Note: Descriptions are shown in the official language in which they were submitted.
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PROCESS BELT AND METHOD OF FORMING THE SAME
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent
Application No.
60/341,873, "Schmitt Seam," Maguire et al., filed December 21, 2001, the
contents of which
are incorporated herein by reference in their entirety.
1. Field of the Invention
[0002] The field of the invention relates to process belts and more
specifically, to process
belts used in manufacturing processes, e.g., the manufacture of pressed board
or other paper
products.
2. Background Information
[0003] Generally, process belts are used in the preparation of pulp or
materials in sheet or
non-woven fabric, such as paper or board, in the Paper or Board Making
Industry. Such
process belts are typically woven wire fabric formed into continuous or
endless belts by
brazing or welding. For example, end sections of such process belts are
generally brazed or
welded together to form a brazed or welded seam between the end sections of
the process
belt, thereby introducing a local stiffiiess at the seam.
[0004] However, brazing or welding typically degrades the strength and
malleability of the
wires adjacent the brazed or welded seam due to elevated temperatures. The
degradation can
result in premature failure of such process belts at or near the brazed or
welded seam, which
generally requires the process belt to be removed, repaired and reinstalled on
the paper
process machine or to be replaced with a new process belt.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The accompanying drawings, which are incorporated in and constitute a
part of the
specification, of embodiments of the invention, together with the general
description given
above and the detailed description of the embodiments given below, serve to
explain the
principles of the invention wherein:
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[0006] FIG. 1 is an illustrative view of a process belt having a seam
connecting a first end
of the process belt to a second end of the process belt in accordance with
principles of the
invention;
[0007] FIG. 2 is an enlarged illustrative view of the process belt shown in
FIG. 1, which
shows the seam in greater detail;
[0008] FIG. 3 is an exaggerated side view of the seam shown in FIG. 2;
[0009] FIG. 4 is an illustrative view of the seam shown in FIG. 2;
[0010] FIG. 5 is an illustrative view of another seam in accordance with
principles of the
invention;
[0011] FIG. 6 is an illustrative view of another seam in accordance with
principles of the
invention;
[0012] FIG. 7 is an illustrative view of another seam in accordance with
principles of the
invention;
[0013] FIG. 8 is an enlarged view of the seam shown in FIG. 7, which shows an
enlarged
section of the seam to better show certain portions thereof;
[0014] FIG. 9 is an illustrative view of another seam in accordance with
principles of the
invention;
[0015] FIG. 10 is a schematic view of the process belt operatively engaged
with a board
processing machine; and
[0016] FIG. 11 is a flow chart illustrating a method in accordance with the
principles of
the invention.
DESCRIPTION OF EMBODIMENTS OF INVENTION
[0017] FIGS. 1-4 show an embodiment of a process belt, generally indicated at
10, for use
in a board processing machine or other paper converting machine (FIG. 10) to
process a
board stock or other paper product. The belt 10 is referred to as a "process
belt" herein, but
can be used in processing both paper or board, oriented strand board, pressed
board or joists,
depending on the desired process. The process belt 10 comprises a body
portion, generally
indicated at 12, separating a first end section 14 and a second end section
16. The first end
section 14 and the second end section 16 form ends of the body portion 12. The
body portion
12 is only partially shown in FIG. 1. The first end section 14 is operatively
coupled to the
second end section 16 by a seam, generally indicated at 17, such that the body
portion 12, the
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first end section 14 and the second end section 16 are substantially
continuous with one
another and configured to operatively engage the board processing machine or
other paper
converting machine, as is further described below. The seam 17 can include at
least one
elongated resilient coupling filament 24 (FIGS. 2-4) to fixedly secure the
first and second end
sections 14, 16 to one another.
