The present invention relates generally to the joining of woven fabrics to render them endless. More particularly, the invention relates to joining papermakers to render them as an endless belt on the papermaking equipment. Most particularly, the present invention relates to joining woven papermakers dryer fabrics by interleaving complementary projections and recesses on each end of the fabric and inserting a retaining means into a channel formed in the cross machine direction.

It is known to join woven fabrics in order to render them endless. Likewise, it has been known to join woven fabrics through the use of complementary projections and recesses which are interleaved to define a channel into which a retaining means is inserted. As will be appreciated by those skilled in the art; the prior art has developed a number of techniques for producing the complementary projections and recesses which are interleaved and a number of techniques for producing the cross machine direction channel(s) into which the retaining means is/are inserted. It has been recognized by the art that the join area should, to the extent possible, duplicate the weave pattern, caliper, permeability and interstice configuration of the fabric. Efforts to accomplish such a seam configuration have produced techniques in which yarns are woven back into the fabric in an effort to create complementary ends having a substantially uniform construction with than of the remainder of fabric. In addition, techniques have been developed for folding the end of the fabric back and forming interleaving projections.

Another technique for forming a join is disclosed in GB-A-1259287. This reference teaches joining a woven fabric by cutting back alternate warp filaments on one end of a fabric, and cutting back warp filaments on the opposite end of the fabric in a complementary pattern. The weft filaments in the join area at each fabric end are then removed, leaving only the alternating warp ends which were not cut back. The fabric ends are then moved to place the warps ends into interfitting relationship, such that the corresponding and complementary warp filaments in each end portion of the fabric abut one another. Replacement weft yarns are then manually interwoven with the warp ends to form the join. The abutting warp ends are bonded together and, if desired, the warp and weft yarns in the join area are bonded together with an adhesive.

In all of the known prior art techniques, the process may be labor intensive and/or produce a seam which does not have the same caliper as the remainder of the fabric or does not share other fabric characteristics with the remainder of the fabric.

As a result of the above, efforts were undertaken to produce a join area which, except for the retaining means, was formed entirely from the fabric as woven. In addition, the efforts were directed toward preserving the fabric construction, caliper and operating characteristics throughout the seam area. Still further, it was concluded that the desired seam would not require a doubling or folding back of the fabric end.

The present invention provides an endless papermakers felt which is formed from a length of woven fabric. The fabric consists of interwoven machine direction and cross machine direction yarns having interleaving joining means at each end which are joined together to form the endless belt. The improvement is characterized by projections formed entirely from the original woven fabric with both the machine and cross machine direction yarns of the projections retained in their original woven orientation and position. Each of the projections has a cross machine direction void at least one yarn position back from the end of the projection, with each void being formed in a complementary position to the void in the opposing projections. The joined area maintains all of the woven characteristics of the fabric and is substantially identical to the remainder of the fabric.

In addition to the above, the present invention provides a method for preparing the fabric ends. In the method of the invention, each end of the woven fabric is trimmed to establish a maximum fabric length and to provide a true cross machine direction edge on each end of the fabric. Each cross machine direction edge is parallel to the last cross machine direction yarn on the respective edge. After formation of the edge of the fabric with a true cut, at least one cross machine direction yarn is removed from each end of the fabric. The removed yarns are positioned at least one cross machine direction yarn from the respective fabric edge and create a cross machine direction void on the respective fabric edge. A plurality of alternating projections and recesses are formed on each end of the fabric. The alternating projections and recesses are formed on the respective ends so that they will complement each other and the cross machine direction void at each respective end is at substantially the same distance from the respective edge.

A further method of seaming a fabric having its ends prepared in accordance with the above method is also provided. The projections and recesses of the fabric ends are interleaved to form an uninterrupted linear continuation of the original woven fabric and to align the cross machine direction voids. After the voids have been aligned, retaining means are inserted in the cross machine direction to render the fabric endless.

Figure 1 is a perspective view of a section of woven fabric prior to its preparation in accordance with the invention.

Figure 2 is a top plan view of a section of fabric as illustrated in Figure 1.

