U.S. patent application number 12/490075 was filed with the patent office on 2009-10-15 for belt.
This patent application is currently assigned to FORBO SIEGLING, LLC. Invention is credited to Sandra Vause Canipe, Jay Philip Leighton.
Application Number | 20090258744 12/490075 |
Document ID | / |
Family ID | 32681309 |
Filed Date | 2009-10-15 |
United States Patent
Application |
20090258744 |
Kind Code |
A1 |
Leighton; Jay Philip ; et
al. |
October 15, 2009 |
BELT
Abstract
A belt assembly is provided for use as an endless belt traveling
relative to a frame structure. The belt assembly comprises a first
plain woven fabric layer having an inner surface and an outer
surface that at least partially forms an upper surface of the belt.
The first fabric layer includes synthetic yarns having a denier of
at least about 1000. A second lofty woven fabric layer has an inner
surface and an outer surface that at least partially forms a bottom
surface of the belt. The second fabric layer includes an effective
amount of textured synthetic yarns and/or synthetic staple filament
yarns. An adhesive composition comprising an elastomeric material
is adhered to the inner surface of the first fabric layer and the
inner surface of the second fabric layer for joining the fabric
layers.
Inventors: |
Leighton; Jay Philip;
(Charlotte, NC) ; Canipe; Sandra Vause;
(Harrisburg, NC) |
Correspondence
Address: |
MOORE & VAN ALLEN PLLC
P.O. BOX 13706
Research Triangle Park
NC
27709
US
|
Assignee: |
FORBO SIEGLING, LLC
Huntersville
NC
|
Family ID: |
32681309 |
Appl. No.: |
12/490075 |
Filed: |
June 23, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10337706 |
Jan 7, 2003 |
7549938 |
|
|
12490075 |
|
|
|
|
Current U.S.
Class: |
474/267 ;
474/266 |
Current CPC
Class: |
B29D 29/00 20130101;
A63B 22/02 20130101; A63B 22/0207 20151001; A63B 22/0285
20130101 |
Class at
Publication: |
474/267 ;
474/266 |
International
Class: |
F16G 1/10 20060101
F16G001/10 |
Claims
1. A belt for use as an endless belt traveling relative to a frame
structure, the belt comprising: a lofty woven fabric that at least
partially forms a bottom surface of the belt, the fabric including
an effective amount of textured synthetic yarns.
2. A belt as recited in claim 1, wherein the yarns are warp
yarns.
3. A belt as recited in claim 1, wherein the yarns are weft
yarns.
4. A belt as recited in claim 1, wherein the yarns are
polyester.
5. A belt as recited in claim 1, wherein the yarns have a denier of
about 300.
6. A belt as recited in claim 1, wherein the fabric comprises about
73 warp ends per inch in the lateral direction and about 40 weft
ends per inch in the longitudinal direction.
7. A belt as recited in claim 1, wherein the yarns are continuous
filament yarns.
8. A belt as recited in claim 1, wherein the yarns are continuous
multifilament yarns.
9. A belt as recited in claim 1, wherein the fabric is a plain
weave.
10. A belt as recited in claim 1, wherein the fabric is a twill
weave.
11. A belt as recited in claim 10, wherein the fabric is a 2/1
twill weave.
12. A belt for use as an endless belt traveling relative to a frame
structure, the belt comprising: a lofty woven fabric that at least
partially forms a bottom surface of the belt, the fabric including
an effective amount of synthetic staple filament yarns.
13. A belt as recited in claim 12, wherein the yarns are
polyester.
14. A belt as recited in claim 12, wherein the yarns have a denier
of about 300.
15. A belt as recited in claim 12, wherein the fabric comprises
about 73 warp ends per inch in the lateral direction and about 40
weft ends per inch in the longitudinal direction.
16. A belt as recited in claim 12, wherein the fabric is a plain
weave.
17. A belt as recited in claim 12, wherein the fabric is a twill
weave.
18. A belt as recited in claim 17, wherein the fabric is a 2/1
twill weave.
19. A belt for use as an endless belt traveling relative to a frame
structure, the belt comprising: a plain woven fabric that at least
partially forms a top layer of the belt, the fabric including
synthetic yarns having a denier of at least about 1000.
20. A belt as recited in claim 19, wherein the fabric comprises
multifilament yarns.