[0018] FIG. 2 shows the process belt 10 and the seam 17 in greater detail. As
illustrated,
the body portion 12 comprises a first plurality of elongated resilient
filaments 20 oriented in a
vertical (or first) direction. The vertical direction can be referred to as a
machine direction
and each elongated resilient filament 20 can be referred to as a warp
filament, for example.
The body portion 12 can also include a second plurality of elongated resilient
filaments 22
oriented in a horizontal direction (a second direction) transverse to the
vertical (or first)
direction. The horizontal direction can be referred to as a cross machine
direction and each
elongated resilient filament 22 can be referred to as a shute or weft
filament, for example.
[0019] The individual filaments 20, 22 can be woven together, for example,
using a
weaving machine, or may be weaved manually, to form the body portion 12.
Alternatively, a
single beam loom or a double beam loom can be used depending on the type of
weave pattern
chosen for the belt 10. In the particular weave pattern of the seam 17 shown
in FIG. 3, for
example, each vertically extending filament 20 can be woven around each
horizontally
extending filament 22.
[0020] A first plurality of looped segments 26 can be attached to the first
end section 14 of
the process belt 10, for example, by weaving, bonding or welding. For example,
each looped
segment 26 can include a first end 28, a second end 30 (FIG. 3) and a looped
section 32
extending between the first and second ends 28, 30. The looped section 32 can
be configured
to form a coupling filament receiving opening 33 therein (FIG. 3) configured
to receive the
coupling filament 24 therethrough. The first and second ends 28, 30 can be
attached to the
first end section 14 of the process belt 10, for example, by weaving (FIG. 3)
or bonding, such
as welding or fusing, so that the looped section 32 and the coupling filament
receiving
opening 33 outwardly extend away from the first end section 14. The weaving
can be
performed manually or mechaucally.
[0021] Similarly, a second plurality of looped segments 34 are attached to the
second end
section 16 of the process belt 10, for example, by weaving or bonding such as
welding or
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fusing. For example, each looped segment 34 can include a first end 36, a
second end 38
(FIG. 3) and a looped section 40 extending between the first and second ends
34, 36. The
looped section 40 forms a coupling element receiving opening 41 therein (shown
in
substantial alignment with the coupling element receiving opening 33 shown in
FIG. 3). The
first and second ends 34, 36 are attached to the second end section 16 of the
process belt 10,
for example, by weaving (FIG. 3) or bonding such as welding or fusing, so that
the looped
section 40 outwardly extends away from the second eud section 16.
[0022] During manual weaving of the looped segments 26, 34, the looped
segments 26, 34
may be distinguished from one another with markings, such as being painted
different colors,
for example. The distinguishing markings can help ensure that a sufficient
number of looped
segments 26 and 34 are attached to respective end portions 14, 16 of the belt
10.
[0023] To effect weaving of the looped segments 26, 34 into respective end
sections 14,
16 of the belt 10, holes may need to be formed in the existing belt 10. Such
holes, which may
be formed with a drill, an awl, a plasma arc cutter or other tool capable of
fornzing a hole in
the belt 10, can allow ends 28, 30 or ends 34, 36 of the respective looped
segment 26, 34 to
be woven into the belt 10, as described above, about the horizontally
extending filaments 22.
Such holes may also be formed by displacing the filaments 20, 22 to create a
space with no
need to drill or cut the belt 10 in any manner.
[0024] Alternatively, in another embodiment, one or both of the first and
second ends 28,
30 of the looped segment 26 can be bonded, for example, by welding or fusing,
to either the
vertically extending filaments 20 or the horizontally extending filaments 22.
Also, the first
end 28 can be bonded or fused to the second end 30 after the looped portion 32
has been
formed. The first and second ends 34, 36 of the looped segment 32 can also be
bonded or
fused to the vertically extending filaments 20, to the horizontally extending
filaments 22 or to
one another.
