Classifications

• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D3/00—Woven fabrics characterised by their shape
  • D03D3/04—Endless fabrics
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
  • D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D1/00—Woven fabrics designed to make specified articles
  • D03D1/0094—Belts
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
  • D03D15/242—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
  • D03D15/267—Glass
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
  • D03D15/47—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads multicomponent, e.g. blended yarns or threads
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
  • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
  • D03D15/513—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads heat-resistant or fireproof
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D19/00—Gauze or leno-woven fabrics
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D9/00—Open-work fabrics
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
  • D10B2321/021—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polyethylene
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
  • D10B2331/06—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyethers
  • D10B2331/061—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyethers polyetherketones, polyetheretherketones, e.g. PEEK
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
  • D10B2331/14—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polycondensates of cyclic compounds, e.g. polyimides, polybenzimidazoles
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
  • D10B2331/30—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polycondensation products not covered by indexing codes D10B2331/02 - D10B2331/14
  • D10B2331/301—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polycondensation products not covered by indexing codes D10B2331/02 - D10B2331/14 polyarylene sulfides, e.g. polyphenylenesulfide
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/04—Heat-responsive characteristics
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2505/00—Industrial

Definitions

• This invention relates generally to high temperature polymer materials and, more particularly, to high temperature fabrics made from polymer filaments for use in various articles, such as belting and tray liners.
• Polyphenylene sulfide is used in chemical and heat resistant products.
• PPS Polyphenylene sulfide
• the filament will shrink at elevated operating temperatures, such as by 15% or more, depending on grade and filament manufacturing process, and application operating temperature.
• PPS monofilament generally can have a 'roughness' after weaving that limits use in applications such as steam bulking and heat setting of yarns, various food applications, etc. There is a continuing need for improved monofilament materials for belting and other articles.
• a general object of the invention is to provide improved polymer fabrics that can be used as a substrate with higher temperature resistance and/or dimensional stability in various fabricated parts for high temperature and/or liquid applications.
• the invention provides, at least in part, a fabricated part for a high temperature operation including a non-metallic substrate formed of a polymer fabric of woven non-absorbent polymer filaments, wherein the substrate is heat-resistant and heat set at a temperature that is above a predetermined operating temperature of an intended operation of the fabricated part.
• references to the term "non-metal” or “non-metallic” are to be understood to refer to an element or material being devoid of metal.
• the polymer filament includes a high temperature chain extended or cured polymer material, desirably obtained by the heat setting.
• Heat setting involves keeping the material at the setting temperature for a period of time such that a curing and/or crosslinking process occurs. This is discernable by a color change in the fabric and the heat set material of this invention has increased dimensional stability (little to no shrink) at the in-use temperature after being subjected to the curing temperature again.
• the heat setting of the substrate according to this invention provides benefits such as pre-shrinking the polymer fabric and/or curing or chain extending the polymer material to impart higher heat resistance.
• Heat setting the substrate above the intended operating temperature, or the temperature of the intended use allows for heat resistance and dimensional stability at that operating temperature.
• curing PPS with heat in the presence of oxygen results in property changes that are a result of molecular chain extension and formation of molecular chain branches via an oxygen ion bonded between the aromatic rings of PPS.
• the curing increases the molecular weight, resulting in some thermoset- like properties, including good thermal stability, dimensional stability, and resistance to harsh chemical environments.
• PPS is a thermoplastic and does not suffer from many of the shortcomings of thermosets.
• the substrate and articles of this invention are pre-shrunk or thermally stabilized via the heat setting such that the product will not fail due to shrinkage or other destabilization in the operation at, for example, 212° F (100°C) and higher.
