circumvents the limitations and needs of conventional looms because the penetrating cavities can be placed at any desired location or in any desired pattern. The support member may also have a texture produced on one or both surfaces using any means known in the art, such as sanding, graving, embossing, or etching. .

  It will be appreciated that the term “through cavity” is synonymous with the term “through hole” and represents any opening that completely penetrates a support member, such as a belt or sleeve. Support members referred to herein include, but are not limited to, industrial fabrics, such as belts or conveyors and sleeves or cylindrical belts, particularly used in the manufacture of nonwovens. As previously mentioned, the terms fabric and fabric structure are used to describe the preferred embodiment, whereas fabric, belt, conveyor, sleeve, support member, and fabric structure are of the present invention. Used interchangeably to describe a structure.

  FIG. 1 is a perspective view of an industrial fabric, belt, or sleeve 10 of the present invention. The fabric, belt or sleeve 10 has an inner surface 12 and an outer surface 14, and a strip of polymer material 16 such as, for example, an industrial strapping material is spirally wound in a plurality of turns abutting and adjacent to each other. Formed by turning. The strip material 16 is helically wound substantially longitudinally around the length of the fabric, belt or sleeve 10 based on the helical manner in which the fabric, belt or sleeve 10 is constructed.

  FIG. 2 illustrates an exemplary method by which a fabric, belt, or sleeve 10 can be manufactured. The apparatus 20 includes a first processing roll 22 and a second processing roll 24, both of which are rotatable about its longitudinal axis. The first treatment roll 22 and the second treatment roll 24 are parallel to each other and separated by a distance, which is the distance of the fabric, belt, or sleeve 10 that will be produced on those rolls. The total length when measured in the longitudinal direction around it is determined. A supply reel (not shown) provided on the side of the first processing roll 22 so as to be rotatable around an axis and displaceable in parallel with the processing rolls 22 and 24 is wound and supplied. For example, the strip material 16 having a width of 10 mm or more is accommodated. The supply reel is first positioned at the left hand end of the first processing roll 12, for example, and then continuously displaced to the right side or the other side at a predetermined speed.

  In starting the manufacture of the fabric, belt or sleeve 10, the beginning of the strip of polymer strap material 16 is stretched tightly from the first treatment roll 22 and directed to the second treatment roll 24. , Around the second processing roll 24 and back to the first processing roll 22 to form the first coil of the closed spiral 26. To close the first coil of the closing helix 26, the beginning portion of the strip 16 is joined at point 28 to the end of the first coil. As discussed below, adjacent turns of spirally wound strip material 16 are joined together by mechanical means and / or adhesive means.

  Accordingly, the coil of the continuous closed helix 26 feeds the strip material 16 onto the first processing roll 22, while the first processing roll 22 and the second processing roll 24 are in the common direction indicated by the arrows in FIG. It is manufactured by rotating it. At the same time, the strip material 16 newly wound on the first processing roll 22 has already been subjected to the first processing roll 22 and the second processing, for example by mechanical means and / or adhesive means or any other suitable means. Additional coils of the closed helix 26 are manufactured, continuously joined to the strip material on the roll 24.

  This process continues until the closed helix 26 has the desired width as measured axially along the first processing roll 22 or the second processing roll 24. In that respect, the strip material 16 that has not yet been wound on the first processing roll 22 and the second processing roll 24 is cut, and the closed spiral 26 produced therefrom is also connected to the first processing roll 22 and the first processing roll 22. Removed from the two treatment rolls 24, the fabric, belt or sleeve 10 of the present invention is provided.

  Although a two-roll device is described herein, the strip may be wound around the surface of a single roll or mandrel to form the fabric, belt, or sleeve of the present invention. May be apparent to those skilled in the art. An appropriately sized roll or mandrel may be selected based on the desired dimensions of the fabric, belt, or sleeve to be manufactured.

  The present method for manufacturing a fabric, belt or sleeve 10 is very versatile and is non-woven and / or industrial, with various longitudinal and transverse dimensions of the fabric, belt or sleeve. Can be adapted to the manufacture of That is, the manufacturer no longer needs to produce a woven fabric of the appropriate length and width for a given nonwoven manufacturing machine by practicing the present invention. Rather, the manufacturer wants a closed helix 26 to separate the first treatment roll 22 and the second treatment roll 24 at an appropriate distance to determine the appropriate length of the appropriate fabric, belt, or sleeve 10. It is only necessary to wind the strip material 16 on the first processing roll 22 and the second processing roll 24 until the appropriate width is reached.

