Title:
METHOD FOR PRODUCING A FELT BELT
Kind Code:
A1


Abstract:
The present invention relates to a method for producing a felt belt, particularly a press felt for a paper machine, including the steps of producing a longitudinal thread structure by continuous helical winding of at least one longitudinal thread in the direction of the provided width of the felt belt, particularly up to the provided width of the felt belt; placing a transverse reinforcement structure on the longitudinal thread structure and connecting the same to the longitudinal thread structure to form a tube-like composite structure; placing opposing sections of the tube-like structure one atop the other such that the tube-like structure forms a flat structure whose length corresponds to approximately half the circumference of the tube-like structure and which provides seam loops on its opposing longitudinal sides, the loops being formed by the at least one helically wound longitudinal thread; making the flat structure continuous by merging the opposing seam loops and connecting the same to one another; and connecting the sections of the flat structure placed one atop the other to form a base structure.



Inventors:
Kockritz, Uwe (Heidenheim, DE)
Application Number:
12/473638
Publication Date:
12/03/2009
Filing Date:
05/28/2009
Primary Class:
Other Classes:
28/142, 139/383A
International Classes:
D04H1/46; D04H3/10; D04H11/08; D04H17/10
View Patent Images:
Related US Applications:
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20100056981Tampon Having An Improved Finger PocketMarch, 2010Karapasha et al.
20100087113STEAM PERMISSIVE AND WATER NON PERMISSIVE SCREEN, AND METHOD FOR MAKING SAMEApril, 2010Bindschedler et al.
20020116802Soft and stretchable textile fabrics made from polytrimethylene terephthalateAugust, 2002Moerman et al.
20050188514Sound absorbing secondary nonwoven carpet backingSeptember, 2005Hartgrove et al.
20060191116Biodegradable nonwovensAugust, 2006Noelle
20080000038WOVEN MAT WITH BOOT SCRAPERJanuary, 2008Koncherry
20100072233Fringe makerMarch, 2010Herb-weinert et al.
20080010793Textile fabric with variable heat-shrunk yarn constituentsJanuary, 2008Wildeman



Primary Examiner:
BLADES, JOHN A
Attorney, Agent or Firm:
TAYLOR IP, P.C. (P.O. Box 560 142. S Main Street, Avilla, IN, 46710, US)
Claims:
What is claimed is:

1. A method for producing a felt belt for a papermaking machine, the method comprising the following steps: producing a longitudinal thread structure by continuously helically winding at least one longitudinal thread in a direction of a width of the felt belt up to an entire width of the felt belt; placing a transverse reinforcement structure on said longitudinal thread structure and connecting said transverse reinforcement structure and said longitudinal thread structure to form a tube-like composite structure; placing a first section of said tube-like structure on top of a second opposing section of said tube-like structure to form a flat structure having opposing longitudinal sides and a length equal to approximately one-half of a circumference of said tube-like structure, said flat structure having opposing seam loops on said opposing longitudinal sides, said seam loops being formed by said at least one helically wound longitudinal thread; making said flat structure continuous by merging and connecting said opposing seam loops; and connecting at least one first section of said flat structure and at least one second section previously placed one atop the other to form a base structure.

2. The method according to claim 1, wherein said flat structure is one of made continuous and formed into a continuous belt before said step of connecting said at least one first section of said flat structure and said at least one second section of said flat structure.

3. The method according to claim 2, further comprising the step of tensing at least one of a plurality of said flat structures in a longitudinal direction after making said flat structure continuous.

4. The method according to claim 1, wherein said flat structure is one of made continuous and formed into a continuous belt after said connection of said at least one first section of said flat structure and said at least one second section of said flat structure.

5. The method according to claim 4, further comprising the step of applying a carrier layer after said step of producing said longitudinal thread and before said step of applying said transverse reinforcement structure to said longitudinal thread.

6. The method according to claim 5, further comprising the step of connecting said longitudinal thread structure and said transverse reinforcement structure through said carrier layer.

7. The method according to claim 6, wherein said carrier layer is at least one of a non-woven fibrous layer and a film layer.