Figure 3 is a top plan view similar to that of Figure 2 and shows the removal of a cross machine direction yarn.

Figure 4 is a top plan view of a fabric according to the present invention prior to being joined and retained as an endless fabric.

Figure 5 is a perspective illustration of the fabric as shown in Figure 4.

Figure 6 is a top plan view illustrating the fabric in its joined configuration.

Figure 7 is a top plan view illustrating the fabric in position for the formation of a true cut.

Figure 8 illustrates one device for forming the fabric ends in accordance with the present invention.

Figure 9 illustrates a rotary device for further preparing the fabric edge in accordance with the present invention.

Figure 10 illustrates a non-rotary device for preparing the ends of the fabric in accordance with the present invention.

Figure 11 illustrates one potential pattern for preparing the fabric ends in accordance with the present invention.

Figure 12 illustrates one suitable retainer means for joining the fabric.

This description of the preferred embodiment will be made with reference to the attached drawings and like elements are identified by the same numeral throughout. In describing the preferred embodiment, the illustrative fabric is a flat woven fabric which is more fully described in International Application Number PCT/US 91/01776 which was filed on March 15, 1991 with a designation for Canada and is assigned to the common assignee. It will be understood by those skilled in the art that the fabric weave is illustrative and does not form a limitation of the present invention. Likewise, it will be understood by those skilled in the art, after a full review of the description set forth hereinafter, that the fabric must be comprised of bondable or thermoplastic yarns.

Turning to Figure 1, the fabric is constructed of synthetic, thermoplastic monofilament yarns. In the illustrated configuration, the upper machine direction yarns 16 and the lower machine direction yarns 18 have a non-circular or flattened profile. The machine direction yarns are woven so that paired upper and lower yarns are stacked in the same relative vertical alignment throughout the body of the fabric. The cross machine direction yarns system is comprised of alternating yarns 12 and 14. As illustrated in Figure 1, the cross machine direction yarn 14 is of a smaller diameter than cross machine direction yarn 12. As a result, the caliper of the fabric is substantially consistent throughout its length despite the fact that the machine direction yarns 16 and 18 both interweave at the same position with yarn 14. By way of example, the cross machine direction yarn 12 may be about 0.8 mm and the cross machine direction 14 may be about 0.6 mm.

With reference to Figures 1 and 2, the preparation of the ends of the fabric will be discussed in more detail. As will be appreciated by those skilled in the art, the drawing figures represent a portion of the weave for the sake of clarity. The actual fabric will have a length that is at least as long as the maximum length of the desired finished fabric. Each end of the fabric length will be prepared in a similar fashion. Accordingly, the discussion of one fabric end will apply equally to that of the other fabric end, unless otherwise described. As shown in Figures 1 and 2, the fabric has been trimmed so as to establish the maximum length of the fabric and to provide a cross machine direction edge which is parallel to the last cross machine direction yarn 12. In the present construction, it is preferred to trim the fabric in this manner since the cross machine direction yarn 12 is in direct contact with the machine direction yarns from both the upper and lower systems. However, if desired, the fabric could be trimmed parallel to the cross machine direction yarn 14. As shown in Figures 1 and 2, the thermoplastic nature of the machine direction yarns will result in the formation of a bond areas as shown at 20 and 22. With reference to Figure 2, the bond areas will continue along the cross machine direction edge of the fabric and will bond each of the machine direction yarns 16 and 18 to the same cross machine direction yarn 12. The trim location can also be adjusted to cause the ends of the machine direction yarns 16 and 18 to bond to each other, capturing the last MD yarn 12. The apparatus and method for preparing the end of the fabric as shown in Figures 1 and 2 will be described hereinafter.

With reference to Figure 3, the description of seam formation will be continued. After the fabric has been true cut, at least one cross machine direction yarn is removed from each end of the fabric. The removal of the cross machine direction yarn results in the creation of a cross machine direction void. - In the present fabric construction, it is preferred that one of the larger cross machine direction yarns 12 be the removed yarn. In addition, it is preferred that the removed yarn be spaced from the cross machine direction edge of the fabric by at least one cross machine direction yarn.

