Patent Application

App. No. 13/534,353

Abstract

Claims (23)

1 . A fiber cement felt comprising:

a base fabric layer including MD and CMD yarns interwoven with each other, wherein the CMD yarns comprise twisted monofilaments; and

at least one batt layer overlying the base fabric layer.

2 . The fiber cement felt defined in claim 1 , wherein the MD yarns comprise spunbond-multifilament hybrid yarns.

3 . The fiber cement felt defined in claim 1 , wherein the twisted monofilament yarns are substantially free of spunbond material.

4 . The fiber cement felt defined in claim 1 , wherein the MD yarns and CMD yarns are interwoven in a plain weave pattern.

5 . The fiber cement felt defined in claim 1 , wherein the twisted monofilaments have a structure selected from the group consisting of: 0.3×2×3; 0.3×2×4; 0.3×3×3; 0.2×3×4; and 0.2×3×5.

6 . The fiber cement felt defined in claim 1 , wherein the CMD yarns have a size of between about 200 and 800 tex.

7 . A method of forming a fiber cement article, comprising the steps of:

(a) providing a fiber cement felt, the fiber cement felt comprising:

a base fabric layer including MD and CMD yarns interwoven with each other, wherein the CMD yarns comprise twisted monofilaments; and

at least one batt layer overlying the base fabric layer;

(b) positioning the fiber cement felt on a series of support rolls of a fiber cement forming machine;

(c) depositing a fiber cement slurry on the fiber cement felt; and

(d) removing moisture from the slurry to form a fiber cement web.

8 . The fiber cement felt defined in claim 7 , wherein the MD yarns comprise spunbond-multifilament hybrid yarns.

9 . The fiber cement felt defined in claim 7 , wherein the twisted monofilament yarns are substantially free of spunbond material.

10 . The fiber cement felt defined in claim 7 , wherein the MD yarns and CMD yarns are interwoven in a plain weave pattern.

11 . The fiber cement felt defined in claim 7 , wherein the twisted monofilaments have a structure selected from the group consisting of: 0.3×2×3; 0.3×2×4; 0.3×3×3; 0.2×3×4; and 0.2×3×5.

12 . The fiber cement felt defined in claim 7 , wherein the CMD yarns have a size of between about 200 and 800 tex.

13 . A fiber cement felt comprising:

a base fabric layer including MD and CMD yarns interwoven with each other, wherein the CMD yarns comprise twisted monofilaments having a size of between about 200 and 800 tex, and wherein the MD yarns have a size of between about 1000 and 5000 tex; and

at least one batt layer overlying the base fabric layer.

Assignments (10)