Abstract
An endless fabric belt having a seam region, the seam region comprising: a) machine direction (MD) threads; b) cross-direction (CD) threads interwoven with the MD threads; and c) termination zones distributed throughout the entire seam region, with each termination zone comprising two ends of an MD thread; wherein: a plurality of the CD threads are fusible, with the fusible (F) and non-fusible (N) CD threads distributed in a pattern throughout the seam region such that in a repeating unit of the pattern, the ratio of F threads to CD threads is at most 0.75; and a plurality of the termination zones further comprise at least one fusible CD thread attached to the MD thread in the termination zone.
Claims
1. An endless fabric belt having a seam region, the seam region comprising: a) machine direction (MD) threads; b) cross-direction (CD) threads interwoven with the MD threads; and c) termination zones distributed throughout the entire seam region, with each termination zone comprising two ends of an MD thread; wherein: a plurality of the CD threads are fusible, with the fusible (F) and non-fusible (N) CD threads distributed in a pattern throughout the seam region such that in a repeating unit of the pattern, the ratio of F threads to CD threads is at most 0.75; and a plurality of the termination zones further comprise at least one fusible CD thread attached to the MD thread in the termination zone.
2. The belt of claim 1, wherein the ratio of F threads to CD threads in the repeating unit is at most 2:3.
3. The belt of claim 1, wherein the CD threads are fusible based on laser-weld technology, low-melt polymer technology, sheath-core technology or ultrasonic technology.
4. The belt of claim 1, wherein the MD and CD threads independently comprise a polymeric material.
5. The belt of claim 4, wherein the polymeric material is a polyamide or a polyethylene terephthalate.
6. The belt of claim 4, wherein the polymeric material is selected from the group consisting of polyphenylene sulfide (PPS), polybutylene terephthalate (PBT), polyurethane and polyethylene naphthalate (PEN).
7. The belt of claim 4, wherein the fusible CD thread further comprises an additive that permits fusing of the fusible CD thread based on laser-weld technology.
8. The belt of claim 7, wherein the additive is added in a range of from about 0.1 wt % to about 3 wt % of the weight of the CD thread.
9. The belt of claim 7, wherein the additive is added in a range of from about 0.3 wt % to about 1 wt % of the weight of the CD thread.
10. The belt of claim 6, wherein: a plurality of the CD threads are fusible in a wavelength range of laser; the MD threads are transparent to light of the wavelength range; and at least some of the MD threads are laser-welded to the fusible CD threads by the laser.
11. The belt of claim 6, wherein the fusible CD threads comprise carbon.
12. The belt of claim 11, wherein the fusible CD thread comprises carbon black.
13. The belt of claim 1, wherein there is at least one non-fusible CD thread in between two fusible CD threads in the repeating unit of the pattern.
14. The belt of claim 1, wherein the seam region is a single layer weave, and the repeating unit of the patter is FN.
15. The belt of claim 1, wherein the seam region is a single layer weave, and the repeating unit of the pattern is FFNNNFFNNNN.
16. The belt of claim 1, wherein the seam region is a single layer weave, and the repeating unit of the pattern is FNN.
17. The belt of claim 1, wherein the seam region is a single layer weave, and the repeating unit of the pattern is FNFNNN.
18. The belt of claim 1, wherein the seam region is a multilayer weave, and an overall repeating unit of the pattern is FNNNNN.
19. The belt of claim 1, wherein the seam region is a multilayer weave, and an overall repeating unit of the pattern is FNNNNNNNNNN.
20. The belt of claim 1, wherein the seam region is a multilayer weave, and an overall repeating unit of the pattern is FNNNNNNN.
21. The belt of claim 1, wherein the termination zone comprises weaving of at least one of the MD thread ends with one or more CD threads.
Description
BRIEF DESCRIPTION OF FIGURES
[0026] FIG. 1 illustrates a plan view of one embodiment of a seam.
[0027] FIG. 1b illustrates an enlarged portion of the seam shown in FIG. 1.
[0028] FIG. 2 illustrates a second view of the embodiment shown in FIG. 1.
[0029] FIG. 3 illustrates successive warp paths of the embodiment shown in FIG. 2.
[0030] FIG. 4 illustrates a plan view of another embodiment of a seam.
[0031] FIG. 5 illustrates a second view of the embodiment shown in FIG. 4.
[0032] FIG. 6 illustrates successive warp paths of the embodiment shown in FIG. 5.
[0033] FIG. 7 illustrates successive warp paths of another embodiment of a seam.
[0034] FIG. 8 illustrates successive warp paths of another embodiment of a seam.