It will be appreciated by those skilled in the art that the cross machine direction yarn may be removed prior to forming the cross machine direction edge. However, it is presently believed that the additional stabilization which results from formation of the cross machined direction edge will facilitate the removal of the yarn and will help to stabilize the fabric during yarn removal.

Referring to Figure 4, there is illustrated the ends 30 of the fabric prior to interleaving in order to form the endless fabric. Although each end of the fabric is identified as 30, the projections and recesses on the opposed ends of the fabrics have been identified by different numerals in the interest of clarity. As can be seen from Figure 4, the recesses 32 will be positioned opposite the projections 36. Likewise, the recesses 38 which alternate with the projections 36 will be positioned opposite the projections 34 which alternate with the recesses 32. This manner of interleaving is well known in the art. When the two fabric have been interleaved, the cross machine direction voids 28 will be aligned. Likewise, the cross machine direction yarn segments 12 and 14 from each of the respective ends will be aligned.

With reference to Figure 5, there is shown a partial orthographic view of the fabric prior to interleaving. Also shown in Figure 5, in a schematic manner, is the remaining portion of the fabric which will extend from each of the portions. Since those skilled in the art will understand that the weave continues throughout the body of the fabric, there is no need to illustrate the full weave pattern as it extends throughout the fabric. As can be seen from Figure 5, the cross machine direction voids 28 will be spaced from the cross machine direction edge of the fabric by one cross machine direction yarn 14 and one cross machine direction yarn 12. Likewise, the cross machine direction voids 28 will be spaced in the center of the recesses 32 and 34. Accordingly, each of the projections will include a cross machine direction yarn 12 and 14 on either side of the cross machine direction voids 28.

As can be seen from Figure 5, the thermoplastic nature of the yarns will result in material bond between the machine direction yarns 16 and 18 and the cross machine direction yarns 12 and 14. This is generally illustrated by the numeral 40 in Figure 5. It will be appreciated by those skilled in the art that this bonding is localized and that it will not produce deformation in the fabric construction or interference with the projections and recess. As explained in more detail hereinafter, current techniques for producing the fabric will permit the formation of the projections and recesses within very close tolerances. In addition to the machine direction edge bonding which is illustrated at 40, there is additional cross machine direction bonding which takes place between the cross machine direction yarn and the machine direction yarns as illustrated at 42. As can be seen in the illustration of Figure 5, the machine direction yarns 16 and 18 are weaving on the same side of the cross machine direction yarn 14 in the illustration of Figure 5. Due to the illustrated weave construction, both of the machine direction yarns will be bonded on the same side of the cross machine yarn 14.

Referring now to Figure 6, a top plan partial view of the assembled fabric, assembly of the seam will be discussed. As noted previously, the projections 34 and 36 are interleaved to align the cross machine direction voids 28. After alignment, retaining means 50 is inserted into the cross machine direction void and the fabric is rendered endless. The use of such a pintle 50 will be well known to those skilled in the art. It will also be recognized by those skilled in the art that pintle 50 should be selected to compliment the fabric weave. It is also known to use a metal lead wire to insert and guide the pintle 50 into the void. In the present application, the use of such a lead wire has been found to be of particular advantage. Although the cross machine direction voids 28 are generally undisturbed by the processing of the fabric, it is possible to experience small variations in the void due to material flow or realignment. Accordingly, the use of a thin lead wire will permit an easy insertion. In addition, the use of a conical or funnel like ferrule to connect the lead wire and the pintle will further assist insertion of the pintle. The geometry of one acceptable pintle is shown in Figure 12.

