Patent Application
20120125473
The disclosed invention is directed toward an improved construction for a reinforcing fabric for belts.
Recent developments in high tension abuse resistant conveyor belt fabrics have created fabrics which are too thick and rigid to be used in multi-layer constructions. They either have too little crimp in the warp to allow multi-ply construction or are so thick the distance between two plies creates longitudinal flexibility and troughing issues. This invention takes the positives of the high tension fabrics and combines them with the benefits from using lighter weight conveyor belt fabrics.
Most high tension/abuse resistant fabrics being produced today use a straight warp tension member. This straight warp yarn has 0-1% crimp which limits the ultimate elongation of the finished belt, but also makes it very rigid if produced in multi-ply constructions.
High volume conveyor belt fabrics are produced using a plain, crowfoot, or twill pattern. These weave patterns can produce fabrics with 3-10% crimp. They excel in multi-ply conveyor belts but create too much stretch and poorer abuse resistance than their straight warp counterparts.
This invention takes a crowfoot or twill pattern and improves its stretch and abuse characteristics by creating 2 layers. The two layers induce a moderate amount of crimp, 2-5%, which allow the fabric to be used in 2, 3, or 4 ply applications. They also improve the abuse resistance over standard weave patterns in that the warp yarns are protected by the weft yarns. The exposure of the warp yarns is kept to a minimum by the unique weave pattern.
In accordance with the present invention, a reinforcing fabric for a belting is disclosed. The reinforcing fabric is a composite fabric which provides the belt with superior properties such as high rip resistance, transverse tear resistance, impact resistance, anti-fraying, and flexibility. In accordance with the present invention, the composite has two layers, the weft yarns have a corresponding binder, and there is a top warp yarn which covers some of the top weft yarns, and a bottom warp yarn which covers some of the bottom weft yarns.
“Binder Yarn” denotes yarn that is used to bind together different yarns in a fabric.
“Fabric” denotes a network of essentially unidirectionally extending cords/yarns, which may be twisted, and which may in turn be composed of a plurality of a multiplicity of filaments (which may also be twisted).
“Crimp Percentage” is defined as the mean difference between the straightened yarn length and the distance between the ends of the yarn while in cloth, expressed as a percentage.
“Warp” refers to a network of essentially unidirectional extending cords/yarns, which extend in the longitudinal direction of the belt.
“Weft” (filling) refers to the cord/yarn placed at right angles to the warp cords/yarns.
“Woven Fabric” refers to the interlacing of two sets of yarn, the warp and weft yarns, at right angles.
“Plain Weave” refers to a type of weave wherein each warp yarn interlaces one yarn at a time with each weft yarn and vise versa. Plain weave fabric has the same appearance on both sides of the fabric.
“Twill Weave” refers to a type of weave wherein there are fewer interlacings between the warp and weft yarns than plain weave fabrics. Twill weaves are characterized by diagonal lines on the fabric.
Various aspects of the invention are presented in
According to an aspect of the invention, a composite fabric 10 for use in a conveyor belt 5 comprises a first weft sheet 30, a second weft sheet 40, a top warp yarn 1, a bottom warp yarn 2, and a binder yarn B.
The first weft sheet 30 is comprised of individual weft yarns W1-W3, wherein each yarn has an outer side 34 and an opposing inner side 36.
The second weft sheet 40 is also comprised of individual weft yarns W4-W6, wherein each yarn has an outer side 44 and an opposing inner side 46. The second weft sheet yarn inner side 46 is adjacent to the first weft sheet yarns inner side 36.
According to an aspect of the invention, a top warp yarn 1 extends at least in part between the first and the second weft sheet 30/40, and is at least in part woven around at least one first weft sheet yarn outer side 34.
According to an aspect of the invention a bottom warp yarn 2 extends at least in part between the first and the second weft sheet 30/40, and is at least in part woven around at least one second weft sheet yarn outer side 44.
The top warp yarn 1 does not weave around any second weft sheet yarns 40, and the bottom warp yarn 2 does not weave around any first weft sheet yarns 30.
The binder yarn B weaves alternately around a first weft sheet yarn outer side 34 and a second weft sheet yarn outer side 44.
According to a further aspect of the invention, the top warp yarn 1 extends around a single first weft sheet yarn outer side 34, and subsequently around two first weft sheet yarns inner sides 36, and repeats this weave pattern.
According to another aspect of the invention, the bottom warp yarn 2 extends around a single second weft sheet yarn outer side 44, and subsequently around two second weft sheet yarns inner sides 46, and repeats this weave pattern.
In a further embodiment, the top warp yarn 1 extends around a single first weft sheet yarn outer side 34, and subsequently around two first weft sheet yarns inner sides 36, and repeats this weave pattern, and the bottom warp yarn 2 extends around a single second weft sheet yarn outer side 44, and subsequently around two second weft sheet yarns inner sides 46, and repeats this weave pattern.
According to another aspect of the invention, a first weft sheet yarn having a top warp around its outer side (see W3) is adjacent to a second weft sheet yarn having a bottom warp around its outer side (see W4).
In a preferred embodiment, the top warp yarn 1 and the bottom warp yarn 2 weave through the first weft sheet 30 and the second weft sheet 40 respectively such that the resulting crimp is between 2%-5%.
This inventive composite fabric ply may be used in construction of a conveyor belt 5. The inventive fabric may be employed as the sole reinforcing structure in a belt or combined with other layers for multiple ply beltings. A conveyor belt 5 using this fabric may use just one ply of this composite fabric 10, or multiple plies. If multiple plies of this composite fabric 10 are used, they may be separated by plies of rubber 20, or other elastomeric material. In a further embodiment of the invention, the top and bottom layers of a conveyor belt are rubber plies 20 and composite fabric plies 10 are alternated throughout the construction. The number of plies and the combinations employed are dependent upon the desired application for the belting.
In another embodiment of the invention, the binder yarn B weaves at least around a first weft sheet yarn outer side 34, and a second weft sheet yarn outer side 44.
In a further aspect of this embodiment, the top warp yarn 1 extends around a single first weft sheet yarn outer side 34, and subsequently around three first weft sheet yarns inner sides 36, and repeats this weave pattern.
In a further aspect of this embodiment the bottom warp yarn 2 extends around a single second weft sheet yarn outer side 44, and subsequently around three second weft sheet yarns inner sides 46, and repeats this weave pattern.
According to another aspect of this embodiment, the first weft sheet yarn W1 having the top warp 1 around the first weft sheet yarn outer side 34 is adjacent to the second weft sheet yarn W5 having the bottom warp 2 around the second weft sheet yarn outer side 44.
In a further embodiment of this invention, the binder yarn B weaves around two adjacent first weft sheet yarn outer sides 34, and then a second weft sheet yarn outer side 44, and repeats this pattern.
This application claims the benefit of U.S. Provisional Application No. 61/414,944, filed Nov. 18, 2010.
| Number | Date | Country | |
|---|---|---|---|
| 61414944 | Nov 2010 | US |