8. The method according to claim 7, wherein said transverse reinforcement structure is a transverse thread arrangement.

9. The method according to claim 8, wherein said transverse thread arrangement is at least one of a woven fabric, a knitted fabric, a transverse thread structure and a gauze fabric.

10. The method according to claim 9, further comprising the step of forming said transverse reinforcement structure from a plurality of transverse reinforcement modules extending over only a part of a length of said longitudinal thread structure, said transverse reinforcement modules including at least one first transverse reinforcement module and at least one second transverse module abutting said at least one first transverse reinforcement module in a longitudinal direction of the felt belt.

11. The method according to claim 10, further comprising the step of connecting said longitudinal thread structure to said non-woven fibrous layer by needling.

12. The method according to claim 11, wherein said longitudinal thread structure is embedded in said non-woven fibrous layer.

13. The method according to claim 12, wherein said non-woven fibrous layer includes hot melt adhesive fibers, said non-woven fibrous layer and said longitudinal thread structure being connected by melting and resolidifying said hot melt adhesive fibers.

14. The method according to claim 13, further comprising the steps of melting and resolidifying said hot melt adhesive fibers to connect said transverse reinforcement structure and said non-woven fibrous layer.

15. The method according to claim 14, further comprising the step of producing said carrier layer by continuously winding a carrier strip extending only over part of said width of the felt belt up to an entire width of the felt belt.

16. The method according to claim 15, further comprising the step of placing one edge of said carrier strip one of flush with and regionally overlapping an opposing edge of said carrier strip.

17. The method according to claim 16, wherein said base structure is placed under said tension and subjected to said heat treatment after connecting said at least one first section of said flat structure and said at least one second section to form a base structure.

18. The method according to claim 17, further comprising the step of connecting said merged seam loops with a fixing wire.

19. The method according to claim 18, further comprising the step of needling at least one of a top side and a bottom side of said base structure with at least one non-woven fibrous layer.

20. The method according to claim 19, further comprising the step of incorporating a particulate polymer material into said at least one non-woven fibrous layer on said at least one of said top side and said bottom side of said base structure, said particulate polymer material being attaching to fibers of said at least one non-woven fibrous layer to form a composite structure.

21. The method according to claim 20, further comprising the step of melting and resolidifying said particulate polymer material after said incorporation into said non-woven fibrous layer to form said porous composite structure and said fibers of said non-woven fibrous layer.

22. The method according to claim 21, wherein said longitudinal thread structure includes at least one monofilament thread and said transverse reinforcement structure includes a plurality of multifilament threads.

23. A method for producing a felt belt for a papermaking machine, the method comprising the following steps: producing a longitudinal thread structure by continuously helically winding at least one longitudinal thread in a direction of a width of the felt belt up to an entire width of the felt belt; placing a transverse reinforcement structure on said longitudinal thread structure and connecting said transverse reinforcement structure and said longitudinal thread structure to form a tube-like composite structure; placing a first section of said tube-like structure on top of a second opposing section of said tube-like structure to form a flat structure having opposing longitudinal sides and a length equal to approximately one-half of a circumference of said tube-like structure, said flat structure providing opposing seam loops on said opposing longitudinal sides, said seam loops being formed by said at least one helically wound longitudinal thread; forming a continuous belt by arranging a plurality of flat structures, said plurality of flat structures being connected with seam loops; and connecting at least one first section of said flat structure and at least one second section previously placed one atop the other to form a base structure including a plurality of said tube-like structures.

24. The method according to claim 23, wherein said flat structure is one of made continuous and formed into a continuous belt before said step of connecting said at least one first section of said flat structure and said at least one second section of said flat structure.

25. The method according to claim 24, further comprising the step of tensing at least one of a plurality of said flat structures in a longitudinal direction after making said flat structure continuous.

26. The method according to claim 23, wherein said flat structure is one of made continuous and formed into a continuous belt after said connection of said at least one first section of said flat structure and said at least one second section of said flat structure.

27. The method according to claim 26, further comprising the step of applying a carrier layer after said step of producing said longitudinal thread and before said step of applying said transverse reinforcement structure to said longitudinal thread.