[0025] Each individual vertically extending filament 20, each horizontally
extending
filament 22 and the at least one elongated resilient coupling filament 24 can
be made from
carbon steel, stainless steel or other sufficiently hardened material, for
example, into solid
filaments as shown in FIG. 4. The filaments 20, 22, 24 can have equal or
different sized
diameters. Alternatively, each individual filament 20, 22, 24 can include a
plurality of
filaments braided or twisted together to form a braided or twisted filament.
Filaments 20,
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22, 24 can include different twist patterns, for example, a left-handed twist
or a right-handed
twist, to increase durability of the belt 10. Combinations of solid and
braided or twisted
filaments can also be used for the filaments 20, 22, 24.
[0026] Each filament 20, 22 and 24 can be coated, for example, to reduce
corrosion and/or
abrasion, through a coating process. The coating may be a low friction and
contaminant
resistant protective coating, for example, and may include brass or some other
hardening
(corrosion and abrasion resistant) material. The low friction and contaminant
resistant
protective coating can be applied by conventional coating techniques, such as
dipping or
continuously running the filaments through a bath. Alternatively, a batch
dipping can be
used.
[0027] FIGS. 2-4 show the looped segments 26, 34 in greater detail. As
illustrated, the
looped sections 32 and 40 ca~.i be aligned with one another such that the at
least one elongated
resilient coupling filament 24 can be received through the openings 33, 41
(FIG. 3). End
portions (not shown) of each coupling filament 24 can be bent in a cross
machine direction
(opposite to the side of the belt 10, which engages rollers during operation)
to help axially
position the coupling filament 24 in the horizontal or cross machine
direction.
[0028] The looped segments 26, 34 can be made from a sufficiently flexible
material, such
as soft stainless steel, or plasticized material, e.g., a plastic, a
synthetic, a thermoplastic or a
polymer. Other flexible materials can also be used, such as metal wire, sewing
wires, cables
wire or high tensile wires. The sufficiently flexible material can be more
flexible and softer
than the hardened material used to form the filaments 20, 22, 24. The
sufficiently flexible
material allows for formation of the looped sections 32, 40 described above
and may
determine whether respective ends of the looped segments 26, 32 are weaved,
bonded or
fused to the belt 10 or bonded or fused to one another.
[0029] Alternatively, as shown in FIG. 5, a process belt 110 can have a seam
117 formed
into a castellated configuration. For example, the belt 110 includes a
plurality of the body
portions 12, as described above. Each body portion 12 has a first set of the
elongated
resilient filaments (not shown) oriented in a vertical (or first) direction
located in a middle
portion 121 and respective edge portions 123, 125. Each body portion 12 also
has a second
set of the elongated resilient filaments (not shown) oriented in a horizontal
(or second)
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direction. The vertically and horizontally extending filaments can be
substantially similar in
construction and operation as the filaments 20, 22, respectively, described
above.
[0030] Adj acent body portions 12 can be operatively connected to one another
by the
seam 117 to form a continuous belt 110. The seam 117 is substantially similar
in
configuration and operation as the seam 17, and includes the looped segments
26, 32.
Because the edge portions 123, 125 do not operatively connect adj acent body
portions 12
together at the same plane as the middle portion 121, the seam 117 can be
referred to as
castellated.
[0031] In this embodiment, one or more (e.g., three) coupling filaments 24 can
be
provided to cooperate with the looped segments 26, 32 to one another. For
example, the
middle portion 121 of one body portion 12 can be operatively connected to a
corresponding
middle portion of another body portion 12 and each edge portion 123, 125 of
the one body
portion 12 can be operatively connected to corresponding edge portions 123,
125 of the other
body portion 12. In this regard, the middle portion 121 and edge portions 123,
125 of one
body portion 12 substantially act as a first end section 14 and the middle
portion 121 and
edge portions 123, 125 of an adjacent body portion 12 substantially act as a
second end
section 16.