21. A belt as recited in claim 20, wherein the yarns are
polyester.
22. A belt assembly for use as an endless belt traveling relative
to a frame structure, the belt assembly comprising: a first plain
woven fabric layer having an inner surface and an outer surface
that at least partially forms an upper surface of the belt, the
first fabric layer including synthetic yarns having a denier of at
least about 1000; a second lofty woven fabric layer having an inner
surface and an outer surface that at least partially forms a bottom
surface of the belt, the second fabric layer including an effective
amount of textured synthetic yarns; and an adhesive composition
comprising an elastomeric material, the adhesive composition
adhered to the inner surface of the first fabric layer and the
inner surface of the second fabric layer for joining the fabric
layers.
23. A belt assembly as recited in claim 22, wherein the first
fabric layer comprises multifilament yarns.
24. A belt assembly as recited in claim 22, wherein the first
fabric layer comprises a polyester fabric.
25. A belt assembly as recited in claim 22, further comprising a
composition including polyvinyl chloride, the composition adhered
to the outer surface of the first fabric layer such that the
composition at least partially forms the outer surface of the first
fabric layer.
26. A belt assembly as recited in claim 22, wherein the textured
yarns of the second fabric layer are warp yarns.
27. A belt assembly as recited in claim 22, wherein the textured
yarns of the second fabric layer are weft yarns.
28. A belt assembly as recited in claim 22, wherein the second
fabric layer comprises a polyester fabric.
29. A belt as recited in claim 22, wherein the textured yarns of
the second fabric layer have a denier of about 300.
30. A belt assembly as recited in claim 22, wherein the second
fabric layer comprises about 73 warp ends per inch in the lateral
direction and about 40 weft ends per inch in the longitudinal
direction.
31. A belt assembly as recited in claim 22, wherein the second
fabric layer is a plain weave.
32. A belt assembly as recited in claim 22, wherein the second
fabric layer is a twill weave.
33. A belt assembly as recited in claim 32, wherein the second
fabric layer is a 2/1 twill weave.
34. A belt assembly as recited in claim 22, wherein the elastomeric
material is a cured polyurethane.
35. A belt assembly for use as an endless belt traveling relative
to a frame structure, the belt assembly comprising: a first plain
woven fabric layer having an inner surface and an outer surface
that at least partially forms an upper surface of the belt, the
first fabric layer including synthetic yarns having a denier of at
least about 1000; a second lofty woven fabric layer having an inner
surface and an outer surface that at least partially forms a bottom
surface of the belt, the second fabric layer including an effective
amount of synthetic staple filament yarns; and an adhesive
composition comprising an elastomeric material, the adhesive
composition adhered to the inner surface of the first fabric layer
and the inner surface of the second fabric layer for joining the
fabric layers.
36. A belt assembly as recited in claim 35, wherein the first
fabric layer comprises multifilament yarns.
37. A belt assembly as recited in claim 35, wherein the first
fabric layer comprises a polyester fabric.
38. A belt assembly as recited in claim 35, further comprising a
composition including polyvinyl chloride, the composition adhered
to the outer surface of the first fabric layer such that the
composition at least partially forms the outer surface of the first
fabric layer.
39. A belt assembly as recited in claim 35, wherein the second
fabric layer comprises a polyester fabric.
40. A belt as recited in claim 35, wherein the yarns of the second
fabric layer have a denier of about 300.
41. A belt assembly as recited in claim 35, wherein the second
fabric layer comprises about 73 warp ends per inch in the lateral
direction and about 40 weft ends per inch in the longitudinal
direction.
42. A belt assembly as recited in claim 35, wherein the second
fabric layer is a plain weave.
43. A belt assembly as recited in claim 35, wherein the second
fabric layer is a twill weave.
44. A belt assembly as recited in claim 43, wherein the second
fabric layer is a 2/1 twill weave.
45. A belt assembly as recited in claim 35, wherein the elastomeric
material is a cured polyurethane.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 10/337,706 for a "Belt" filed on Jan. 7, 2003,
in the name of Jay Philip Leighton, et al., now U.S. Pat. No.
7,549,938, the contents of which are hereby incorporated by
reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The present inventions relate to belts and belt lubricants,
and more particularly to lubricated, endless belts for
treadmills.