  Furthermore, because the fabric, belt or sleeve 10 is manufactured by spirally winding a strip of polymer strap material 16 and not a woven fabric, the outer surface 12 of the fabric, belt or sleeve 10 is smooth and continuous. There is no knuckle that prevents the surface of the woven fabric from being completely smooth. However, the fabric, belt, or sleeve of the present invention improves the topography and volume of the nonwoven product produced thereon. Other advantages of the support member of the present invention include easier web removal, improved contamination resistance, and reduced fiber strandedness. Yet another advantage is that this support member circumvents the limitations and needs of conventional looms because the penetrating cavities can be placed at any desired location or in any desired pattern. The fabric, belt, or sleeve has a texture produced on one or both surfaces using any means known in the art, such as sanding, graving, embossing, or etching. May be. Alternatively, the fabric, belt, or sleeve may be smooth on one or both surfaces.

  3A to 3I are cross-sectional views from the width direction of some embodiments of strip material used to manufacture the fabric, belt, or sleeve of the present invention. Each embodiment includes an upper surface and a lower surface that may be flat (planar) and parallel to each other or may have a certain contour intended to suit a particular application. Turning to FIG. 3A, according to one embodiment of the invention, the material strip 16 comprises an upper surface 15, a lower surface 17, a first planar side surface 18, and a second planar side surface 19. . The upper surface 15 and the lower surface 17 may be flat (planar) and parallel to each other, and the first planar side surface 18 and the second planar side surface 19 of the strip material 16 wound in a spiral shape. Each first planar side surface 18 may be inclined in a parallel direction so as to be in close contact with the second planar side surface 19 of the immediately preceding winding. Each of the windings of the strip material 16 is joined to its adjacent winding by joining their respective first planar side surfaces 18 and second planar side surfaces 19 together, for example with an adhesive. May be heat activated, room temperature cure (RTC) or hot melt adhesive, or any other suitable means.

  In FIG. 3B, the material strip 16 may have a cross-sectional structure that allows a mechanical combination to join adjacent strip members 16 in a spirally formed fabric, belt, or sleeve. Adjacent strips 16 can be the same or different sizes and / or outlines, but each has a locked position, as shown in FIG. 3B. Other examples of mechanical mating structures are shown in FIGS. 3C-3G, where cross sections of individual strip members 16 are illustrated. In each case, one side of the strip material 16 may be designed to mate or connect with the other side of the adjacent strip material 16. For example, referring to the embodiment shown in FIG. 3G, the strip material 16 may have an upper surface 42, a lower surface 44, a tongue 46 on one side, and a groove 48 on the other side. The tongue 46 has a dimension corresponding to the dimension of the groove 48 so that the tongue 46 in each of the spirally wound turns of the strip 16 fits into the groove 48 of the immediately preceding winding. You can do it. Each of the windings of the strip material 16 is joined to its adjacent winding by securing the tongue 46 in the groove 48. The upper surface 42 and the lower surface 44 may be flat (planar) and parallel to each other, or may not be planar and parallel depending on the application, or their width as shown in FIG. 3F. It may even be rounded convex or concave in the direction. Similarly, each side of the strip may be formed in a convex or concave cylindrical shape having the same radius of curvature.

  FIG. 3H shows another embodiment of the present invention.

  In addition to having opposite hemispheres or extruded strips with the above profile, various other shapes can be extruded or rectangular to have mating edges with raised rails. It can be machined from the extruded material, which can facilitate bonding by mechanical and / or adhesive means. One such structure according to one exemplary embodiment of the invention is shown in FIG. 3I. Alternatively, the material strip may not require left and right sides that fit or join together. For example, as shown in FIG. 4A, the cross section of the strip 16 may have grooves that mate on its upper surface or on the upper side, or grooves that mate on its lower surface or on its bottom side, as shown in FIG. 4B. May be included.