28. The method according to claim 27, further comprising the step of connecting said longitudinal thread structure and said transverse reinforcement structure through said carrier layer.

29. The method according to claim 28, wherein said carrier layer is at least one of a non-woven fibrous layer and a film layer.

30. The method according to claim 29, wherein said transverse reinforcement structure is a transverse thread arrangement.

31. The method according to claim 30, wherein said transverse thread arrangement is at least one of a woven fabric, a knitted fabric, a transverse thread structure and a gauze fabric.

32. The method according to claim 31, further comprising the step of forming said transverse reinforcement structure from a plurality of transverse reinforcement modules extending over only a part of a length of said longitudinal thread structure, said transverse reinforcement modules including at least one first transverse reinforcement module and at least one second transverse module abutting said at least one first transverse reinforcement module in a longitudinal direction of the felt belt.

33. The method according to claim 32, further comprising the step of connecting said longitudinal thread structure to said non-woven fibrous layer by needling.

34. The method according to claim 33, wherein said longitudinal thread structure is embedded in said non-woven fibrous layer.

35. The method according to claim 34, wherein said non-woven fibrous layer includes hot melt adhesive fibers, said non-woven fibrous layer and said longitudinal thread structure being connected by melting and resolidifying said hot melt adhesive fibers.

36. The method according to claim 35, further comprising the steps of melting and resolidifying said hot melt adhesive fibers to connect said transverse reinforcement structure and said non-woven fibrous layer.

37. The method according to claim 36, further comprising the step of producing said carrier layer by continuously winding a carrier strip extending only over part of said width of the felt belt up to an entire width of the felt belt.

38. The method according to claim 37, further comprising the step of placing one edge of said carrier strip one of flush with and regionally overlapping an opposing edge of said carrier strip.

39. The method according to claim 38, wherein said base structure is placed under said tension and subjected to said heat treatment after connecting said at least one first section of said flat structure and said at least one second section to form a base structure.

40. The method according to claim 39, further comprising the step of connecting said merged seam loops with a fixing wire.

41. The method according to claim 40, further comprising the step of needling at least one of a top side and a bottom side of said base structure with at least one non-woven fibrous layer.

42. The method according to claim 41, further comprising the step of incorporating a particulate polymer material into said at least one non-woven fibrous layer on said at least one of said top side and said bottom side of said base structure, said particulate polymer material being attaching to fibers of said at least one non-woven fibrous layer to form a composite structure.

43. The method according to claim 42, further comprising the step of melting and resolidifying said particulate polymer material after said incorporation into said non-woven fibrous layer to form said porous composite structure and said fibers of said non-woven fibrous layer.

44. The method according to claim 43, wherein said longitudinal thread structure includes at least one monofilament thread and said transverse reinforcement structure includes a plurality of multifilament threads.

Description:

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method for producing a felt belt, particularly a press felt, for a paper, cardboard, or tissue machine.

2. Description of the Related Art

Felt belts, in particular press felts for paper, cardboard, or tissue machines, generally have a base structure providing dimensional stability to the felt, which is needled on both sides with one or more non-woven fibrous layers.

Press felts may be provided either as continuous belts or as continuous belts with a seam. Press felts embodied as continuous belts have the disadvantage as compared to press felts with a seam that such press felts are difficult to install in the paper machine since they cannot be pulled into the machine as an open belt.

As a rule, the base structure of the known press felts is woven. Woven structures have the disadvantage that they are often very complex to produce. Therefore, the prior art already proposes press felts with non-woven base structures in which the base structure has, for example, a longitudinal thread structure. Such a basic structure formed by a longitudinal thread structure is known, for example, from U.S. Pat. No. 4,495,680. Most of the press felts having longitudinal thread structures known up to now are embodied as continuous belts.

In addition, a method is known from EP1808527A1 by means of which a seamable press felt may be produced. In practice, however, this method has the disadvantage in many cases that, in an intermediate stage of production, the structure lacks the necessary stability in the longitudinal thread direction, therefore, complicating handling during the production process.

What is needed in the art is a method for the production of a seamable base structure having a longitudinal thread structure that does not have the disadvantages discussed above.