[0003] Treadmills used for exercise are well known and very
popular. A prior art exercise treadmill typically includes an
endless belt that is driven by a motor so that the bottom surface
of an upper run of the belt slides across an upper surface of a
stationary deck. In use, a person using the treadmill engages the
top surface of the upper run of the belt at a position above the
deck, which contributes to friction between the bottom surface of
the upper run and the upper surface of the deck. Over the years,
efforts have been made to reduce this friction, in an effort to
reduce: the power required to drive the belt, friction-induced
heating, and friction-induced noise. Reducing the friction can
enhance the operation and life of the belt. It is known to reduce
the friction between treadmill belts and decks through the use of
lubrication, and there are several known lubricants and associated
methods.
[0004] It is prior art to apply a lubricant, such as a lubricant
consisting of polypropylene wax, a polyurethane binder and solvent,
to rolls of belt material before forming endless belts (e.g.,
"light duty" belts, which are discussed below in this Background
section) from the belt material. Then, the solvent is driven off by
heating, so that the resultant lubricant is impregnated in the belt
material and is substantially in solid form at room temperature.
Thereafter, sections are cut from the belt material and joined
(e.g., spliced) end-to-end to form the endless belts that are used
as treadmill belts. Although the foregoing method of lubricating is
very efficient in some regards, it can only be used with limited
types of lubricants, because some lubricants will interfere with
the splicing.
[0005] It is prior art to apply a liquid silicone lubricant to the
bottom surface of an endless treadmill belt. When using a liquid
silicone lubricant, the lubricant is typically individually sprayed
or rolled onto individual treadmill belts after the treadmill belts
have been formed/made endless. According to one prior art method,
an endless belt is placed on a lubricating fixture having three
rollers that the belt extends around such that the "bottom" (i.e.,
"inner") surface of the belt engages the pulleys and the "top"
(i.e., "outer") surface of the belt faces away from the pulleys.
One of pulleys is driven and an applicator applies the silicone
lubricant to the bottom surface as the belt travels relative to the
applicator.
[0006] The liquid silicone provides adequate lubrication, but since
it remains in liquid form, it has a tendency to migrate to the top
surface of the belt, to any packaging materials used when shipping
the belt, or to other locations where lubrication is not desired.
Additionally, if too much silicone liquid is applied, belt tracking
problems can result, meaning that the belt can become misaligned
around the pulleys of the treadmill. If too little silicone liquid
is used, belts are inadequately lubricated, which can
disadvantageously increase the amount of power required to drive
the belt, as well as the heat and noise generated by the belt
sliding across the deck, which can negatively impact the life and
operation of the belt. Finally, lubricating endless belts
individually is slow and labor intensive compared with coating
rolls of belting prior to forming endless belts therefrom.
Typically, liquid silicone cannot be efficiently applied to rolls
of belting before making numerous endless belts therefrom because
the liquid silicone will interfere with bonding/adhesion that is
necessary for satisfactorily splicing.
[0007] It is also prior art to apply wax to the upper surface of
the deck of a treadmill. The wax can provide adequate lubrication
only if a sufficient quantity is used. If too much is used, wax
clings to treadmill rollers resulting in excessive noise and
tracking difficulties. After a period of use, wax is typically lost
from the deck such that some form of relubrication is necessary. As
one example, U.S. Pat. No. 3,659,845 discloses a treadmill with a
stationary support surface over which the upper run of a belt
travels, and the upper surface of the support surface is formed
from canvas that is impregnated with a wax, such as carnauba
wax.
[0008] Whether or not a lubricant is used, the underlying
construction of a treadmill belt can also affect the amount of
friction resulting from the treadmill belt sliding across the deck.
For example, a prior art "light-duty" treadmill belt, which is
particularly well suited for use in homes, will now be described.
The light-duty belt has all polyester top and bottom plies that are
joined by an adhesive (e.g., polyurethane or PVC) positioned
between the top and bottom plies. The top ply is a plain weave of
1000 denier multifilament polyester yarns, and the bottom ply,
which includes the bottom surface that slides across the deck, is a
plain weave, with both weft and warp yarns being spun polyester
yarns formed from staple fibers. This "light-duty" belt is formed
by cutting a section from a roll of belt material after the belt
material has been lubricated as described above, so that the bottom
surface of the bottom ply of the belt is impregnated with a
lubricant mixture of polypropylene wax and polyurethane binder. The
endless belt is formed by splicing the opposite ends of the cut
section together. The splice is a "Z" splice, meaning that opposite
ends of the section are cut in a zigzag pattern and then meshed
together, with a PVC strip hot-pressed at the meshed area, over the
top surface of the top ply.
