Dual layer twill fabric for conveyor belt applications

Abstract

A composite fabric has a first weft sheet and a second weft sheet, each of individual weft yarns, a top warp yarn, a bottom warp yarn, and a binder yarn. The first and second weft sheet yarns each have an outer side and adjacent inner sides. Part of the top warp yarn extends between the first and second weft sheet, and part is woven around at least one first weft sheet yarn outer side. Part of the bottom warp yarn extends between the first and second weft sheet, and part is woven around at least one second weft sheet yarn outer side. The top warp yarn does not weave around any second weft sheet yarns. The bottom warp yarn does not weave around any first weft sheet yarns. The binder yarn weaves alternately around a first weft sheet yarn outer side, and a second weft sheet yarn outer side.

1 . A composite fabric for use in a conveyor belt, comprising:
 A first weft sheet of individual weft yarns, wherein said first weft sheet yarns have an outer side and an opposing inner side;   A second weft sheet of individual weft yarns, wherein said second weft sheet yarns have an outer side and an opposing inner side, wherein said inner side is adjacent to said first weft sheet yarns inner side;   At least one pair of warp yarns comprising a top warp yarn, and a bottom warp yarn,   wherein said top warp yarn extends at least in part between said first and said second weft sheet, and at least in part is woven around at least one first weft sheet yarn outer side;   wherein said bottom warp yarn extends at least in part between said first and said second weft sheet, and at least in part is woven around at least one second weft sheet yarn outer side,   wherein said top warp yarn does not weave around any second weft sheet yarns, and wherein said bottom warp yarn does not weave around any first weft sheet yarns; and   a binder yarn wherein said binder yarn weaves alternately around a first weft sheet yarn outer side, and a second weft sheet yarn outer side.   
     
     
         2 . The composite fabric of  claim 1  wherein said top warp yarn extends around a single first weft sheet yarn outer side, and subsequently around two first weft sheet yarns inner sides, and repeats this weave pattern. 
     
     
         3 . The composite fabric of  claim 1  wherein said bottom warp yarn extends around a single second weft sheet yarn outer side, and subsequently around two second weft sheet yarns inner sides, and repeats this weave pattern. 
     
     
         4 . The composite fabric of  claim 2 , wherein said bottom warp yarn extends around a single second weft sheet yarn outer side, and subsequently around two second weft sheet yarns inner sides, and repeats this weave pattern. 
     
     
         5 . The composite fabric of  claim 4  wherein a first weft sheet yarn having said top warp around said first weft sheet yarn outer side is adjacent to second weft sheet yarn having said bottom warp around said second weft sheet yarn outer side. 
     
     
         6 . The composite fabric of  claim 1  wherein said top warp yarn and said bottom warp yarn weave through said first weft sheet and said second weft sheet respectively such that the resulting crimp is between 2%-5%. 
     
     
         7 . A conveyor belt comprised of:
 at least one composite fabric ply comprising;   a first weft sheet of individual weft yarns, wherein said first weft sheet yarns have an outer side and an opposing inner side;   a second weft sheet of individual weft yarns, wherein said second weft sheet yarns have an outer side and an opposing inner side, wherein said inner side is adjacent to said first weft sheet yarns inner side;   at least one pair of warp yarns comprising a top warp yarn, and a bottom warp yarn,   wherein said top warp yarn extends at least in part between said first and said second weft sheet, and at least in part is woven around at least one first weft sheet yarn outer side;   wherein said bottom warp yarn extends at least in part between said first and said second weft sheet, and at least in part is woven around at least one second weft sheet yarn outer side,   wherein said top warp yarn does not weave around any second weft sheet yarns, and wherein said bottom warp yarn does not weave around any first weft sheet yarns; and   a binder yarn wherein said binder yarn weaves alternately around a first weft sheet yarn outer side, and a second weft sheet yarn outer side.   
     
     
         8 . The conveyor belt of  claim 7  further comprising at least two said composite fabric plies, up to four said composite fabric plies. 
     
     
         9 . The conveyor belt of  claim 8  further comprising rubber layers between any said composite fabric plies. 
     
     
         10 . The conveyor belt of  claim 9  further comprising rubber layers on top of any exposed said composite fabric plies. 
     
     
         11 . A composite fabric for use in a conveyor belt, comprising:
 A first weft sheet of individual weft yarns, wherein said first weft sheet yarns have an outer side and an opposing inner side;   A second weft sheet of individual weft yarns, wherein said second weft sheet yarns have an outer side and an opposing inner side, wherein said inner side is adjacent to said first weft sheet yarns inner side;   At least one pair of warp yarns comprising a top warp yarn, and a bottom warp yarn;   wherein said top warp yarn extends at least in part between said first and said second weft sheet, and at least in part is woven around at least one first weft sheet yarn outer side;   wherein said bottom warp yarn extends at least in part between said first and said second weft sheet, and at least in part is woven around at least one second weft sheet yarn outer side,   wherein said top warp yarn does not weave around any second weft sheet yarns, and wherein said bottom warp yarn does not weave around any first weft sheet yarns; and   a binder yarn wherein said binder yarn weaves at least around a first weft sheet yarn outer side, and a second weft sheet yarn outer side.   
     
     
         12 . The composite fabric of  claim 11  wherein said top warp yarn extends around a single first weft sheet yarn outer side, and subsequently around three first weft sheet yarns inner sides, and repeats this weave pattern. 
     
     
         13 . The composite fabric of  claim 11  wherein said bottom warp yarn extends around a single second weft sheet yarn outer side, and subsequently around three second weft sheet yarns inner sides, and repeats this weave pattern. 
     
     
         14 . The composite fabric of  claim 12 , wherein said bottom warp yarn extends around a single second weft sheet yarn outer side, and subsequently around three second weft sheet yarns inner sides, and repeats this weave pattern. 
     
     
         15 . The composite fabric of  claim 14  wherein a first weft sheet yarn having said top warp around said first weft sheet yarn outer side is adjacent to second weft sheet yarn having said bottom warp around said second weft sheet yarn outer side. 
     
     
         16 . The composite fabric of  claim 11  wherein said top warp yarn and said bottom warp yarn weave through said first weft sheet and said second weft sheet respectively such that the resulting crimp is between 2%-5%. 
     
     
         17 . The composite fabric of  claim 11  wherein said binder yarn weaves around two adjacent first weft sheet yarn outer side, and then a second weft sheet yarn outer side, and repeats this pattern.