  For example, FIG. 4C shows the material strip of FIGS. 4A and 4B positioned to mate. The arrows in FIG. 4C indicate, for example, the direction in which each of the material strips 16 must be moved to engage the groove and combine the two strips. FIG. 4D shows the two material strips 16 after being combined or joined together. It should be noted that although the exemplary embodiment shows only two mating material strips, the final fabric, belt, or sleeve is formed from several of the material strips combined together. It is. Obviously, sheet materials in the form of endless loops can be formed when material strips are combined in a spiral winding process. Although a mechanical combination is shown, the strength of the combination is as exemplified by an industrial process known as “Clearweld” (see www.clearweld.com), for example by thermal bonding. It should also be noted that this can be improved by a technique known as selective binding.

  FIG. 5A shows a cross-sectional view of a material strip 16 having grooves on both the top side and the bottom side. FIG. 5B shows how two material strips 16 having the cross-sectional shape shown in FIG. 5A can be combined. The combined structure results in grooves on the top and bottom surfaces of the final product.

  Referring to the embodiment shown in FIG. 5C, FIG. 5C shows the combination of the two material strips 16 shown in FIGS. 5A and 4B. This results in a sheet product having grooves on the bottom surface and a flat top surface. Similarly, a structure having a groove on the top surface and a flat bottom surface can be formed.

  Another exemplary embodiment is a fabric, belt, or sleeve formed from a strip of material 16 having a knurled combination or “positive” lock that forms a stronger combination due to mechanical design. is there. This design is in the sense that the pins and pin receptors have mechanical interference that requires significant force to either join the ribbons together or separate them. Has an “aggressive” association. For example, FIG. 6A illustrates the features of the corrugated combination in individual ribbon-like material strips 16. FIG. 6B illustrates the features of the corrugated combination in an opposing configuration of individual ribbon-like material strips 16 designed to combine with the structure shown in FIG. 6A. FIG. 6C shows the individual ribbon-like material strips 16 of FIGS. 6A and 6B positioned to mate. It should be noted here that the top and bottom ribbons are staggered in order to accommodate another material strip 16 of the opposite configuration. Finally, FIG. 6D illustrates these same strips after being pushed together to form a combined structure. Several ribbon-like material strips such as these can be combined together to form the final fabric, belt, or sleeve.

  Another exemplary embodiment is a fabric, belt, or sleeve formed from a strip of material 16 having grooves on both the top and bottom sides, for example as shown in FIG. 7A. These two ribbon-like material strips 16 are designed to be joined together to form a positive combination, as shown in FIG. 7B. It should be noted that both the top surface and the bottom surface hold grooves on their respective surfaces. 7A and 7B, it can be apparent to one skilled in the art to join the three strips to create a three-layer structure, or the top strip if only two strips are used. The outer shape of the groove of the groove portion can be different between the upper side and the bottom side. Similarly, the groove profile of the groove in the lower strip can be the same or different on each side. As pointed out above, embodiments described in the present invention relate to a single layer of spirally wound ribbons or strips, but various geometries that form a belt of two or more layers. There may be advantages to using a strip having a shape. Thus, according to one exemplary embodiment, the belt may have more than one layer, where the strip may be formed such that the two or more layers are mechanically combined. Each layer may be spirally wound in the opposite direction or at an angle in the MD to provide additional strength.

  For example, FIG. 7C shows a combined structure that results in a grooved bottom surface and a flat top surface, while FIG. 7D results in a combined structure that results in a flat bottom surface and a grooved top surface. Indicates.

  Many shapes can be considered to create such positive combinations, as may be apparent to those skilled in the art. For example, some of the previous embodiments have focused on round-shaped protrusions and round receiving portions. However, other shapes can be used to achieve the same effect. An example of an aggressive combination having such a shape is shown in FIG. 8A. Alternatively, shapes can be mixed to achieve a positive combination. Examples of mixed shapes are shown in FIGS. 8B and 8C.

  The mechanical combination thus formed between adjacent strip materials as described in the above embodiment enhances the ease with which a spiral wound foundation fabric or foundation structure can be created, for the reason Without such a lock, the adjacent strip material can stray and separate during the process of making a spirally wound fabric. By mechanically combining adjacent spiral windings, stray and separation between adjacent spiral windings can be prevented. Furthermore, a thermal weld can also be formed in the mechanically locked area of the fabric, so that it is not necessary to rely solely on the mechanical lock strength for bond strength. According to one embodiment of the present invention, this is done by placing a near-infrared or infrared or laser-absorbing dye before locking the male / female component into one, and then in the area of the mechanical lock. This is accomplished by applying the mechanical lock to near infrared or infrared energy or a laser source that causes thermal welding of the mechanical lock without melting the external material.