[0009] As an additional example, a prior art "heavy-duty" treadmill
belt, which is particularly well suited for use in spas, will now
be described. The heavy-duty belt has all polyester lop and bottom
plies that are joined by an adhesive (e.g., polyurethane or PVC)
positioned between the top and bottom plies. The top ply is a plain
weave of 1000 denier multifilament polyester yarns. In the bottom
ply of these belts, the weft yarns, which extend across the belt,
are monofilament, and warp yarns, which extend in the longitudinal
direction (i.e., the direction of belt travel), are 1000 denier
multifilament polyester yarns (i.e., "continuous" filament yarns).
Plain weaves as well as twill weaves (e.g., 3/1) are used for the
bottom ply. In the twill bottom plies, the long, floating portions
of the warp yarns contact the deck that the belt slides across,
with the belt traveling in the longitudinal direction in which the
warp yarns extend. Likewise, the belt travels in the longitudinal
direction in which the warp yarns extend for the plain weaves. In
these belts, the warp yarns are twisted about 130 turns/meter. For
this "heavy-duty" belt, it is formed by cutting a section from a
roll of belt material and forming a continuous belt via splicing
the opposite ends of the section together. The splice is formed by
peeling back plies at the opposite ends and then overlapping and
sealing together those overlapped portions. This type of belt is
typically run on a waxed deck or otherwise used in a treadmill with
an automatic lubricating system that sprays lubricant onto the belt
during use of the treadmill.
[0010] Although prior treadmill belts operate reasonably well,
there is always a desire for new treadmill belts that provide an
improved balance of properties.
BRIEF SUMMARY OF THE INVENTION
[0011] An embodiment of a belt for use as an endless belt traveling
relative to a frame structure comprises a lofty woven fabric that
at least partially forms a bottom surface of the belt. In
particular, the fabric includes an effective amount of textured
synthetic yarns.
[0012] Another embodiment of a belt for use as an endless belt
traveling relative to a frame structure comprises a lofty woven
fabric that at least partially forms a bottom surface of the belt.
The fabric includes an effective amount of synthetic staple
filament yarns.
[0013] A further embodiment of a belt for use as an endless belt
traveling relative to a frame structure comprises a plain woven
fabric that at least partially forms a top layer of the belt. The
fabric includes synthetic yarns having a denier of at least about
1000.
[0014] An embodiment of a belt assembly for use as an endless belt
traveling relative to a frame structure comprises a first plain
woven fabric layer having an inner surface and an outer surface
that at least partially forms an upper surface of the belt. The
first fabric layer includes synthetic yarns having a denier of at
least about 1000. A second lofty woven fabric layer has an inner
surface and an outer surface that at least partially forms a bottom
surface of the belt. The second fabric layer includes an effective
amount of textured synthetic yarns. An adhesive composition
comprising an elastomeric material is adhered to the inner surface
of the first fabric layer and the inner surface of the second
fabric layer for joining the fabric layers.
[0015] Another embodiment of a belt assembly for use as an endless
belt traveling relative to a frame structure comprises a first
plain woven fabric layer having an inner surface and an outer
surface that at least partially forms an upper surface of the belt.
