FABRIC FORMED BY THREE-DIMENSIONAL PRINTING PROCESS
The present invention is directed generally to fabrics, and more specifically to fabrics and belts employed in industrial processes.
1 . A method of manufacturing a fabric, comprising the steps of:
developing a three-dimensional model of a fabric; and
utilizing the three-dimensional model in an additive manufacturing process to build a fabric.
2 . The method defined in claim 1 , wherein the utilizing step comprises a multi-jet printing process.
3 . The method defined in claim 1 , wherein the fabric is based on a woven fabric structure.
4 . The method defined in claim 1 , wherein the fabric is based on a non-woven structure.
5 . The method defined in claim 4 , wherein the non-woven structure has at least one of: non-uniform hole sizes on the support surface with an open area of at least 15%; an internal void volume of 40-70%; and a higher mass distribution on the machine-side surface to provide mechanical stability and wear resistance.
6 . The method defined in claim 1 , wherein the fabric is produced in an endless loop without seaming, bonding or welding.
7 . The method defined in claim 1 , wherein the fabric comprises a digital alloy material.
8 . The method defined in claim 1 , wherein the fabric comprises a papermaker's fabric.
9 . The method defined in claim 1 , wherein the fabric comprises an industrial textile.
10 . A method of providing an enhanced support surface on an existing fabric, comprising the steps of:
developing a three-dimensional model of a support surface; and
utilizing the three-dimensional model in an additive manufacturing process to build a support surface on the existing fabric.
11 . The method defined in claim 10 , wherein the utilizing step comprises a multi-jet printing process.
12 . The method defined in claim 10 , wherein the enhanced support surface is based on a fine woven fabric structure.
13 . The method defined in claim 10 , wherein the enhanced support surface is a random distribution of support fibers or strands.
14 . The method defined in claim 10 , wherein the fabric comprises a digital alloy material.
15 . The method defined in claim 10 , wherein the existing fabric is a papermaker's fabric.
16 . The method defined in claim 15 , wherein the existing fabric is an endless coarse single layer base fabric.
17 . A method of providing an reduced drag wear surface on an existing fabric, comprising the steps of:
developing a three-dimensional model of a wear surface; and
utilizing the three-dimensional model in an additive manufacturing process to build a wear surface on an endless fabric.
18 . The method defined in claim 17 , wherein the fabric comprises a digital alloy material.
19 . The method defined in claim 17 , wherein the existing fabric is a papermaker's fabric.