[0035] FIG. 9 illustrates another embodiment of a single layer seam region.
[0036] FIG. 10 illustrates another embodiment of a single layer seam region.
[0037] FIG. 11 illustrates another embodiment of a seam region.
[0038] FIG. 12 illustrates an embodiment of a multilayer seam region.
[0039] FIG. 13 illustrates another embodiment of a multilayer seam region.
[0040] FIG. 14 illustrates another embodiment of a multilayer seam region.
[0041] FIG. 15 illustrates another embodiment of a multilayer seam region.
[0042] FIG. 16 illustrates another embodiment of a single layer seam region.
DETAILED DESCRIPTION
[0043] FIG. 1 illustrates a plan view of one embodiment of a seaming region (5) that is comprised of CD threads (10, 15) and MD threads (not shown). The MD threads connect at termination zones (20) throughout the seaming region (5). The CD threads are of two types: fusible (F,10) and non-fusible (N,15). As shown, the fusible (10) and non-fusible (15) CD threads are arranged in a pattern throughout the seam region (5). In this embodiment, the repeating pattern unit is FNNthat is, one fusible thread (10) followed by two non-fusible threads (15). Other patterns of F- and N-type CD threads are also possible, and a few other examples are discussed below. Furthermore, as shown in FIG. 1, the termination zones (20) are distributed throughout the entirety of the seam region (5). In this embodiment, the termination zones (20) are distributed throughout the seam region (5) in a pattern as well; i.e. the termination zones (20) are evenly spaced apart throughout. It should be noted that the termination zones (20) can be distributed throughout the seam region (5) in a random manner, so long as the termination zones (20) are distributed through the entire seam region (5).
[0044] FIG. 1b illustrates an enlarged portion of the seam shown in FIG. 1, to clearly show that the termination zones are not aligned in the MD direction, but, instead, are offset in the CD direction.
[0045] For example, in the illustration shown in FIG. 1b, termination zone 22 is offset by one MD thread from termination zone 21. In addition, there are 8 CD threads (in the sequence NNFNNFNN) between successive termination zones 21 and 22. Similarly to successive termination zones 21 and 22, successive termination zone 23 is offset by one MD thread from termination zone 24, with 8 CD threads between termination zones 23 and 24. Note that termination zone 23 is offset by three MD threads from termination zone 22, with 11 CD threads (in the sequence NNFNNFNNFNN) between successive termination zones 22 and 23. There are other possible alignments of the termination zones in the seam region.
[0046] FIG. 2 illustrates a second view of the embodiment shown in FIG. 1, in which two ends of an MD thread (25, 30) are woven through CD threads (10, 15), and meet at a termination zone (20). The fusible (10) and non-fusible (15) CD threads are arranged in the FNN repeat pattern shown in FIG. 1. In this embodiment, the termination zone (20) occurs at fusible CD thread (10), where the two ends of the MD thread (25, 30) cross over and are attached to the fusible CD thread (10). As an example, if laser welding is used to connect the two ends of the MD thread (25, 30) to the fusible CD thread (10) at termination zone (20), the two ends of the MD thread (25, 30) are transparent to the wavelength of the laser used for laser welding, whereas the fusible CD thread (10) absorbs energy in the wavelength range of the laser used in laser welding. While FIG. 2 shows each end of an MD thread (25, 30) terminating not far beyond termination zone (20), it is understood that one or both ends of MD threads (25, 30) can extend beyond termination zone (20) to mechanically weave with CD threads (10, 15).
[0047] FIG. 3 illustrates successive warp paths (35a, 35b) of the embodiment shown in FIG. 2. In this figure, the CD threads and MD threads are as in FIG. 2, in that the fusible (10) and non-fusible (15) CD threads are arranged in a FNN repeat pattern. In warp path (35a), the termination zone is at (20a), where MD thread ends (25a, 30a) cross over and are connected to CD fusible thread (10a). In the adjacent warp path (35b), the termination zone is at (20b), where MD thread ends (25b, 30b) cross over and are connected to CD fusible thread (10b). As can be seen, the termination zones (20a, 20b) in successive warp paths (35a, 35b) are separated by two successive non-fusible CD threads, for the FNN pattern shown. Other termination zone patterns are possible for the FNN pattern. For example, successive termination zones can occur at CD fusible threads (10a) and (10c), instead of (10a, 10b). In this case, the termination zones would be separated by five CD threads (with a NNFNN sequence).