  The strip material described in the above embodiment is extruded from any polymer resin material known to those skilled in the art, such as, for example, polyester resin, polyamide resin, polyurethane resin, polypropylene resin, polyetheretherketone resin. Good. An industrial strap material is uniaxially oriented, that is, it has a tensile modulus at least twice that of a biaxially oriented material (film) and a tensile factor of up to 10 times that of an extruded material (molded article). Any other suitable material can be used, although it is attractive as a base material in view of having it. That is, the resulting structure from the uniaxially oriented material requires less than half the thickness of the biaxially oriented material (film) and less than one-tenth the thickness of the extruded material (molded article). . This feature is illustrated in FIG. 9, where the results are shown for designing a part designed to obtain a specific force and strain for a fixed width. The equation used in this design problem is the relationship between stress and strain and is as follows:

Force = (coefficient x strain)
(Width x thickness)

  In this example, the force (or load) is kept constant with width and strain. The equation shows that the required thickness is inversely proportional to the material's tensile modulus. This equation represents the problem of designing the fabric of a nonwoven manufacturing machine to be dimensionally stable, i.e. the load is known, the maximum strain is known, and the width of the machine is fixed. The result is shown by the final thickness of the part required depending on the tensile factor of the material used. As shown by FIG. 9, uniaxial materials such as straps or ribbons clearly have a significant advantage over films and molded polymers. However, the support member, belt, or sleeve of the present invention is not limited to these orientations in that either uniaxial or biaxial orientation of the strap material or both can be used in the practice of the invention.

  According to one exemplary embodiment, the strip or strap material described in the above embodiments may include a stiffener to improve the mechanical strength of the overall structure. For example, the reinforcement may be a fiber, yarn, monofilament, or multifilament yarn that can be oriented along the length of the strap material to the MD of the fabric, sleeve, or belt. The reinforcement can be included through an extrusion or pultrusion process in which fibers or yarns are extruded or drawn with the material forming the strip or strap material. They can be fully embedded within the strap material, or can be partially embedded on one or both surfaces of the strap material, or both. The reinforcing fibers or yarns may be formed of high modulus materials such as, but not limited to, aramids including, but not limited to, Kevlar® and Nomex®, and further strength, tensile modulus, tear resistance and / or Or, the strip- or strap material can be provided with resistance to cracking, abrasion resistance and / or resistance to chemical degradation. Broadly speaking, the reinforcing fibers or yarns can be made from thermoplastic and / or thermoset polymers. Non-limiting examples of suitable fiber materials include metals such as glass, carbon, polyester, polyurethane, and steel. According to a further embodiment, the melting temperature of the reinforcing fiber or yarn may be higher than the melting temperature of the strip material or strip material, or vice versa.

  The strap is usually supplied in a continuous length and the product has a rectangular cross section. The strap is a durable, versatile, usually untreated polyester strip with excellent handling properties that makes it suitable for many industrial applications. As pointed out above, the strap has excellent mechanical strength and dimensional stability and does not become brittle over time under normal conditions. The strap is resistant to moisture and most chemicals and can withstand temperatures from 70 degrees Celsius to 150 degrees Celsius or above. Typical cross-sectional dimensions of the strap material that can be used in the present invention are, for example, a thickness of 0.30 mm (or more) and a width of 10 mm (or more). Although the strap material can be spirally wound, adjacent wraps of strap material that do not have the means of assembly to be held together may need to be welded or joined in some manner. In such cases, adjacent ribbons using laser or ultrasonic welding to improve cross-machine direction (“CD”) characteristics such as strength and reduce the risk of separation of adjacent material strips. The material strip can be fixed or welded together.

  While uniaxial strap materials are found to have a maximum MD tensile modulus, properties other than tensile modulus can also be important. For example, if the MD tensile modulus is too high with respect to the strap material, the crack resistance and bending fatigue resistance of the final structure may be unacceptable. Alternatively, the final structure CD characteristics may also be important. For example, referring to a PET material and a material strip of the same thickness, an unoriented strip may have a typical MD tensile modulus of about 3 GPa and a typical MD strength of about 50 MPa. On the other hand, biaxially, biaxially oriented strips may have an MD tensile modulus of about 4.7 GPa and an MD strength of about 170 MPa. It has been found that modifying the processing of the uniaxial strip so that the MD tensile modulus can be 6-10 GPa and the MD strength can be 250 MPa or more, resulting in a strip with a CD strength approaching approximately 100 MPa. Furthermore, the material can be less brittle, i.e. it can not crack even if it is repeatedly bent, and it can be handled well when joining the strips together. The bond between the strips can also withstand separation during intended use on the production machine.

