Embossed fabrics and method of making the same

Abstract

An industrial process fabric is embossed in a device, such as a continuously operating two-roll calender having a preselected embossing pattern. The roll(s) of the calender may alternatively themselves be engraved or etched to provide the embossing. Embossing takes place with controlled temperature, pressure, speed and gap (between the rolls) settings. The fabric may be a forming, press, dryer or TAD fabric used in paper and pulp production, pulp forming fabric or an engineered fabric used to produce nonwoven textile products by meltblowing, spunbonding, hydroentangling or air laid needle punching.

What is claimed is:  
     
         1 . A method for embossing an industrial process fabric in an endless loop which functions in the manner of a conveyor in making paper and paper related products or nonwoven textiles, said method comprising the steps of: 
 providing a device having two opposed elements between which said fabric may be compressed at a preselected level of compression for a preselected time interval;    providing at least one of said two elements with an embossing medium having a preselected embossing pattern;    providing an industrial process fabric; and    compressing said fabric between said two opposed elements of said device at said preselected level of compression for a preselected time interval to emboss said industrial process fabric with said preselected embossing pattern.    
     
     
         2 . The method as claimed in  claim 1  wherein said device is a two roll calender having a first roll and a second roll with an embossing medium on at least one roll of the calender.  
     
     
         3 . The method as claimed in  claim 2  wherein said embossing medium comprises an engravement or etching on at least one roll of the calender.  
     
     
         4 . The method as claimed in  claim 3  wherein at least one roll of the calender includes a polymeric roll surface.  
     
     
         5 . The method as claimed in  claim 3  wherein both rolls of the calender are engraved or etched so as to provide embossments on both sides of the fabric.  
     
     
         6 . The method as claimed in  claim 3  wherein said rolls create in-plane deformation of the fabric.  
     
     
         7 . The method as claimed in  claim 5  wherein said rolls create out-of-plane deformation of the fabric.  
     
     
         8 . The method as claimed in  claim 1  which includes the step of heating the fabric prior to or during embossing.  
     
     
         9 . The method as claimed in  claim 3  which includes the step of heating the fabric prior to or during embossing.  
     
     
         10 . The method as claimed in  claim 1  which includes performing one or more of the following steps: 
 controlling the speed of the calender;  
 controlling the space of the gap between the rolls; and  
 controlling the temperature of the fabric.  
 
     
     
         11 . The method as claimed in  claim 1  which includes providing a fabric having a woven substrate.  
     
     
         12 . The method as claimed in  claim 11  which includes providing a fabric having a polymeric substrate.  
     
     
         13 . The method in accordance with  claim 1  which includes providing a fabric having a polymeric substrate.  
     
     
         14 . The method in accordance with  claim 1  which includes a fabric which is nonwoven.  
     
     
         15 . The method as claimed in  claim 1  which includes providing an industrial process fabric which is selected from the following group: forming fabric, press fabric, drying fabric, TAD fabric, pulp forming fabric, or engineered fabric.  
     
     
         16 . The method as claimed in  claim 12  which includes providing a fabric which is selected from the following group: forming fabric, press fabric, drying fabric, TAD fabric, pulp forming fabric, or engineered fabric.  
     
     
         17 . The method as claimed in  claim 3  wherein said first and second rolls are separated from one another at a gap formed therebetween to provide for a preselected compression of the fabric.  
     
     
         18 . The method as claimed in  claim 1  wherein said device is a platen press.  
     
     
         19 . An industrial process fabric embossed in accordance with the method of  claim 1 .  
     
     
         20 . A fabric as claimed in  claim 19  wherein said fabric has a woven substrate.  
     
     
         21 . A fabric as claimed in  claim 20  wherein said fabric is woven in a single-layer weave.  
     
     
         22 . A fabric as claimed in  claim 20  wherein said fabric is woven in a multi-layer weave.  
     
     
         23 . A fabric as claimed in  claim 19  wherein said fabric has a polymeric substrate.  
     
     
         24 . A fabric as claimed in  claim 19  wherein said fabric is woven from monofilament or multifilament yarns.  
     
     
         25 . A fabric as claimed in  claim 24  wherein said yarns are made from a polymeric resin.  
     
     
         26 . A fabric as claimed in  claim 19  wherein said fabric is nonwoven.  
     
     
         27 . A fabric as claimed in  claim 20  which includes a fiber batt.  
     
     
         28 . A fabric as claimed in  claim 26  which includes a fiber batt.  
     
     
         29 . A fabric as claimed in  claim 19  wherein said industrial process fabric is a forming fabric, press fabric, drying fabric, TAD fabric, pulp forming fabric, or engineered fabric.  
     
     
         30 . An industrial process fabric in the form of an endless loop which functions in the manner of a conveyor in making paper and paper related products or nonwoven textiles, comprising: 
 a substrate having a nominal thickness along a plane;    a pattern embossed upon the substrate which is a result of an in-plane deformation of the substrate;    said substrate being compressed in the area defining the pattern; and    said substrate having a pattern side and an opposite relatively smooth side.    
     
     
         31 . An industrial process fabric in the form of an endless loop which functions in the manner of a conveyor in making paper and paper related products or nonwoven textiles, comprising: 
 a substrate having a nominal thickness along a plane;    a pattern embossed upon the substrate which is a result of an out-of-plane deformation;    said nominal thickness of the substrate being increased in the area defining the pattern due to displacing the substrate during embossing; and    said substrate having a pattern on one side comprising a cavity with a corresponding protuberance on an opposite side as a result of the out-of-plane deformation.