[0048] FIG. 4 illustrates a plan view of another embodiment of a seaming region (5) that is comprised of CD threads (50, 55) and MD threads (not shown). The MD threads connect at termination zones (60) throughout the seaming region (5). The CD threads are of two types: fusible (F,50) and non-fusible (N,55). As shown, the fusible (50) and non-fusible (55) CD threads are arranged in a pattern throughout the seam region (5). In this embodiment, the repeating pattern unit is FNFNNN. Furthermore, as shown in FIG. 4, the termination zones (60) are distributed throughout the entirety of the seam region (5) in a pattern in which the termination zones (60) are evenly spaced apart throughout. It should be noted that the termination zones (60) can be distributed throughout the seam region (5) in a random manner, so long as the termination zones (60) are distributed through the entire seam region (5).
[0049] FIG. 5 illustrates a second view of the embodiment shown in FIG. 4, in which two ends of an MD thread (65, 70) are woven through CD threads (50, 55), and meet at a termination zone (60). The fusible (50) and non-fusible (55) CD threads are arranged in the FNFNNN repeat pattern shown in FIG. 4. In this embodiment, the termination zone (60) occurs over a breadth of three CD threads (51, 52, 56). Here, the two ends of the MD thread (65, 70) are attached to two fusible CD threads (51, 52), with a non-fusible CD thread (56) in between the two CD fusible threads (51, 52). While FIG. 5 shows each end of the MD thread (65, 70) terminating without crossing over, it is possible for one or both ends of the MD thread (65, 70) to continue weaving with non-fusible CD thread (56) and beyond. As an example, if laser welding is used to connect the ends of the MD thread (65, 70) to the fusible CD threads (51, 52) at termination zone (60), the ends of the MD thread (65, 70) are transparent to the wavelength of the laser used for laser welding, whereas the fusible CD threads (51, 52) absorb energy in the wavelength range of the laser used in laser welding.
[0050] FIG. 6 illustrates successive warp paths (75a, 75b) of the embodiment shown in FIGS. 4 and 5. In this figure, the CD threads and MD threads are as in FIG. 5. In warp path (75a), the termination zone is at (60a) and occurs over a distance of three CD threads (51a, 52a, 56a). The two ends of the MD thread (65a, 70a) are attached to two CD fusible threads (51a, 52a), with a non-fusible CD thread (56a) in between the two CD fusible threads (51a, 52a). In the adjacent warp path (75b), the termination zone is at (60b) and occurs over a distance of three CD threads (51b, 52b, 56b). The two ends of the MD thread (65b, 70b) are attached to two CD fusible threads (51b, 52b), with a non-fusible CD thread (56b) in between the two CD fusible threads (51b, 52b). As can be seen, the termination zones (60a, 60b) in successive warp paths (75a, 75b) are separated by three successive non-fusible CD threads, for the FNFNNN pattern shown. Other termination zone patterns are possible for the FNFNNN pattern. For example, successive termination zones can have nine successive CD threads (in the sequence NNNFNFNNN) in between.
[0051] FIG. 7 illustrates successive warp paths (80a, 80b) of an embodiment in which the repeating pattern is FFN. In warp path (80a), the termination zone is at (85a) and occurs over a distance of six CD threads. The two ends of the MD thread are attached to two CD fusible threads (90a, 95a) with two non-fusible CD threads and two fusible CD threads in between the two CD fusible threads (90a, 95a). In the adjacent warp path (80b), the termination zone is at (85b) and occurs over a distance of six CD threads. The two ends of the MD thread are attached to two CD fusible threads (90b, 95b), with two non-fusible CD threads and two fusible CD threads in between in between the two CD fusible threads (90b, 95b). As can be seen, the termination zones (85a, 85b) in successive warp paths (80a, 80b) actually overlap by three CD threads for the FFN pattern shown. Other termination zone patterns are possible for the FFN pattern. For example, successive termination zones can have two successive CD threads (with the sequence FF) in between.
[0052] FIG. 8 illustrates successive warp paths (81a, 81b) of an embodiment in which the repeating pattern is FFN. In warp path (81a), the termination zone is at (86a) and occurs over a distance of three CD threads. The two ends of the MD thread are attached to two CD fusible threads (91a, 96a), with one non-fusible CD thread in between the two CD fusible threads (91a, 96a.). In the adjacent warp path (81b), the termination zone is at (86b) and occurs over a distance of three CD threads. The two ends of the MD thread are attached to two CD fusible threads (91b, 96b), with one non-fusible CD thread in between in between the two CD fusible threads (91b, 96b). As can be seen, the termination zones (86a, 86b) in successive warp paths (81a, 81b) are separated by three CD threads for the FFN pattern shown. Other termination zone patterns are possible for the FFN pattern. For example, successive termination zones can have zero successive CD threads in between.
