Kirby, Garry E.;

Low permeability dryer fabric

A low permeability dryer fabric woven from monofilament plastic polymeric warp strands and weft strands in which at least some of the weft strands exhibit preferential softening under the influence of heat, said strands adapting to conform to mesh interstices and thereby restrict the passage of air through the fabric.

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I claim:

1. A dryer fabric comprising a plurality of interwoven monofilament plastic polymeric warp and weft strands, at least some of said weft strands are stuffer strands formed of a material softened under the influence of controlled heat during a heat-setting treatment, said stuffer strands being selected from a deformable material which is more absorbtive of said controlled heat than are the remainder of said strands, so that said deformable material softens preferentially whereby said material becomes narrower at crossings of adjacent warp strands and correspondingly bulges between alternate warp strands to reduce the spaces in the interstitial areas formed by surrounding strands thereby lowering the permeability of said fabric, said deformable material retaining its solid property during deformation thereof.

2. A dryer fabric as claimed in claim 1 wherein said heat-setting treatment is in the range of about from 350.degree. F. to 430.degree. F. whereby said stuffer strands soften and deform to a greater extent than the other strands of said fabric.

3. A dryer fabric as claimed in claim 2 wherein said stuffer strands are nylons, polybutylene terephthalate or other similar material.

4. A dryer fabric as claimed in claim 1 wherein said stuffer strands are colored strands to improve the absorption of infra-red radiation.

5. A dryer fabric as claimed in claim 4 wherein said stuffer strands are colored with a blackening agent, such as carbon black.

6. A dryer fabric as claimed in claim 1 wherein said warp strands are flattened strands.

7. A dryer fabric as claimed in claim 1 wherein all of said weft strands are stuffer strands.

8. A dryer fabric as claimed in claim 1 wherein said fabric is a duplex fabric, said weft strands being disposed in pairs between said warp strands, each weft strand of each pair extending into a respective upper and lower weft layer, said stuffer strands extending between opposed layers of said weft strands in mid-plane interstices formed between each adjacent pair of weft strands.

9. A dryer fabric as claimed in claim 8 wherein said warp strands are flattened strands.

10. A method of making a dryer fabric having reduced permeability, said fabric having a plurality of warp and weft strands with at least some of said weft strands being stuffer strands, said method comprising the steps of:

(i) selecting said weft stuffer strands from a material that is softened and deforms under the influence of controlled heat, said stuffer strands being selected from a deformable material which is more absorbtive of said controlled heat than are the remainder of said strands, to soften preferentially and to become narrower at crossings of adjacent warp strands and correspondingly bulges between alternate warp strands, said deformable material retaining its solid property during deformation thereof;

(ii) weaving all said strands together to form a fabric sheet;

(iii) stretching said fabric sheet; and

(iv) heating said fabric sheet to a desired temperature range where said stuffer strands will deform to a greater extent than the other strands of said fabric to reduce the interstitial areas formed by surrounding strands to thereby lower the permeability of said fabric.

11. A method as claimed in claim 10 wherein said fabric is stretched to a tension up to about 10 lbs. per linear inch of width and heated to a temperature in the range of from about 350.degree. F. to 430.degree. F.

12. A method as claimed in claim 10 wherein step (ii) comprises weaving said strands to form a duplex fabric with said weft strands being disposed in pairs between said warp strands, each weft strand of each pair extending into a respective upper and lower weft layer, said stuffer strands being woven between opposed layers of weft strands in mid-plane interstices formed between each adjacent pair of weft strands.

13. A method as claimed in claim 10 wherein said selected weft strands of step (i) have been colored to improve absorption of infra-red radiation whereby said weft stuffer strands will soften to a greater extent than the other strands of said fabric when subjected to infra-red radiation.

14. A method as claimed in claim 10 wherein said selected weft strands of step (i) are formed of a material having a lower melting point than the other strands of said fabric whereby said weft stuffer strands will soften to a greater extent than the other strands of said fabric when subjected to conductive heat.

15. A method as claimed in claim 13 or 14 wherein said step (iv) comprises subjecting said fabric sheet to ambient heat in the range of from about 350.degree. F. to 430.degree. F.