Still with reference to Figure 6, it can be seen that the machine direction yarns 16 are aligned in the seam area. Although not visible in this view, the machine direction yarns 18 are also aligned. Likewise, the cross machine direction yarns 12 and 14 are aligned in the seam area. As noted previously, pintle 50 is approximately the same size as cross machine direction yarn 12. As can be seen from an examination of the seam area, it will have the same repeat characteristics as the remainder of the fabric. However, the seam area will have machine direction gaps between the projections 34 and 36. It will be obvious to those skilled in the art that the machine direction gaps 52 result from the removal of the cross machine direction yarn segments during preparation of the fabric ends. Likewise, the cross machine direction gaps 54 result from the removal of machine direction yarn segments during formation of the recesses. It will be appreciated by those skilled in the art that the gaps between the projections 34 and 36 will vary with the fabric weave and Figure 6 is only illustrative of the resulting configuration. Likewise, it will be appreciated that the gaps 52 and 54 maybe beneficial since they permit free movement of the yarn without interference between and among the bonding points 20, 22, 40 and 42.

With reference to Figures 5 and 6, it can be seen that the endless fabric will have the same continuous weave pattern throughout its length, that the caliper of the fabric will not be altered, that the loops at each end of the fabric are formed entirely from and are a linear continuation of the original woven fabric and that there are no elements added to the fabric as part of the formation of the seaming loops. The insertion of a pintle as a joining expedient is a substitution for the removed cross machine direction yarn. If so desired, one of the removed cross machine direction yarns may be reinserted as the pintle. At present, the use of a pintle 50 is preferred.

With references to Figures 6 through 11, the formation of the projections and recesses will be more fully described. It will be appreciated by those skilled in the art that I prefer to establish a regular cross machine direction edge on each end of the fabric 10. At present, the formation of these preliminary edges is achieved by selecting a cross machine direction yarn, marking that yarn and then cutting the fabric parallel to that yarn. The cut may be either purely mechanical or a mechanical cut aided by heat or a thermal cut such as by ultrasonics or lasers. After the initial cut on each end has established the reference cross machine direction yarn, the fabric is prepared for the establishment of a true cross machine direction cut on each end.

In order to establish the spacing and desired yarn orientation, the fabric 10 is presented to a cutting table. As shown in Figure 7, the previously trimmed fabric is presented against the side of a bar 60 which establishes a cross machine direction reference point. At that point, a cross machine direction yarn is selected as the location of the true cut. The fabric 10 is marked, 64, along that cross machine direction yarn. The cross machine direction marking 64 will become the true cut. The true cut may be made by means of a laser which is optically guided along the marking 64 or by other means such as a sharp hot knife or the like. In any event, it is preferred that the true cut be accomplished by a means which includes the generation of heat which is sufficient to cause a softening or flow of the material without a deformation thereof. As will be appreciated by those skilled in the art, the desired temperature will vary according to the selected yarn materials. In any event, the cut must be a clean cut which will establish a cross machine direction edge which is parallel to the last cross machine direction yarn. If the yarns are not maintained parallel to each other, it is very possible that the final formation of the projections 32 and 34 will result in irregular alignment of the yarns when they are interleaved and pintled.

At present, the preferred technique for establishing the fabric end 64 is a laser cut under computer control. With reference to Figure 11, there is illustrated a pattern which may be followed by the computer in accomplishing the desired cuts. By using a single control pattern and two independently operating cutting means the laser will control the cutting means so as to make the recesses and projections at the same time. For straight line cutting a single straight line pattern will still control both cuts. This should aid in creating uniformity of cut and match.

Turning now to Figure 8, there is shown a computer controlled laser cutting apparatus 100 which will accomplish both the true cut edges and the formation of the opposed projections and recesses. The apparatus 100 has a fabric support table 102 and fabric positioning rolls 104 which assist in addressing the fabric around the table. Each end of the fabric is addressed to a side of the bar 60. Bar 60 extends across the table, which is preferably of a width greater than the width of the fabric, and provides a true edge. The fabric is positioned against the bar and the true cut marking 64 is established along the cross machine direction yarn. The fabric is held in position by clamps 106. The clamps 106 are spaced from the bar 60 by a sufficient distance to permit easy operation in the seaming area while relieving the seam area from tension which is associated with the weight of the fabric hanging over the rollers 104. The true cut edge 64 may be accomplished in a number of ways. One way to accomplish the edge cut is to position the laser guns 116 and 118 with the respective cutting points 120 and 122 on the true cut marks 64. The lasers may be guided by a pattern or may be optically guided along the marks 64 as they traverse the cross machine direction.