[0032] The middle portion 121 or the edge portions 123, 125 can include equal
or different
numbers of individual filaments 20, 22 of equal or different diameters. Each
edge portion
123, 125 may extend about 4-8 inches in width in the cross machine direction
of the belt 110
and about 6-18 inches in length in the machine direction of the belt 110.
Other numbers of
filaments and configurations are possible for each portion 121, 123, 125 and
the number and
configuration of each group may differ from portion to portion of the
different body portions
12.
[0033] Although FIG. 5 shows three castellated seams 117, more or less seams
117 can be
used in the belt 110. The castellated seam 117 allows for independent
replacement of a
particular body portion 12, without having to replace the entire belt 110. The
castellated
seam 117 also can reduce localized stress of the belt 110 during a board
processing machine
or other paper converting maclune operation, which can increase the life of
the belt 110. For
example, if one body portion 12 becomes worn or damaged after repeated use,
the body
portion 12 could be replaced without having to replace the entire belt 110.
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[0034] The seam 117 can be used to replace the seam 17 shown in FIG. 1. The
castellated
seam 117 allows for independent replacement of a particular portion of the
seam 117, without
having to replace the entire seam. For example, if one edge portion 123 or 125
would
become worn or damaged after repeated use, the edge portion 123 or 125 could
be replaced
leaving the middle portion 121 and the other edge portion
unrepaired/unreplaced.
[0035] In either seam 17 or 117, the coupling filament 24 can form a
continuous seam
between the end sections 14, 16 so that the belt 10, 110 can be continuous or
endless. To
help increase the strength of the continuous seam, more than one coupling
filament 24 can be
used to form the continuous seam between the end sections 14, 16, as described
above,
depending on the process.
[0036] Seams 17, 117 have been described above as having looped segments 26
and 32
that cooperate with one or more coupling filaments 24. FIGS. 6-9 illustrate
alternative ways
of attaching first and second ends 28, 30 and 34, 36 of looped segments 26, 32
to a respective
end section 14, 16 of a process belt.
[0037] For example, FIG. 6 shows a portion of a seam 217, which is variation
of the seam
17, attached to one end section 14 of a process belt 210. The belt 210 is of
the woven type
with a plurality of vertically extending filaments 220 woven about a plurality
of horizontally
extending filaments 222. Different weave patterns or alternative
configurations of the belt
210 could also be used.
[0038] Although the seam 217 includes looped segments 226, 232, only looped
segment
226 is shown in FIG. 6. Since looped segments 226, 232 are substantially
similar in
construction and operation to looped segments 26, 32, the description of
looped segment 226
will suffice for looped segment 232.
[0039] One end 228 of the looped segment 226 is attached to the end section 14
of the belt
210, at a first horizontally extending fila.~nent 222. The opposite end 230 of
the looped
segment 226 is attached to the end section 14 of the belt 210, at a different
horizontally
extending filament 222 as the end 228. By attaching the ends 228, 230 to
different
horizontally extending filaments 222, stress can be distributed and strain can
be reduced on
the seam 217 and the belt 210. To further distribute stress and reduce strain,
adjacent looped
segments 226 can have respective ends 230 attached to different horizontally
extending
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filaments 222. In this manner, adj acent ends 230 of the looped segments 226
are staggered so
that every other end 230 is attached to the same horizontally extending
filament 222.
[0040] Alternatively, adjacent groups of looped segments 226 can have
respective ends
230 contacted with different horizontally extending filaments 222, with looped
segments of
each group having an end 230 contacted with the same horizontally extending
filament 222.
[0041] In this embodiment, ends 228, 230 can be_ attached to one or more
horizontally
extending filaments 222 by weaving one or both of the ends 228, 230 about one
or more
horizontally extending filaments 222 or by bonding, such as welding or fusing,
to one or
more horizontally extending filaments 222. Alternatively, the ends 228, 230
can extend
through holes formed between adjacent filaments 220, 222 and can be bonded
together, for
example. In this configuration, the ends 228, 230 need not be attached to the
belt 210, but
rather the attachment of the ends 228, 230 to the belt 210 can be effected by
the engagement
of the ends 228, 230 with the filaments 220, 222. For example, the ends 228,
230 can be
fixedly secured to either the belt 210, the filaments 220, the filaments 222
or to one another.