SUMMARY OF THE INVENTION

The method of the present invention includes the steps of first creating a helically wound longitudinal thread structure, applying a transverse reinforcement structure to the longitudinal thread structure and connecting it to the longitudinal thread structure only in a later step. In this manner, a tube-like composite structure is obtained. Subsequently, opposing sections of the tube-like composite structure are placed one atop the other such that the tube-like composite structure forms a flat structure whose length corresponds to approximately half the circumference of the tube-like structure and that provides seam loops on its opposite longitudinal ends formed by the at least one helically wound longitudinal thread. Then, the flat structure is made continuous in that the opposing seam loops are merged and connected to one another. The sections of the flat structure placed one atop the other are furthermore connected to one another in order to form a base structure.

According to a second embodiment of the present invention, multiple flat structures are produced that are placed in a row next to one another and connected to one another at the seam loops in order to form a continuous belt. This means that the flat structures placed one behind the other form a continuous belt together.

In both embodiments of the present invention a longitudinal thread structure forming a “closed tube” is first produced, which has the necessary tensile strength for the subsequent handling. By means of the alternative embodiment, it is possible to build base structures for press felts of virtually any length using identically constructed modules.

The thread(s) is/are helically wound, for example, around two rollers located at a distance from one another and oriented essentially parallel to one another, with the progression of the helical winding, i.e., the winding direction, occurring perpendicularly to the two rollers. Here, the length of a winding corresponds to the circumference of the tube-like composite structure. The transverse reinforcement structure may be connected, directly or indirectly, for example, via an intermediate layer, to the longitudinal thread structure.

It is possible for only one single longitudinal thread to be helically wound in order to produce the longitudinal thread structure. However, it is also possible for a skein of longitudinal threads to be helically wound in order to form the longitudinal thread structure. The one or more longitudinal thread(s) forming the longitudinal thread structure is/are embodied as monofilament thread(s). By providing a longitudinal thread structure made of one or more longitudinal thread(s) whose seam loops are formed by monofilaments, the present invention provides a press felt that is particularly easy to seam.

A third embodiment of the method according to the present invention provides for the belt to be made continuous or for the formation of a continuous belt before the connection of the sections placed one atop the other. By virtue of the fact that the base structure is first made continuous before the layers and/or sections of the tube-like composite structure placed one atop the other are connected to one another and their position relative to one another is thus fixed, it is possible to correct, for example, discrepancies in length and warping in the flat structure. For this purpose, the flat structure(s) may be tensed in its/their longitudinal direction after being made continuous. This may occur, for example, in that the flat structure that has been made continuous or the continuous belt is guided over a pair of rollers disposed at a distance from and parallel to one another and the distance between the rollers is increased in the longitudinal direction of the flat structure.

A fourth embodiment of the present invention proposes that the structure be made continuous or that a continuous belt be formed after the sections placed one atop the other have been connected.

A further development of the present invention provides for at least one carrier layer to be applied to the longitudinal thread structure after the production of the longitudinal thread structure and before the application of the transverse reinforcement structure. Alternately, it is also conceivable for the carrier layer to be applied to the longitudinal thread structure together with the transverse reinforcement structure. In such a case, the transverse reinforcement structure is, for example, first connected to the carrier layer before this arrangement is applied to the longitudinal thread structure and connected thereto. This may occur, for example, in order to fix the distance between sequential thread windings before applying the transverse reinforcement structure. In such a case, the transverse reinforcement structure, for example, has no direct contact with the longitudinal thread structure; rather, the transverse reinforcement structure is connected to the longitudinal thread structure via the carrier layer.

A fifth embodiment of the present invention provides for the longitudinal thread structure and the transverse reinforcement structure to be connected to one another via the carrier layer. This means that the carrier layer can be disposed between the transverse reinforcement structure and the longitudinal thread structure. Moreover, the carrier layer may, for example, be formed alone or in combination by a non-woven fibrous layer or a film layer.

The carrier layer, which is embodied as a non-woven fibrous layer, may comprise hot melt adhesive fibers. In this case, it is conceivable for the longitudinal thread structure be connected to the non-woven fibrous layer by the hot melt adhesive fibers being melted and resolidified and/or by the transverse reinforcement structure being connected to the non-woven fibrous layer by the hot melt adhesive fibers being melted and resolidified.