  One method of holding adjacent strips together is in accordance with an embodiment of the present invention, where adjacent strips are welded ultrasonically between edges while simultaneously providing lateral pressure to contact the edges together. Is to keep it in a state. For example, one part of the welding device can hold one strip, preferably a strip already wound in a spiral, against the support roll and hold it down, while another part of the device A strip, preferably an unrolled strip, can be pushed against the strip held below. The welding between the edges is illustrated in FIG. 11A, for example.

  Application of ultrasonic gap welding results in particularly strong bonds. In contrast, ultrasonic welding in either time mode or energy mode, which is known as conventional ultrasonic welding, results in a bond that can be described as brittle. Therefore, it can be concluded that the bond formed by ultrasonic gap welding is preferable compared to conventional ultrasonic welding.

  Another exemplary method of holding adjacent strips together is to apply adhesive 30 to the ends 34, 36 of adjacent strips 16, 16 and join them, according to one embodiment of the present invention. This method is illustrated in FIGS. 10A-10D. It should be noted that the filler material 32 can be used to fill gaps or portions where the strips do not contact each other.

  Another way to hold adjacent strips or functional strips together is to use a “welded strip” consisting of the same base material as the strip material, according to one embodiment of the invention. For example, the weld strip is shown in FIG. 11B as a thin material visible above and below the strip material. In such an arrangement, the weld strip provides a material for welding the strip material so that the assembled structure does not rely on the edge-to-edge weld shown in FIG. 11A. Using the welding strip method may result in edge-to-edge welding, which is neither necessary nor preferred. As shown in FIG. 11B, a “sandwich” or stacked structure can be formed using the welding strip method with the horizontal surface of the strip material welded to the horizontal surface of the welding strip. Here, in the sense that the welding strip may be disposed only either above or below the strip material, the welding strip need not be disposed both above and below the strip material. It should be noted. According to one aspect, the weld strip may be the central part of a sandwich-like structure with the strip material above and / or below the weld strip. Further, although the weld strip is shown as being thinner than the strip material and as wide as the strip material, this is for illustrative purposes only. The weld strip may be narrower or wider than the strip material, and may be the same thickness as the strip material or even thicker than the strip material. The weld strip may also be another piece of strip material, not a special material created solely for the purpose of the weld strip. The weld strip may also have an adhesive applied to one surface thereof to help hold the weld strip in place for the welding operation. However, when such an adhesive is used, it is preferred that the adhesive be applied partially to the entire surface of the weld strip because the ultrasonic application or laser welding may be applied by partial application. This is because, during stripping, strong welding between similar materials (for example, polyesters) of the strip material and the welding strip can be promoted.

  If the weld strip is made from an unoriented extruded polymer, it is preferred that the weld strip be much thinner than the strip material because, as exemplified earlier in this disclosure, the unoriented extrusion weld. This is because the strip is less capable of maintaining the dimensional stability of the final structure. However, if the weld strip is made from an oriented polymer, it is preferred that the weld strip combined with the strip material be as thin as possible. As pointed out above, the weld strip may be another piece of strip material. In this case, however, it is preferred that the thickness of the individual materials be selected so that the overall thickness of the sandwich or laminate can be minimized. As also pointed out above, the weld strip may be coated with an adhesive used to hold the structure together for further processing. According to one aspect, for example, a welding strip with an adhesive may be used to create a structure that goes directly to the drilling step, which may be a laser drilling without any ultrasonic coupling, This causes laser drilling or laser drilling to produce a spot weld that can hold the sandwich structure together.

  Another way of holding adjacent strip materials together is to weld adjacent strips using a laser welding technique, according to one embodiment of the present invention.