[0042] FIGS. 7-8 show a seam 317, which is variation of the seam 17, which
operatively
couples end sections 314, 316 of a process belt 310. The belt 310 is of the
woven type with a
plurality of vertically extending filaments 320 woven about a plurality of
horizontally
extending filaments 322. Different weave patterns or alternative
configurations of the belt
310 could also be used.
[0043] FIG. 8 shows looped segments 326, 332 of the seam 317 in greater
detail, but only
a portion of the looped segment 326 is shown. Since looped segments 326, 332
are
substantially similar in construction and operation to looped segments 26, 32
described
above, the description of looped segment 332 will suffice for looped segment
326.
[0044] Each looped segment 332 has ends thereof bonded, fused or connected
together so
that each looped segment 332 substantially forms a oo shape. Each looped
segment 332
includes an end portion 334, a connecting portion 335 that connects one end of
the end
portion 334 to one end of an opposite end portion 336 and a connecting portion
337 that
connects another one end of the end portion 336 to the other end of the end
portion 334.
[0045] In this embodiment, the end portion 334 is formed to have a generally
arcuate
configuration to receive a coupling filament 24 therethrough. The end portion
334 receives a
coupling filament 24 in a similar manner as described above with respect to
coupling filament
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receiving opening 41, for example. The connecting portion 335 extends from the
end portion
334 over a plurality of horizontally extending filaments 322 before extending
below a
plurality of horizontally extending filaments 322 away the coupling filament
24 to connect to
one end of the end portion 336. The end portion 336 is formed to have a
generally arcuate
configuration to contact a selected horizontally extending filament 322. The
connecting
portion 337 extends from the end portion 336 over a plurality of horizontally
extending
filaments 322 before extending below a plurality of horizontally extending
filaments 322
away the coupling filament 24 to connect to one end of the end portion 334.
[0046] When the comzecting portion 335 extends from one end the end portion
334 over a
plurality of horizontally extending filaments 322, the connecting portion 337
extends below
the same plurality of horizontally extending filaments 322 to connect to
another end of the
end portion 334. Similarly, when the connecting portion 335 extends below a
plurality of
horizontally extending filaments 322, the connecting portion 337 extends from
one end of the
end portion 336 above the same plurality of horizontally extending filaments
322. Because
of this intersection, each looped segment 332 can be referred to as being in a
oo shape.
[0047] To distribute stress and reduce strain on the belt 310, adjacent looped
segments 332
can have respective end portions 336 contacted with different horizontally
extending
filaments 322, as shown in FIG. 8. Alternatively, adjacent groups of looped
segments 332
can have~respective end portions 336 contacted with different horizontally
extending
filaments 322, with looped segments of each group having an end portion 336
contacted with
the same horizontally extending filament 322.
[0048] FIG. 9 shows a belt 410, which is substantially similar in construction
and
operation as the belt 10 shown in FIG. 1, but with certain vertically
extending filaments 20
removed from the belt 410. Some vertically extending filaments 20 can be
removed from the
belt 410 to allow easier formation of the seam 17, for example. With some
vertically
extending filaments 20 removed, looped segments, such as looped segments 26,
32 shown in
FIG. 1, for example, can be attached to the belt 410. Ends of the looped
segments can be
woven about the plurality of horizontally extending filaments 22 to attach the
looped
segments to the belt 410. The removal of some vertically extending filaments
20 can
eliminate the need to form holes in the belt 410 prior to attachment of the
looped segments.