Before melting the hot melt adhesive fibers of the non-woven fibrous layer, or as an alternative thereto, it is moreover conceivable for the non-woven fibrous layer to be needled to the longitudinal thread structure and/or to the transverse reinforcement structure. In such a case, the longitudinal thread structure and/or the transverse reinforcement structure can be at least partially embedded in the non-woven fibrous layer. This means that the connection between the thread structure and the carrier layer and/or between the transverse reinforcement layer and the carrier may occur by means of needling or melting. Alternatively or in addition, adhesion is also conceivable.

If the longitudinal thread structure and the transverse reinforcement structure are connected to the non-woven fibrous layer comprising hot melt adhesive fibers by the hot melt adhesive fibers being melted and resolidified, the longitudinal thread structure, the transverse reinforcement structure, and the non-woven fibrous layer can be hot calendered together, for example, in that they are guided together around a heated roller.

The transverse reinforcement structure may comprise a transverse thread arrangement, which may be, for example, alone or in combination, a woven fabric, a knitted fabric, a knotted fabric, a gauze fabric, or a transverse thread structure.

If the transverse thread structure is, for example, a woven or knitted fabric, it may include transverse threads and longitudinal threads that are relatively thin in comparison to the transverse threads, and which hold the transverse threads in position. However, the transverse threads may also be held in position by a film or fibrous non-woven layer upon which the transverse threads are fixed.

In order to produce the base structure in a cost-effective manner, it is conceivable, for example, for the transverse reinforcement structure to be formed by multiple transverse reinforcement modules extending only over part of the length of the longitudinal thread structure, which are disposed one behind the other on the longitudinal thread structure in the longitudinal direction of the felt belt in order to form the transverse reinforcement structure. The transverse reinforcement modules may extend over the width of the longitudinal thread structure. In addition, the transverse reinforcement modules may be formed with a transverse reinforcement output strip such that the transverse reinforcement modules may be placed on the longitudinal thread structure as follows:

a) laterally placing the transverse reinforcement module output strip relative to the longitudinal thread structure, i.e., transverse to the longitudinal direction of the longitudinal thread structure;

b) flatly depositing the transverse reinforcement module output strip onto the longitudinal thread structure;

c) separating the section of the transverse reinforcement module output strip deposited on the longitudinal thread structure from the remaining transverse reinforcement module output strip in order to form a transverse reinforcement module;

d) moving the longitudinal thread structure in its longitudinal direction relative to the transverse reinforcement module output strip on a path that essentially corresponds to the width of the transverse reinforcement module output strip; and

e) repeating steps a) to d) such that the transverse reinforcement modules are disposed lying one behind the other in the longitudinal direction of the felt belt.

The method of the present invention may be carried out such that, when the base structure has been completely produced, each transverse reinforcement module placed on the longitudinal thread structure extends over the width of the longitudinal thread structure and the transverse reinforcement modules disposed lying one behind the other combine to measure the length of the longitudinal thread structure.

The production of the base structure is particularly cost effective when the transverse reinforcement module output strip is present as rolling stock and is unrolled from the roll when it is laterally placed.

In order to produce the carrier layer in a cost-effective manner, a winding method is used such that a carrier layer extending over the entire width of the felt belt may be produced by the helical winding of a partial-width carrier strip. As a result, one embodiment of the invention provides for the carrier layer to be produced in that a carrier strip extending only over part of the provided width of the felt belt is helically wound in a continuous fashion in the direction of the provided width of the felt belt, particularly up to the provided width of the felt belt. If the carrier strip is helically wound, depending on the present requirements, for example, whether the carrier layer is to be embodied in single or multiple layers, edges facing one another may be placed flush or in a regionally overlapping manner.

After the production of the base structure, it may be placed under tension and subjected to a heat treatment in order to attain a high level of dimensional stability. The seam loops that have been merged, or are to be connected to one another, are connected by a fixing wire.