The first fabric layer including synthetic yarns having a denier of
at least about 1000. A second lofty woven fabric layer has an inner
surface and an outer surface that at least partially forms a bottom
surface of the belt. The second fabric layer includes an effective
amount of synthetic staple filament yarns. An adhesive composition
comprising an elastomeric material is adhered to the inner surface
of the first fabric layer and the inner surface of the second
fabric layer for joining the fabric layers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Having thus described the invention in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0017] FIG. 1 is a schematic, perspective view of portions of a
prior art treadmill in accordance with a comparative embodiment,
and FIG. 1 is illustrative of features of an exemplary embodiment
of the present invention;
[0018] FIG. 2 is a schematic, elevational, partial view of a
longitudinally extending edge of an upper run of the prior art belt
of FIG. 1, in accordance with the comparative embodiment;
[0019] FIG. 3 diagrammatically illustrates prior art methods and
apparatus for forming endless belts from a roll of belt material,
in accordance with the comparative embodiment, and FIG. 3 is
illustrative of features of the exemplary embodiment of the present
invention; and
[0020] FIG. 4 is a schematic, elevational, partial view of a
longitudinally extending edge of an upper run of a treadmill belt,
in accordance with the exemplary embodiment of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present invention now will be described more fully
hereinafter with reference to the accompanying drawings, in which
some, but not all embodiments of the invention are shown. Indeed,
the invention may be embodied in many different forms and should
not be construed as limited to the embodiments set forth herein;
rather, these embodiments are provided so that this disclosure will
satisfy applicable legal requirements. Like numbers refer to like
elements throughout.
[0022] A lubricated treadmill belt of an exemplary embodiment of
the present invention has an improved balance of properties.
Nonetheless, some features of the exemplary embodiment of the
present invention are not novel per se. Accordingly, in the
following, a comparative embodiment, which is prior art to the
present invention, is first described with reference to FIGS. 1-3,
followed by a description of the exemplary embodiment of the
present invention. FIGS. 1-3 are diagrammatically/generally
illustrative of some features of the exemplary embodiment of the
present invention.
Comparative Embodiment
[0023] FIG. 1 is a schematic, perspective view of portions of a
prior art treadmill 20 in accordance with a comparative embodiment.
The treadmill 20 includes an endless belt 21 that is carried by a
frame and driven by a motor 22. The belt 21 is endless by virtue of
opposite ends of the belt being joined together at a joint 23,
which is preferably in the form of a splice. That is, the joint 23
is diagrammatically illustrative of a splice. The belt 21 is
substantially uniform along its length, except for at the joint
23.
[0024] The frame includes a pair of longitudinally extending frame
members 24 that are spaced apart from one another in a lateral
direction. The belt 21 is partially cut away in FIG. 1, to more
fully show a stationary deck 26 that is mounted to and extends
laterally between medial portions of the frame members 24. Front
and rear pulleys 28 are rotatably mounted to the frame members 24
and extend laterally between the frame members. The pulley 28 at
the front of the frame is driven, via a drive belt 30, by the motor
22, which is mounted to the frame. The belt 21 extends around the
pulleys 28 and the deck 26 so that the bottom surface of the upper
run of the belt engages the pulleys and deck, and the top surface
of the upper run faces away from the pulleys and deck. In use, the
feet of a person using the treadmill engage the top surface of the
belt 21 at a position above the deck 26, which contributes to the
friction resulting from the bottom surface of the belt sliding
across the upper surface of the deck. In some cases, the upper
surface of the deck 26 is unwaxed, or the upper surface of the deck
26 can have wax 32 thereon, in an effort to reduce the
friction.
[0025] FIG. 2 is a schematic, elevational, partial view of a
longitudinally extending edge of the upper run the prior art belt
21, in accordance with the comparative embodiment. The belt 21
includes top and bottom plies 34, 36 that are each woven polyester,
and the top and bottom plies are joined to one another by an
intermediate ply/adhesive 38 therebetween. In use, the feet of a
person using the treadmill 20 engage a top surface 40 of the belt
21 at a position above the deck 26. The top surface 40 is defined
by a PVC coating 41 that is adhered to and covers the top ply 34.
The bottom ply 36 includes the bottom surface 42 of the belt that
slides across the upper surface of the deck 26 (FIG. 1). The belt
21 includes a lubricant coating composition 43 that is impregnated
in the bottom ply 36 and is proximate the bottom surface 42. In
FIG. 2, the lubricant coating composition 43 is schematically
illustrated by stippling (i.e., dots and flicks) in the bottom ply
36.
[0026] FIG. 3 diagrammatically illustrates prior art methods and
apparatus for forming endless belts 21 from a roll 44 of belt
material 46, in accordance with the comparative embodiment. The
belt material 46 is unwound from a roll 44 by one or more transport
mechanisms 48 arranged along the travel path of the belt material.