  FIG. 14 illustrates an exemplary apparatus 320 that can be used in a laser welding process in accordance with an aspect of the present invention. In this process, the fabric, belt, or sleeve 322 shown in FIG. 14 should be understood to be a relatively short portion of the overall length of the final fabric, belt, or sleeve. The fabric, belt or sleeve 322 is endless, but very practically it may be mounted around a pair of rolls not shown but known to those skilled in the art. In such an arrangement, the device 320 may be placed on one of the two surfaces of the fabric 322 between the two rolls, very conveniently on the top surface. Whether endless or not, the fabric 322 may preferably be placed under appropriate tension during the process. Further, to prevent sagging, the fabric 322 may be supported from below by a horizontal support member as it moves through the device 320.

  Referring now more specifically to FIG. 14, in FIG. 14, the fabric 322 is shown moving through the device 320 in an upward direction when the method of the present invention is being implemented. The laser head used in the welding process can traverse the fabric in the CD or width “X” direction while the fabric can move in the MD or “Y” direction. It is also possible to build a system in which the fabric moves in a three-dimensional manner relative to the laser welding head, which is mechanically fixed.

  The advantage of laser welding over ultrasonic welding is that ultrasonic welding has an upper speed limit of about 10 meters per minute, whereas laser welding can be achieved at speeds in the range of 100 meters per minute. Adding a light absorbing dye or ink absorber to the edge of the strip can also help to concentrate the thermal effects of the laser. The absorber can be black ink or an IR dye that is invisible to the human eye, such as that utilized by “Clearweld”. (See www.clearweld.com)

  Once the final fabric, belt, or sleeve has been created and adjacent strips in the fabric, belt, or sleeve have been welded or joined in some way, one side of the fabric from the other side of the fabric by means such as laser drilling Can be provided with holes or perforations that allow fluid (air and / or water) to pass through. It should be noted that these through holes or perforations that allow fluid to pass from one side of the fabric to the other can be created either before or after the spiral winding and joining steps. . Such holes or perforations can be created through laser drilling or any other suitable hole / drilling process and can be any size, shape, form and / or pattern depending on the intended use. it can. An exemplary embodiment is shown in FIG. 13, which is a cross-section in the direction across the fabric 80 of the present invention, i.e. across the machine, and the strip 82 has air and its length along its length. A plurality of holes 84 are provided for the passage of water.

  As pointed out above, the fabrics of the present invention can be used as belts or sleeves used in air laying, meltblowing, spunbonding, or hydroentanglement processes. The inventive fabric, belt, or sleeve includes one or more additional layers formed using a strip material on or under the substrate to simply provide functionality rather than reinforcement. be able to. For example, an MD yarn array may be laminated to the back of a belt or sleeve to create a void. Alternatively, one or more layers may be provided between two layers of strap material. Additional layers used include woven or non-woven materials, MD yarn arrays or CD yarn arrays, spirally wound woven material strips having a width smaller than the width of the fabric, fibrous webs, films Or any combination thereof and can be attached to the substrate by any suitable technique known to those skilled in the art. Needle punches, thermal bonds and chemical bonds are just a few examples. The fabric, belt, or sleeve of the present invention can also have a functional coating on either side. The texture on the fabric, belt or sleeve of the present invention can be created before or after applying the functional coating. As described above, the texture on the fabric, belt, or sleeve can be created using any means known in the art, such as sanding, graving, embossing or etching.

  Although preferred embodiments of the present invention and modifications thereof have been described in detail in the present specification, the present invention is not limited to those strict embodiments and modifications, and those skilled in the art will recognize according to the appended claims. Other variations and modifications can be made without departing from the spirit and scope of the invention as defined.

Claims (36)