• the substrate is formed by heat setting a polymer fabric (e.g., a fabric of polymer monofilaments or multifilaments) at the temperature that is above the predetermined operating temperature of the operation for a predetermined time period, to obtain the polymer substrate.
• the heat setting can be performed is any suitable method that preshrinks/thermally stabilizes the fabric and/or otherwise imparts dimensional stability.
• the substrate is formed by winding the polymer fabric with a non-stick layer to form wound material layers, and heating the wound material layers to the heat setting temperature, such as in a batch oven, for a sufficient time.
• the substrate is formed by calendaring the polymer fabric at or above the heat setting temperature, such as using heated calendar rolls.
• the fabricated parts of this invention include endless belts, trays, bakeware or cookware.
• Exemplary endless belts include conveyor belts for, without limitation, steam treatment, article washing, oven drying, baking, or deep frying.
• the conveyor belts desirably include an edge material strip along or over the opposing ends and/or longitudinal edges of the belt.
• the edge material can be a thermoplastic, a fiber-reinforced material, or a silicone material capable of withstanding the predetermined operating temperature.
• Trays, such as cooking or baking sheets can be formed from a piece of fabric and an edge material along or over all side or peripheral edges.
• the tray can be an insert for a cooking device designed to be placed in an oven used for dehydration, baking, or pressing.
• Other articles include thermoformed articles stamped from the substrate, such for cooking, washing, and/or drying food, plant material, or parts or articles (e.g., can washing).
• the invention further provides an apparatus with a heating device configured to operate at a predetermined operating temperature, and a non-metallic endless belt as described above extending through the heating device.
• the heating device includes microwave, steam, and/or a heated liquid.
• the apparatus can be, for example, a washing apparatus, a drying oven, a deep fryer, or a yarn treatment apparatus.
• Fig. 1 is a substrate according to one embodiment of this invention.
• Fig. 2 is a view of a fabric weave, according to one embodiment of this invention.
• Fig. 3 representatively shows a heat setting process according to one embodiment of this invention.
• Fig. 4 representatively shows a heat setting process according to another embodiment of this invention.
• Fig. 5 is an endless conveyor belt, according to one embodiment of this invention.
• Figs. 6 and 7 each show a belt lacing, according to embodiments of this invention.
• Fig. 8 shows a tray, according to one embodiment of this invention.
• Fig. 9 shows a belt according to one embodiment of this invention used in a can washing and drying apparatus.
• Fig. 10 shows a belt according to one embodiment of this invention used in a deep frying apparatus.
• Fig. 11 shows a belt according to one embodiment of this invention used in a yarn or other material treatment apparatus.
• the present invention provides a monofilament fabric having dimensional stability and temperature resistance, and method for making.
• the monofilament fabric is desirably woven, and can be formed as a mesh with a plurality of mesh openings between the woven monofilament strands.
• Fig. 1 illustrates a substrate 20 formed from a polymer monofilament mesh fabric.
• Substrate 20 includes a plurality of parallel monofilament strands 22 extending between edges 30 and 32.
• a second plurality of monofilament strands 24 extend perpendicular to, and are woven alternatively between the strands 22 to form the base polymer fabric and the mesh openings between the individual monofilaments 22 and 24. Any suitable fabric weaving is suitable for the polymer fabric.
• Fig. 2 shows an alternative monofilament fabric substrate 20 where pairs of strands 24 are twisted together and around alternating sides of a corresponding one of the strands 22.
• Mesh opening sizes can vary, depending on need, with a tighter weaves with more strands forming smaller mesh openings.
• the polymer filaments (monofilaments or multifilaments) of this invention can be formed of suitable polymer material, such as polyphenylene sulfide (PPS), polyaminde-imide (PAI), polyphenylene sulfone (PPSU), polyethersulfone (PES), polyethylene (PE), liquid-crystal polymers (LCP), and/or polyether ether ketone (PEEK).
• PPS polyphenylene sulfide
• PAI polyaminde-imide
• PPSU polyphenylene sulfone
• PES polyethersulfone
• PE polyethylene
• LCP liquid-crystal polymers
• PEEK polyether ether ketone
• the polymer material can include additives to impart additional properties. Inclusion of chopped or milled fiberglass within the polymer materials and within the individual filaments can be used to increase strength or stiffness, thereby not requiring separate, continuous fiberglass reinforcement of the substrate or fabric as a whole.
• the substrate 20 is heat set at a heat setting temperature to obtain improved stability and/or temperature resistance.
• Heat setting according to this invention provides benefits such as curing or chain extending of the polymer material, and/or preshrinking the polymer fabric.
