Composite laminated papermaking fabrics and methods of making the same

Abstract

A structured tissue belt assembly including a supporting layer and a nonwoven web contacting layer. The supporting layer has a top surface and a bottom surface and is formed of monofilaments including one or more layers of warp yarns interwoven with weft yarns in a repeating pattern. At least one of: a) at least some of the warp yarns; or b) at least some of the weft yarns, include laser energy absorbent material, and at least one of: a) at least some of the warp yarns; or b) at least some of the weft yarns include laser energy scattering material. Laser welds attach the bottom surface of the web contacting layer to the top surface of the supporting layer at points where the web contacting layer contacts the at least one of: a) the at least some of the warp yarns; or b) the at least some of the weft yarns that include laser energy absorbent material.

We claim: 
     
         1 . A method of making a structured tissue belt assembly, comprising:
 providing a supporting layer made up of monofilaments comprising warp yarns and weft yarns interwoven in a repeating pattern, wherein
 at least one of: a) at least some of the warp yarns; or b) at least some of the weft yarns, are formed at least in part of a laser energy absorbent material, 
 at least one of: a) at least some of the warp yarns; or b) at least some of the weft yarns, comprise a laser energy scattering material, and 
 the supporting layer has a top surface; 
   stretching a web contacting layer and impinging the web contacting layer onto the top surface of the supporting layer with a minimum of 1 PSI downward force;   radiating the web contacting layer with a laser to form one or more first laser welds between a bottom surface of the web contacting layer and the top surface of the supporting layer at points where the web contacting layer contacts the at least one of: a) the at least some of the warp yarns or; b) the at least some of the weft yarns formed at least in part of the laser energy absorbent material,   wherein an embedment distance where the web contacting layer is embedded into the monofilaments of the supporting layer is from 0.05 mm to 0.60 mm, and   wherein a peel force between the web contacting layer and the supporting layer is from 650 gf/inch to 6000 gf/inch.   
     
     
         2 . The method of  claim 1 , wherein at least one of: a) at least some of the warp yarns; or b) at least some of the weft yarns, comprise polymers of varying crystallinities. 
     
     
         3 . The method of  claim 1 , wherein the non-woven web contacting layer comprises at least one of a laser energy scattering material or polymers of varying crystallinities. 
     
     
         4 . The method of  claim 1 , wherein the laser has a laser energy wavelength from 500 nm to 11000 nm. 
     
     
         5 . The method of  claim 1 , wherein at least some of the warp yarns are formed at least in part of a laser energy absorbent material. 
     
     
         6 . The method of  claim 5 , wherein at least some of the weft yarns are devoid of the laser energy absorbent material and contain a laser energy scattering material. 
     
     
         7 . The method of  claim 5  wherein the at least some weft yarns are formed of a laser energy scattering material and the at least some of the weft yarns are connected to the at least some of the warp yarns formed at least in part of the laser energy absorbent material by one or more second laser welds formed at points where the weft yarns pass over the warp yarns formed at least in part of the laser energy absorbent material. 
     
     
         8 . The method of  claim 1 , wherein at least some of the weft yarns are formed at least in part of a laser energy absorbent material. 
     
     
         9 . The method of  claim 8 , wherein at least some of the warp yarns are devoid of the laser energy absorbent material and contain a laser energy scattering material. 
     
     
         10 . The method of  claim 8 , wherein the at least some of the warp yarns are formed of a laser energy scattering material and the at least some of the warp yarns are connected to the at least some of the weft yarns formed at least in part of the laser energy absorbent material by one or more second laser welds formed at points where the warp yarns pass over the weft yarns formed at least in part of the laser energy absorbent material. 
     
     
         11 . The method of  claim 1 , wherein the downward force is from 5 PSI to 15 PSI. 
     
     
         12 . The method of  claim 1 , wherein the laser has a power level of 100 to 1200 watts. 
     
     
         13 . A structured tissue belt assembly comprising:
 a supporting layer comprising a top surface and a bottom surface, the supporting layer being formed of monofilaments comprising multiple layers of warp yarns interwoven with weft yarns in a repeating pattern,   at least one of: a) at least some of the warp yarns; or b) at least some of the weft yarns, comprising laser energy absorbent material, and   at least one of: a) at least some of the warp yarns; or b) at least some of the weft yarns, comprising laser energy scattering material;   the supporting layer being needled with fine synthetic batting; and   a web contacting layer; and   one or more first laser welds that attach a bottom surface of the web contacting layer to the top surface of the supporting layer at points where the web contacting layer contacts the at least one of: a) the at least some of the warp yarns; or b) the at least some of the weft yarns that comprise laser energy absorbent material,   wherein the structured tissue belt assembly allows for air flow in the x, y and z directions,   wherein an embedment distance where the web contacting layer is embedded into the monofilaments of the supporting layer is from 0.05 mm to 0.60 mm, and   wherein a peel force between the web contacting layer and the supporting layer is from 650 gf/inch to 6000 gf/inch.   
     