Furthermore, in order to form the felt belt, the base structure may be needled on its top side to at least one non-woven fibrous layer and/or on its bottom side to at least one non-woven fibrous layer. Here, for example, the outermost of the non-woven fibrous layers on the top side of the base structure provides the paper side of the felt belt. Moreover, the outermost of the non-woven fibrous layers on the bottom side of the base structure provides the machine side of the felt belt.

In order to achieve a good connection of the one or more non-woven fibrous layer(s) to the base structure, another embodiment of the present invention provides for the transverse reinforcement structure to include multifilament threads. Here, the multifilament threads may particularly be twisted. The transverse threads of the transverse reinforcement structure are embodied as multifilament threads. The embodiment described above may also provide for the longitudinal thread(s) of the longitudinal thread structure being embodied as monofilament thread(s).

In order to influence the volume structure and/or the surface structure of the non-woven fibrous layers, particulate polymer material may be incorporated into at least one non-woven fibrous layer that is needled onto the top side and/or the bottom side of the base structure, said polymer material attaching to fibers of the non-woven fibrous layer and forming a porous composite structure therewith.

In this context, it is conceivable, for example, for the particulate polymer material to be melted after its incorporation into the non-woven fibrous layer and, after it resolidifies, to form the porous composite structure along with the fibers of the non-woven fibrous layer.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

FIGS. 1a-1e illustrate a first embodiment of a method according to the present invention;

FIG. 2 illustrates a second embodiment of a method according to the present invention;

FIG. 3 illustrates a variant of the application and connection of a transverse reinforcement structure on a longitudinal thread structure.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, and more particularly to FIGS. 1a-1e, there is shown a first embodiment of a method according to the present invention for producing the base structure of a press felt.

FIG. 1a illustrates the production of longitudinal thread structure 1 of the base structure. To this end, skein of threads 2 parallel to one another are helically wound around two rollers 3, 4 disposed at a distance from and essentially parallel to one another, with the progression of the helical winding, i.e., the winding direction, occurring perpendicularly to the two rollers in the direction of the provided width (CMD) of the felt belt up to the provided width of the felt belt. Here, the length of one winding corresponds to the circumference of thread structure 1 thus formed.

In the step of the method of the present invention shown in FIG. 1b, carrier layer 5 embodied as a non-woven fibrous layer is applied to thread structure 1; the carrier layer may subsequently be needled, for example, to the thread structure. Non-woven fibrous layer 5 includes hot melt adhesive fibers and extends over the length and width of thread structure 1.

The status of the method of the present invention shown in FIG. 1c includes the steps of applying a transverse reinforcement structure embodied as transverse thread structure 6 to longitudinal thread structure 1, which has already been provided with non-woven fibrous layer 5, and connecting the same to longitudinal thread structure 1 in order to form tube-like composite structure 7. In the present case, the connection of transverse reinforcement structure 6 to longitudinal thread structure 1 is facilitated by non-woven fibrous layer 5. To this end, the sandwich of longitudinal thread structure 1, the non-woven fibrous layer 5, and transverse thread structure 6 are first needled and subsequently hot calendered between heated roller pair 8, 9, whereby, in the subsequent step, non-woven fibrous layer 5 is connected to longitudinal thread structure 1 and transverse thread structure 6 by the hot melt adhesive fibers melting and resolidifying. Composite structure 10 thus obtained has the structure of a tube.

The needling allows longitudinal thread structure 1 and/or transverse thread structure 6 to at least partially, for example, completely, be embedded in non-woven fibrous layer 5.

In the step of the method of the present invention shown in FIG. 1d, opposing sections 11, 12 of tube-like structure 10 are placed one atop the other such that tube-like structure 10 forms flat structure 13 whose length corresponds to approximately half of the circumference of tube-like structure 10 and which has seam loops 16, 17 on opposing longitudinal ends 14, 15 that are provided by helically wound longitudinal threads 2.

FIG. 1e illustrates the steps of flat structure 13 being made continuous by combining opposing seam loops 16, 17 and connecting the same to one another by means of fixing wire 18 and connecting sections 11, 12 of flat structure 13 placed one atop the other to form base structure 19. In the present case, the connection of sections 11, 12 of flat structure 13 placed one atop the other occurs by needling, for example, by means of needle arrangement 20.