[0053] FIG. 9 illustrates another embodiment, in which two ends of an MD thread (100, 105) are woven through CD threads, and meet at a termination zone (110). The fusible (115) and non-fusible (120) CD threads are arranged in an FFNNNFFNNNN repeat pattern. In this embodiment, the termination zone (110) occurs over a breadth of seven CD threads Here, each of the two ends of the MD thread (100, 105) are attached to two fusible CD threads (115a, 115b), with three non-fusible CD threads (120a, 120b, 120c) in between the two CD fusible threads (115a, 115b). While FIG. 9 shows each end of the MD thread (100, 105) terminating without crossing over, it is possible for one or both ends of the MD thread (100, 105) to continue weaving with non-fusible CD thread (120b) and beyond. As an example, if laser welding is used to connect the ends of the MD thread (100, 105) to the fusible CD threads (115a, 115b) at termination zone (110) the ends of the MD thread (100, 105) are transparent to the wavelength of the laser used for laser welding, whereas the fusible CD threads (115a, 115b) absorb energy in the wavelength range of the laser used in laser welding.
[0054] FIG. 10 illustrates another embodiment, in which two ends of an MD thread (125, 130) are woven through CD threads and meet at a termination zone (135). The fusible (140) and non-fusible (145) CD threads are arranged in an FNF repeat pattern. In this embodiment, the termination zone (135) occurs over a breadth of two CD threads (140a, 140b). Here, the two ends of the MD thread (125, 130) are attached to two fusible CD threads (140a, 140b) with no other CD threads in between the two CD fusible threads (140a, 140b). While FIG. 10 shows each end of the MD thread (125, 130) terminating without crossing over, it is possible for one or both ends of the MD thread (125, 130) to continue weaving with fusible CD threads (140a, 140b) and beyond. As an example, if laser welding is used to connect the ends of the MD thread (125, 130) to the fusible CD threads (140a, 140b) at termination zone (135), the ends of the MD thread (125, 130) are transparent to the wavelength of the laser used for laser welding, whereas the fusible CD threads (140a, 140b) absorb energy in the wavelength range of the laser used in laser welding.
[0055] FIG. 11 is a photograph of another embodiment of a seam region, in which the CD repeating unit is FNNFN. The fusible threads are shown as 155, with the non-fusible threads shown as 150.
[0056] FIG. 12 is a photograph of an embodiment of a multilayer seam region. The fusible threads are shown as 160, with the non-fusible threads shown as 165. The machine side warp strand (shown with an arrow) weaves with CD threads of one layer that have a repeating pattern unit of FN. However, the overall multilayer structure has a repeating pattern unit of NNNNNF (one fusible CD thread out of every six CD threads).
[0057] FIG. 13 is a photograph of another embodiment of a multilayer seam region. The fusible threads are shown as 170, with the non-fusible threads shown as 175. The machine side warp strand (shown with an arrow) weaves with CD threads of one layer that have a repeating pattern unit of FNN. However, the overall multilayer structure has a repeating pattern unit of F (one fusible CD thread out of every twelve CD threads).
[0058] FIG. 14 is a photograph of another embodiment of a multilayer seam region. The fusible threads are shown as 180, with the non-fusible threads shown as 185. The machine side warp strand (shown with an arrow) weaves with CD threads of one layer that have a repeating pattern unit of FN. However, the overall multilayer structure has a repeating pattern unit of N NNNNNF (one fusible CD thread out of every eight CD threads).
[0059] FIG. 15 is a photograph of another embodiment of a multilayer seam region. The fusible threads are shown as 190, with the non-fusible threads shown as 195. The machine side warp strand (shown with an arrow) weaves with CD threads of one layer that have a repeating pattern unit of FNN. However, the overall multilayer structure has a repeating pattern unit of F (one fusible CD thread out of every twelve CD threads).
[0060] FIG. 16 illustrates another embodiment of a single layer seam, in which the CD repeating unit is FNN. The fusible threads are shown as 200, with the non-fusible threads shown as 205 in FIG. 16.
[0061] It will be appreciated by persons skilled in the art that the foregoing disclosure constitutes a description of specific embodiments showing how the seam may be applied and put into use. These embodiments are only exemplary and are not meant to limit the disclosure to what has been particularly shown and described herein above. A variety of modifications and variations are possible in light of the above teachings without departing from the scope of the present disclosure. The seam is further described and defined in the claims which now follow.