     
         14 . The structured tissue belt assembly of  claim 13 , wherein at least one of: a) at least some of the warp yarns; or b) at least some of the weft yarns, comprise polymers of varying crystallinities. 
     
     
         15 . The structured tissue belt assembly of  claim 13 , wherein the non-woven web contacting layer comprises at least one of a laser energy scattering material or polymers of varying crystallinities. 
     
     
         16 . A structured tissue belt assembly comprising;
 a supporting layer comprising a top surface and a bottom surface, the supporting layer being formed of monofilaments comprising one or more layers of warp yarns interwoven with weft yarns in a repeating pattern,   the warp yarns and the weft yarns being devoid of laser energy absorbent material, and   at least one of: a) at least some of the warp yarns or b) at least some of the weft yarns, comprising laser energy scattering material;   a non-woven web contacting layer at least a portion of which comprises a laser energy absorbent material; and   one or more laser welds that attach the top surface of the supporting layer to a bottom surface of the web contacting layer at points where the at least a portion of the web contacting layer contacts at least one of: a) at least some of the warp yarns; or b) at least some of the weft yarns,   wherein the structured tissue belt assembly allows for air flow in x, y and z directions,   wherein an embedment distance where the web contacting layer is embedded into the monofilaments of the supporting layer is from 0.05 mm to 0.60 mm, and   wherein a peel force between the web contacting layer and the supporting layer is from 650 gf/inch to 6000 gf/inch.   
     
     
         17 . The structured tissue belt assembly of  claim 16 , wherein at least one of: a) at least some of the warp yarns; or b) at least some of the weft yarns, comprise polymers of varying crystallinities. 
     
     
         18 . The structured tissue belt assembly of  claim 16 , wherein the non-woven web contacting layer comprises polymers of varying crystallinities. 
     
     
         19 . A method of making a structured tissue belt assembly comprising:
 forming a non-woven web contacting layer comprising laser energy absorbent material;   stretching the non-woven web contacting layer;   providing a supporting layer comprising made up of monofilaments comprising warp yarns and weft yarns interwoven in a repeating pattern, wherein:
 the warp yarns and the weft yarns are devoid of laser energy transparent absorbent material, 
 at least one of: a) at least some of the warp yarns; or b) at least some of the weft yarns, comprising a laser energy scattering material; 
   impinging the top surface of the supporting layer to a bottom surface of the web contacting layer with a minimum of 1 PSI downward force; and   radiating the supporting layer with a laser to form one or more laser welds that attach the bottom surface of the web contacting layer to the top surface of the supporting layer at points where the laser energy absorbent material of the web contacting layer contacts at least one of the warp yarns or the weft yarns of the supporting layer,   wherein an embedment distance where the web contacting layer is embedded into the monofilaments of the supporting layer is from 0.05 mm to 0.60 mm, and   wherein a peel force between the web contacting layer and the supporting layer is from 650 gf/inch to 6000 gf/inch.   
     
     
         20 . The method of  claim 19 , wherein at least one of: a) at least some of the warp yarns; or b) at least some of the weft yarns, comprise polymers of varying crystallinities. 
     
     
         21 . A structured tissue belt assembly comprising:
 a supporting layer comprising a top surface and a bottom surface, the supporting layer being formed of monofilaments comprising multiple layers of warp yarns interwoven with weft yarns in a repeating pattern,   the warp yarns and the weft yarns being devoid of laser energy absorbing material, at least one of: a) at least some of the warp yarns; or b) at least some of the weft yarn,s comprising a laser energy scattering material, and   the supporting layer being needled with fine synthetic batting;   a web contacting layer comprising a laser energy absorbent material; and   one or more laser welds that attach a bottom surface of the web contacting layer to the top surface of the supporting layer at points where the laser energy absorbent material of the web contacting layer contacts at least one of the warp yarns or the weft yarns, wherein the structured tissue belt assembly allows for air flow in x, y and z directions,   wherein an embedment distance where the web contacting layer is embedded into the monofilaments of the supporting layer is from 0.05 mm to 0.60 mm, and   wherein a peel force between the web contacting layer and the supporting layer is from about 650 gf/inch to about 6000 gf/inch.   
     
     
         22 . The structured tissue belt assembly of  claim 21 , wherein at least one of: a) at least some of the warp yarns; or b) at least some of the weft yarns, comprise polymers of varying crystallinities. 
     
     
         23 . The structured tissue belt assembly of  claim 21 , wherein the non-woven web contacting layer comprises polymers of varying crystallinities.