• the polymer fabric of the substrate is heat set at a temperature that is greater than a predetermined operating temperature of the intended use of the resulting fabricated part including the substrate. The higher temperature preshrinks/heat stabilizes the fabric before the substrate is put into use, thereby reducing or eliminating shrinkage and rupture during use, particularly at temperatures above 180°F (82°C).
• the substrate shrinks less than 2% during treatment. However, even 1% shrinkage during use can result, for example, in an endless belt prematurely failing on the conveyor rollers.
• the heat setting temperature is above the glass transition temperature of the polymer, and in embodiments of this invention the heat setting temperature is least 15° over the predetermined operating temperature, and preferably at least 25°, and desirably at least 50° over the predetermined operating temperature.
• the heat setting temperature is desirably 212°F (100°C) or above, more desirably at least 250°F (121°C), for at least 15 minutes, and preferably at least 30 minutes, and desirably at least one hour.
• Heat setting can be performed by any suitable heating apparatus.
• Fig. 3 illustrates heat setting according to embodiments of this invention.
• Monofilament fabric web 20 is calendared against one or more pairs of heated calendar rolls 40.
• the rolls 40 are within an oven 42, such as an oven able to reach a temperature of at least 50° over the intended operating temperature.
• Any suitable heated calendar roll can be used, such as one or more heated rolls or pairs of rolls.
• the fabric can also be first heat set, for example in an oven, and then calendared at least once after heat set on heated calendar rolls at or above the heat setting temperature.
• Fig. 4 illustrated an alternative heat setting method that also provides stability and/or reduces roughness.
• an interleaf non-stick film or fabric 52 such as made from polytetrafluoroethylene (PTFE)
• PTFE polytetrafluoroethylene
• the wrapped layers are secured about the roll, such as with PTFE tapes to hold the tightness and shape, and placed in an oven at room temperature.
• the oven is heated to the heat set temperature above the operating temperature for a necessary time, such as near or to the melting point for about 30 minutes.
• the resulting mesh material has improved stability, decreased roughness, and improved temperature resistance at the operating temperature.
• One or more monofilament fabrics can be wound about the roll 50, with two fabric sheets 20 being shown in Fig. 4.
• the monofilament fabric can be further processed according to the intended use.
• the mesh can be spliced or cut into the necessary length/shape, and include necessary edge materials, such as described above in Fig. 1.
• coating materials can be applied to the monofilaments or the heat set mesh, such as a silicon, fluoropolymer and/or fluoroelastomer (e.g., PFA, MFA, PTFE, or FEP) coating to provide further non-stick properties.
• Other exemplary coatings include quartz or silicone polyesters to provide release properties.
• the coating materials can be applied as additives in the monofilament material, and/or applied before or after the heat treatment, such as by spray coating, dipping, curtain coating, and/or roller coating, and then cured as needed.
• the monofilament fabric/mesh of this invention is useful in forming many articles for use.
• the monofilament fabric can be formed into conveyor belts, such as shown in Fig. 5.
• the fabric can be cut and spliced to form endless belt 60, that when assembled around rollers 62 can convey objects 64.
• the opposing longitudinal ends and edges of the belt can include an edge material strip 66, such as W formed of a thermoplastic or silicone material.
• the ends 65 of the belt 60 can includes an attachment mechanism for connecting the opposing ends together, such as with an overlapping and connected ends, a male to female connection mechanism, the lacing 68 shown in Fig. 6, or the alternative spiral lacing 70 shown in Fig. 7.
• Fig. 8 illustrates a representative sheet or tray 80, useful as a food support made from the substrate of this invention.
• the food support 80 is formed from the substrate of this invention, and includes a mesh fabric 82, with an edge material 84 covering all four sides.
• Various shapes and configuration are available for food support, such as a flat sheet or with raised 'basket' edges as shown in Fig. 8.
• the food support 80 which can be formed, for example, as a cooking basket/tray or a planar cooking sheet, and is useful for placing and removing food items from, and holding food items while in, an oven.
• the food support of this invention is desirably durable for multiple heating cycles, high temperature and water/oil resistant, easy to clean, stain resistant, and dissipates heat quickly; all while desirably not having any or much effect on the cooking of food.
• the food support can include a tight weave as a more solid bottom substrate sheet, such as to prevent liquids from dripping on heating elements, or a more open mesh substrate sheet to allow hot air through.
• the thickness of the substrate and/or the size of the mesh openings provide the ability to cook different food items and provide, for example, the desired food browning, toasting and/or heating characteristics.
• the temperature-resistant materials of this invention are also non-absorbent, non- wicking, and resistant to chemicals, steam, and wet conditions, thereby making them particularly useful in numerous applications.
