High temperature monofilament articles

Abstract

A fabricated part for a high temperature operation including a non-metallic substrate formed of a polymer fabric of woven non-absorbent polymer filament. The substrate is heat-resistant and heat set at a temperature that is above a predetermined operating temperature of an operation of the fabricated part. The heat setting pre-shrinks/heat stabilizes the material, thereby reducing failure during use in high temperature and/or wet applications. The substrate is useful as an endless belt and other applications. The invention further includes an apparatus with a heating device configured to operate at the predetermined operating temperature, and the fabricated part within or extending through the heating device.

What is claimed is: 
     
         1 . A fabricated part for a high temperature operation, comprising:
 a non-metallic substrate formed of a polymer fabric of woven non-absorbent polymer filament, wherein the substrate is heat-resistant and heat set at a temperature that is above a predetermined operating temperature of an operation of the fabricated part.   
     
     
         2 . The fabricated part of  claim 1 , wherein the substrate is pre-shrunk at the temperature. 
     
     
         3 . The fabricated part of  claim 1 , wherein the substrate is pre-shrunk such that the product will not further shrink or destabilize in the operation at or above 212° F. 
     
     
         4 . The fabricated part of  claim 1 , wherein the polymer fabric comprises monofilament or multifilament PPS, PAI, PPSU, PES, PE, LCP, or PEEK. 
     
     
         5 . The fabricated part of  claim 4 , wherein the polymer fabric is free of continuous fiber reinforcement of fiberglass, but the monofilament or multifilament includes chopped or milled fiberglass therein. 
     
     
         6 . The fabricated part of  claim 1 , wherein the substrate is connected at opposing ends to form an endless belt. 
     
     
         7 . The fabricated part of  claim 1 , wherein the substrate is heat set at a temperature of at least 212° for at least 15 minutes, and preferably at least 30 minutes, or at least one hour. 
     
     
         8 . The fabricated part of  claim 1 , wherein the temperature is at least 15° over the predetermined operating temperature, and preferably at least 50°. 
     
     
         9 . The fabricated part of  claim 1 , wherein the polymer filament comprises a high temperature chain extended or cured polymer material. 
     
     
         10 . The fabricated part of  claim 1 , comprising a conveyor belt for steam treatment, article washing, oven drying, baking, or deep frying. 
     
     
         11 . The fabricated part of  claim 1 , wherein the substrate is formed by heat setting the polymer fabric at the temperature that is above the predetermined operating temperature of the operation for a predetermined time period, to obtain the substrate. 
     
     
         12 . The fabricated part of  claim 11 , wherein the substrate is further formed by winding the polymer fabric with a non-stick layer to form wound material layers, and heating the wound material layers to the heat setting temperature. 
     
     
         13 . The fabricated part of  claim 11 , wherein the substrate is further formed by calendaring the polymer fabric at or above the heat setting temperature. 
     
     
         14 . The fabricated part of  claim 13 , wherein the calendaring is performed with heated calendar rolls. 
     
     
         15 . The fabricated part of  claim 1 , further comprising a fluoropolymer or fluoroelastomer blended within the monofilament and/or coating the substrate. 
     
     
         16 . The fabricated part of  claim 1 , further comprising a non-stick coating on the substrate. 
     
     
         17 . The fabricated part of  claim 1 , further comprising an edge material strip along or over opposing longitudinal edges of the substrate to form an endless belt, the edge material comprising a thermoplastic, fiber-reinforced material, or silicone material capable of withstanding the predetermined operating temperature. 
     
     
         18 . The fabricated part of  claim 1 , comprising a piece of fabric and an edge material along or over all side or peripheral edges. 
     
     
         19 . A fabricated part of  claim 18 , comprising a tray insert, wherein the part is placed onto a tray in an oven used for dehydration, curing, drying, baking, or pressing. 
     
     
         20 . An apparatus comprising a heating device configured to operate at the predetermined operating temperature, and an endless belt comprising the fabricated part according to  claim 1  and extending through the heating device. 
     
     
         21 . The apparatus of  claim 20 , wherein the heating device includes steam microwave, or a heated liquid. 
     
     
         22 . The apparatus of  claim 20 , wherein the apparatus is selected from a washing apparatus, a drying oven, a deep fryer, or a yarn treatment apparatus.