In the present case, the structure is made continuous before the connection of sections placed one atop the other. To this end, after being made continuous, flat structure 13 is tensed in its longitudinal direction MD. In the present case, this occurs in that the flat structure, which has been made continuous, is guided over a pair of rollers 21, 22 disposed at a distance from and parallel to one another and the distance between rollers 21, 22 is increased in the longitudinal direction MD.

FIG. 2 illustrates base structure 19′ that is formed by a plurality of flat structures 13a-13i disposed in a row next to one another and connected by means of fixing wires 18a-18i on merged seam loops 16a, 17b.

FIG. 3 illustrates a variant of the application and connection of a transverse reinforcement structure on a longitudinal thread structure.

To this end, longitudinal thread structure 23 is provided having a length and a width. Non-woven fibrous layer 24 is deposited on longitudinal thread structure 23 that extends over the length and width of the longitudinal thread structure and that is needled with longitudinal thread structure 23 to form longitudinal reinforcement module 33 such that the longitudinal thread structure is disposed inside non-woven fibrous layer 24. Moreover, transverse reinforcement module output strip 25 is provided, having a length and a width, which is wound onto roll 26 and is present as rolling stock. Transverse reinforcement module output strip 25 is laterally placed relative to longitudinal reinforcement module 33 in that respective free end 27 of transverse reinforcement module output strip 25 is guided from one longitudinal edge 28 of longitudinal reinforcement module 33 to the other longitudinal edge 29 of longitudinal reinforcement module 33 (see arrow). After or during its placement, transverse reinforcement module output strip 25 is deposited on longitudinal reinforcement module 33. After being deposited, the section of transverse reinforcement module output strip 25 placed on longitudinal reinforcement module 33 is separated from remaining transverse reinforcement module output strip 25, forming transverse reinforcement module 30a, 30b.

As an alternative, the section of transverse reinforcement module output strip 25 to be placed on longitudinal reinforcement module 33 may already be separated from remaining transverse reinforcement module output strip 25 during the deposition of transverse reinforcement module output strip 25 onto longitudinal reinforcement module 33 in order to form transverse reinforcement module 30a, 30b. As may be seen from the depiction in FIG. 3, transverse reinforcement modules 30a, 30b are cut such that their length corresponds to the width of longitudinal reinforcement module 33.

In the depiction according to FIG. 3, one transverse reinforcement module 30a has already been deposited onto non-woven fibrous layer 24 according to the method of the present invention described above while, at the moment shown in the depiction, transverse reinforcement module output strip 25 is being laterally placed relative to longitudinal reinforcement module 33 and deposited thereon and, once deposition has occurred (not shown), is cut such that transverse reinforcement module 30b extends over the width of longitudinal reinforcement module 33.

After the deposition of transverse reinforcement module 30a onto longitudinal reinforcement module 33, longitudinal reinforcement module 33 is moved in its longitudinal direction MD on a path relative to transverse reinforcement module output strip 25 that essentially corresponds to the width of transverse reinforcement module output strip 25. By repeating the steps described above, transverse reinforcement modules 30a, 30b, . . . are disposed lying one after the other in the longitudinal direction of the felt belt.

In the present case, the method of the present invention is carried out such that, when base structure 31 is completed, each transverse reinforcement module 30a, 30b deposited on longitudinal reinforcement module 33 extends over the width of longitudinal reinforcement module 33 and transverse reinforcement modules 30a, 30b disposed lying one after the other are expanded by additional transverse reinforcement modules, which are not shown here, to form an uninterrupted layer.

The deposited and cut transverse reinforcement modules 30a, 30b, . . . are connected to non-woven fibrous layer 24 and longitudinal thread structure 23 in that longitudinal thread structure 23, non-woven fibrous layer 24, and transverse reinforcement module(s) 30a, 30b, . . . disposed thereon are subjected together to the effects of heat under pressure, in that they are guided around heated roller 32. In this manner, transverse reinforcement modules 30a, 30b, non-woven fibrous layer 24, and longitudinal thread structure 23 are pressed with one another, which ensures a good bond.

While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.