• Exemplary uses for the belting or other articles made according to this invention include, without limitation, food processing (drying, cooking (oven or microwave)), washing and/or drying of parts or materials (e.g., cans, plant materials (hemp, tobacco, etc.)), yarn bulking/heat setting, high-temperature insulation manufacture, non-woven manufacture, textile drying/shrinking/lamination, screen printing, industrial microwave/RF application, dehydration/drying, bacon cooking, doughnut and corn dog production, pasta belting and pasta screen, extruding corn puffs, and manufacturing pet food.
• Fig. 9 illustrates one exemplary use of the fabric/mesh according to this invention as a conveyor belt 92 in a can, or other article, washing and drying apparatus 90.
• the conveyor belt 92 carries cans 95 through a washing device 94 and then through a drying device 96, such as a hot air dryer or oven.
• the high temperature substrate of this invention is particularly useful in such part washing and/or drying, particularly due its non-absorbent, preshrunk properties.
• Fig. 10 illustrates one exemplary use of the fabric/mesh according to this invention as a conveyor belt 102 in a deep frying apparatus 100.
• the conveyor belt 102 carries food items (not shown) through a deep fryer 104 filled with oil and then through any downstream device for further cooking or application of additional ingredients (e.g., toppings).
• additional ingredients e.g., toppings.
• the high temperature substrate of this invention is particularly useful in deep frying, or other submersed or liquid-based cooking processes (e.g., water boiling), due its non-absorbent, preshrunk properties.
• Fig. 11 illustrates one exemplary use of the fabric/mesh according to this invention as a counterband 1 12 in a yarn production or treatment apparatus 1 10.
• Exemplary treatment apparatuses include heat setting or bulking machines available from Superba SAS (Mulhouse, France) and/or Spindelfabrik Suessen GmbH (Sussen, Germany).
• the counterband 1 12 extends around rollers 1 14 and between pinch rollers 116, and holds a bundle of yarn against the conveyor belt 1 18, which also can be formed of the substrate of this invention, as the bundle of yarn is treated with the oven 1 15.
• Traditional counterbands are formed from woven textile webbing.
• the monofilament fabric of this invention is particularly useful as a counterband due to resistance of the operating temperature of the oven 115. In addition, the monofilament fabric will not absorb any moisture from the heated fluid 1 17, such as steam, within the oven 1 15.
• the counterband holds a bundle of yarn in place as the conveyor carries it through the oven and any yarn cooler. There are several places and mechanisms by which the yarn can become displaced or snagged, which reduces the production efficiency of the entire system.
• a steam chamber of the heat setting oven there is a set of pinch rollers 116 that squeeze the yarn between the counterband 1 12 and the conveyor belt 118.
• the rollers 1 16 substantially seal the chamber at both ends, preventing the pressurized steam from escaping. As the rollers are constantly exposed to the steam and moisture, the counterband also keep the yarn from sticking to the rollers 1 16.
• the monofilament fabrics of this invention can also be thermoformed (i.e., heat pressed) into shaped articles. Due to the temperature resistance, microwave safe, and non-stick capabilities, the monofilament materials are particular suitable for use in or forming cookware or bakeware. Exemplary thermoformed articles include, without limitation, cooking sheets, bread pans, and trays and baskets, particularly for use in high speed ovens.
• a fabric material was heat processed using conventional methods of running the material in a tenter frame through an infrared oven set to 210 °C (410 °F), such that the filament/yarn in the fabric did not reach the actual oven set-point temperature. This process was then followed by the material being calendared at 220 °C (428 °F) using a heated steel two roll calendar. A piece of this material 10" x 218.5" was then placed into a conventional oven set at 220 °C (428 °F) for 8 hours to simulate use. The material was a dull yellow in color after processing. When removed and measured, the material lost 3.75% in the width and 4.75% in the length and the material had changed color to a dull amber color.
• the invention provides a non-absorbent polymer fabric substrate having many uses in heated and/or wet environments.
• the substrate is preshrunk and stabilized for belting applications at higher temperatures than generally thought.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Inorganic Chemistry (AREA)
• Mechanical Engineering (AREA)
• Woven Fabrics (AREA)
• Belt Conveyors (AREA)
• Treatment Of Fiber Materials (AREA)

Applications Claiming Priority (2)

Publications (2)

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• 2018
  • 2018-08-29 BR BR112020003885-7A patent/BR112020003885A2/pt not_active Application Discontinuation
  • 2018-08-29 EP EP18850619.0A patent/EP3676428A4/de not_active Withdrawn
  • 2018-08-29 MX MX2020002173A patent/MX2020002173A/es unknown
  • 2018-08-29 WO PCT/US2018/048451 patent/WO2019046369A1/en not_active Ceased
  • 2018-08-29 CA CA3074214A patent/CA3074214A1/en not_active Abandoned
  • 2018-08-29 US US16/115,831 patent/US20190062959A1/en not_active Abandoned

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