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[0049] As illustrated, the vertically extending filaments 22 are grouped in
groups of five
filaments. In each group 412, every third and fifth vertically extending
filament 22 (as shown
left to right in FIG. 9) is removed from the belt 410, thus leaving the first,
second and fourth
vertically extending filaments 22 to form sufficient support in the machine
direction for the
belt 410. Other configurations are possible and can be used as well. For
example, each
group can include more or less filaments, each group can include equal or
different numbers
of filaments or different filaments from each group can be removed.
[0050] FIG. 10 shows the process belt 10 operatively engaged with a processing
machine,
which can be a board processing machine or other paper converting machine,
generally
indicated at 500, for example in a paper production facility. In general, the
board processing
machine 500 includes a plurality of belts suspended from a plurality of
rollers, some of which
can be driven, to effect transport of paper or board material or stock from
one point in the
production facility to another.
[0051] As illustrated in this embodiment, the board processing machine 500 is
a pressed
board machine configured to process press board. In this embodiment, the board
processing
machine 500 can include the process belt 10 trained around a series of
processing rolls 502
and another process belt 504 which together pull a board product or other
paper product (not
shown) therethrough. The board product can include two or more boaxd layers,
which are to
be joined to one another by a suitable adhesive in the board processing
maclune 500. The
board layers are brought together at one end of the board processing machine
500 and are
pulled across a hot roll 506 (or a series of hot plates) by the belts 10, 102
to dry and/or to cure
the adhesive which bonds the board layers together. A belt 508 operatively
associated with
the hot roll 506 can carry the finished board product to another part of the
paper production
facility.
[0052] The boaxd processing machine 500 is not limited to pressed board
machines, but
can be any processing machine capable of exerting high machine speeds or high
stresses onto
the belt and requiring a high number of operational cycles. For example, the
board
processing machine 500 may be able to process oriented strand boards or joists
in addition to
pressed board.
[0053] FIG. 11 shows a flow chart illustrating a method of manufacturing a
process belt
for use in a board processing maclune to process a board stock or other paper
product. The
method starts at 600. At 602, a body portion of the process belt is formed to
have a first end
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section and a second end section. The body portion can be formed in many ways,
one of
which includes positioning a first plurality of elongated resilient filaments
in a first direction
and positioning a second plurality of elongated resilient filaments in a
second direction
transverse to the first direction. The first plurality of elongated resilient
filaments and the
second plurality of elongated resilient filaments can be woven together in a
conventional
manner, for example, manually or mechanically, in any known weave pattern or
may be
bonded or fused together.
[0054] At 604, at least one first looped segment is attached to the first end
section of the
process belt and at least one second looped segment is attached to the second
end section of
the process belt. The first and second looped segments extend between the
first end section
and the second end section of the process belt and can be aligned to receive
at least one
coupling filament therethrough. The first and second looped segments can be
attached to the
first and second end sections of the process belt in various ways, for
example, by weaving or
bonding as described above with respect to FIGS. 1-9. Other ways of attaching
the first and
second looped segments to the respective first and second end sections of the
process belt can
be used as well.
[0055] At 606, at least one coupling filament operatively connects the first
end section to
the second end section. For example, the coupling filament can be inserted,
for example,
manually or mechanically, through the first and second looped segments to form
a continuous
seam between the first end section, the second end section and the body
portion. That way,
the first end section, the second end section and the body portion are
substantially continuous
with respect to one another. End portions of the coupling filament can be bent
over a number
of the first and second looped segments to fixedly secure the coupling
filament within the
first and second looped segments. At 608, the method ends.
[0056] While the present invention has been particularly shown and described
with
reference to the preferred embodiments thereof, it will be understood by those
skilled in the
art that various changes in form and details can be made therein without
departing from the
spirit and scope of the invention.
[0057] Thus, the foregoing embodiments have been shown and described for the
purpose
of illustrating the functional and structural principles of this invention and
are subject to
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change without departure from such principles. Therefore, this invention
includes all
modifications encompassed within the spirit and scope of the following claims.
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