  A belt or sleeve for use in the manufacture of nonwovens comprising one or more spirally wound strips of polymer material, wherein the one or more strips of polymer material are industrial straps or A belt or sleeve that is a ribbon material.   The belt or sleeve according to claim 1, wherein the belt or sleeve is used in an air lay process, a melt blow process, a spun bond process, or a hydroentanglement process.   The belt or sleeve according to claim 1, wherein the industrial strap material or ribbon material has a thickness of 0.30 mm or more and a width of 10 mm or more.   The belt or sleeve according to claim 1, wherein the belt or sleeve is permeable or impermeable to air and / or water.   The belt or sleeve is permeable to air and / or water and the through-hole or hole in the belt or sleeve is created using mechanical or thermal means. Item 5. The belt or sleeve according to Item 4.   The belt or sleeve according to claim 5, wherein the penetrating cavity or hole is formed in a predetermined size, shape, or orientation.   The belt or sleeve of claim 6, wherein the penetrating cavity or hole has a nominal diameter in the range of 0.005 inches to 0.01 inches or more.   One of a woven or non-woven material, an MD or CD yarn array, a spirally wound woven material strip having a width smaller than the width of the belt or sleeve, a fibrous web, a film, or a combination thereof The belt or sleeve of claim 1, further comprising one or more layers.   The belt or sleeve of claim 1 wherein adjacent strips of polymeric material are mechanically combined.   The belt or sleeve of claim 1, wherein the belt or sleeve has a texture on one or both surfaces.   11. A belt or sleeve as claimed in claim 10 wherein the texture is provided by sanding, graving, embossing or etching.   The belt or sleeve of claim 1, wherein one or both surfaces of the belt or sleeve are smooth.   The belt or sleeve of claim 1, wherein the belt or sleeve comprises at least two layers of spirally wound strap material in opposite directions or opposite to the MD.   The belt or sleeve according to claim 1, further comprising a functional coating on one or both sides of the belt or sleeve.   9. A belt or sleeve according to claim 8, wherein the one or more layers are provided on one or both sides of the belt or sleeve, or between two layers of strap material.   The belt or sleeve of claim 14, wherein the functional coating has a texture on its upper surface.   The industrial strap or ribbon material comprises a fabric, sleeve, or belt MD oriented reinforcement selected from the group consisting of fibers, yarns, monofilaments, and multifilament yarns. Belt or sleeve.   18. The fabric of claim 17, wherein the fibers, yarns, monofilaments, and multifilament yarns are made of a material selected from the group consisting of aramids, thermoplastic polymers, thermosetting polymers, glass, carbon, and steel. Belt or sleeve.   Spirally winding one or more strips of polymer material around a plurality of rolls, wherein the one or more strips of polymer material is an industrial strap or ribbon material A method for forming a belt or sleeve for use in the manufacture of nonwovens, comprising the steps of: joining the edges of adjacent strip materials using a predetermined technique.   20. The method of claim 19, wherein the predetermined technique is laser welding, infrared welding, or ultrasonic welding.   20. The method of claim 19, wherein the industrial strap or ribbon material has a thickness of 0.30 mm or greater and a width of 10 mm or greater.   20. A method according to claim 19, wherein the belt or sleeve is permeable or impermeable to air and / or water.   23. The belt or sleeve of claim 22, wherein the belt or sleeve is permeable to air and / or water by creating a cavity or hole through the belt or sleeve using mechanical or thermal means. The method described.   24. The method of claim 23, wherein the penetrating cavity or hole is formed with a predetermined size, shape, or orientation.   25. The method of claim 24, wherein the penetrating cavity or hole has a nominal diameter in the range of 0.005 inches to 0.01 inches or more.   On the upper or lower surface of the belt or sleeve, a strip of woven or non-woven material, MD or CD yarn array, spirally wound woven material having a width smaller than the width of the belt or sleeve 20. The method of claim 19, further comprising applying one or more layers of a web, a fibrous web, a film, or a combination thereof.   20. The method of claim 19, wherein adjacent strips of polymeric material are mechanically combined.   20. A method according to claim 19, wherein one or both surfaces of the belt or sleeve are textured.   29. The method of claim 28, wherein the texture is provided by sanding, graving, embossing, or etching.   20. A method according to claim 19, wherein one or both surfaces of the belt or sleeve are smooth.   20. The method of claim 19, wherein the belt or sleeve comprises at least two layers of strap material wound spirally in opposite directions or opposite to the MD.   20. The method of claim 19, further comprising the step of coating a functional coating on one or both sides of the belt or sleeve.   27. The method of claim 26, wherein the one or more layers are provided on one or both sides of the belt or sleeve, or between two layers of strap material.   35. The method of claim 32, further comprising providing a texture on the functional coating.   20. The method of claim 19, further comprising reinforcing the industrial strap or ribbon material to a fabric, sleeve, or belt MD with fibers, yarns, monofilaments, or multifilament yarns.   36. The method of claim 35, wherein the fiber, yarn, monofilament, or multifilament yarn is made of a material selected from the group consisting of aramid, thermoplastic polymer, thermoset polymer, glass, carbon, and steel.

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