As can be seen from Figure 8, the laser cutting tools depend from the arm 114 and are adjustable with respect to the positioning of the cutting point 120 or 122 as shown by the arrows on arm 114. The arm 114 is adjustable in the vertical plane as indicated by the arrows adjacent housing 112. Housing 112 supports the arm 114 and encases the control means for generating the laser beams and positioning the lasers. The movement of housing 112 is controlled by a computer in accordance with the fabric design parameters. The control output from the computer is applied via the input 113 to the control housing 112. In light of the various fabric constructions, it is believed that computer control will provide more variability with respect to meeting the various fabric configurations. The cutting apparatus 110 is mounted on a pair of rails 110 which are of equal length with the table. This will permit the cutting apparatus to continue its movement in the cross machine direction and thereby avoid the possibility of introducing errors by stopping the cutting operation or moving the fabric. It will be appreciated by those skilled in the art that the table 102 and the cutting apparatus will be suitably mounted for stability. However, the embodiment shown in Figure 8 includes a moveable arm 108 which is intended to swing away from the table 102 and to permit free access to the fabric as a means of improving the alignment operation.

As noted previously, it is highly desirable to establish the bonds 20 and 22 as shown in Figure 1. While it is expected that the majority of such bonds will be formed as a result of the cutting operation, it has been concluded that the bond should not be left to chance. Accordingly, the true cut edge 64 is subjected to a further bonding step. There are two approaches to this bonding step. The first approach is depicted in Figure 9. In Figure 9, two oppositely turning rollers, 70 and 72, are applied against the true cut 64 of the fabric. Each of the rollers is heated and is particularly configured to the geometry of the fabric. The rollers 70 and 72 have base portions which meet and form a planar surface against which the true edge 64 is abutted. Each roller has an interior portion 74 which is on center line with the base but has a radius which is reduced by the distance 78. The distance 78 is substantially equal to one half of the fabric gauge. Extending between the interior portion 74 and the base of the rollers is the curvilinear portion 76. As can be seen from Figure 9, the rollers 70 and 72 present a continuous interface which maintains the gauge of the fabric and urges the edges of the machine direction yarns 16 and 18 against the side of the cross machine direction yarn 12. This establishes good bonding and a regular true cut edge. With reference to Figure 10, a second device for accomplishing the preferred bonding is illustrated. With the device shown in Figure 10, the plates 80 and 82 are heated plates which will permit local application to accomplish the desired bonding. The faces 84 and 86 of the plates are configured to establish the desired geometry for the true edge of the fabric as previously described in connection with Figure 9. In the embodiment of Figure 10, the plates 80 and 82 may be separated by vertical movement as a means of allowing the device to be placed in smaller areas or areas where a continuous movement in the cross machine direction is not possible. Accordingly, a device such as that shown in Figure 10 may be used for insertion into the recesses 32 so as to assure the efficiency of the bond 42, see Figure 5. It will be understood by those skilled in the art that the size and geometric configuration of the plated 80 and 82 may be altered in light of the fabric construction. In general, the use of a device such as that shown in Figure 9 is preferred for the true cut. However, if so desired a device of the type shown in Figure 10 may be progressively moved in the cross machine direction to accomplish a similar result.

With reference to Figure 12, there is shown a preferred pintle assembly 130. The pintle assembly 130 includes a lead wire 132 which is smaller than the desired pintle 50. The lead wire 132 and the pintle 150 are joined by the conical ferrule 132. As noted previously, insertion of the pintle 50 with the assistance of such a lead wire and ferrule are known in the art. However, it is believed that the configuration as shown in Figure 12 is particularly desirable in the event that the cross machine direction void 28 has been somehow compressed.

Although a computer guided, laser cutting apparatus has been described, it will be appreciated by those skilled in the art that other cutting devices may be used to prepare the ends of the fabric. The critical consideration in preparing the ends of the fabric is to establish the existence of a true cut along with the bonding areas so as to provide a fabric structure of sufficient strength to permit joining of the ends of the fabric without the need for additional elements while preserving the continuous linear weave construction throughout the loops.