The belt material 46 is transported through a coater 50, such that
the surface of the belt material that will eventually contact the
upper surface of the deck 26 (FIG. 1) is facing upward. That is,
the bottom ply of the belt material 46 is facing up. Any type of
suitable coater known in the art of wide web or textile coating may
be used. Exemplary coaters include knife coaters, roll coaters, and
the like. In the coater 56, the belt material is preferably
transported through a nip defined between an upper knife edge and a
lower roller. A liquid coating composition is applied to (e.g.,
poured onto, or the like) the bottom ply of belt material 46 at a
position just upstream from the nip, so that the liquid coating
composition is impregnated into the bottom ply of the belt material
as it passes through the nip. Thereafter, the belt material 46 with
the impregnated liquid coating composition is transported through a
drying oven 52 using a tenter frame, or the like. The solvent
component of the liquid coating composition is volatilized in the
drying oven 52, resulting in an at least substantially solid
lubricant coating 43 being impregnated in the bottom ply of the
belt material.
[0027] The dwell time for each incremental portion of the belt
material within the drying oven 52 is about 1 to 5 minutes, or more
specifically about 2 minutes, and the temperature within the oven
is about 80.degree. to 160.degree. C., or more specifically about
100.degree. C. Thereafter, the belt material is transported through
a cooling mechanism 54, where the coated belt material is cooled,
such as by nipping the coated belt material between chilled
rollers. The coated belt material 56 is then formed into a roll 57.
Thereafter, and in some cases at a different facility, the coated
belt material 56 is unwound from the roll 57 by one or more
transport mechanisms 58 positioned along the travel path of the
coated belt material 56. At a cutting mechanism 60, sections of
belt material 62 are cut from the coated belt material 56. At a
splicing mechanism 64, each of the sections of belt material 62 is
joined end-to-end to form an endless belt 21.
Exemplary Embodiment
[0028] An exemplary embodiment of the present invention is like the
comparative embodiment described above, except for variations noted
and variations that will be apparent to those of ordinary skill in
the art. Accordingly, elements of the exemplary embodiment that at
least generally correspond to elements of the comparative
embodiment are respectively identified by the same reference
numerals, increased by a hundred.
[0029] FIG. 4 is a schematic, elevational, partial view of a
longitudinally extending edge of the upper run of the belt 121 of
the exemplary embodiment of the present invention. The belt 121
includes top and bottom plies 134, 136 that are joined by an
intermediate ply/adhesive 138 therebetween. The top surface 140 of
the belt 121 is preferably substantially planar and is preferably
defined by a coating 141, which is preferably PVC, that is adhered
to and covers the top ply 134. The coating 141 is preferably
embossed with an amorphous, orange-peel-like pattern. Embossing a
treadmill coating with an amorphous, orange-peel-like pattern is
not novel per se.
[0030] The bottom ply 136 includes a bottom surface 142 that slides
across the upper surface of the deck 26 (FIG. 1). Between the
pulleys 28 (FIG. 1), the bottom surface 142 is preferably
substantially planar, except for the texture of the fabric of the
bottom ply 136 and any discontinuity in the region of the splice 23
(FIG. 1). The exemplary embodiment of the present invention is not
limited to the type of deck 26 or type of treadmill 20 illustrated
and described with reference to FIG. 1, because the belt 121 of the
exemplary embodiment of the present invention operates
advantageously with a wide range of different types of decks and
treadmills, and with a wide variety of other types of conveyor
structures.
[0031] In accordance with the exemplary embodiment of the present
invention, the belt 121 is preferably formed by splicing together
opposite ends of a section of belt material. Preferably, the splice
(e.g., see splice 23 in FIG. 1) extends at an oblique angle
relative to the longitudinally extending edges of the endless belt
121, and the belt 121 is preferably substantially uniform along its
length, except for in the region of the splice. The splice is
preferably a "Z" splice, meaning that opposite ends of the section
are cut in a zigzag pattern and then meshed together, with a PVC
strip hot-pressed at the meshed area, over the top surface of the
top ply 134.
[0032] As noted above, the belt 121 preferably includes three main
layers: a top ply 134, an intermediate ply/adhesive 138 and a
bottom ply 136. In accordance with the exemplary embodiment
illustrated in FIG. 4, the top ply 134 is preferably a plainly
woven fabric. The top ply 134 may be formed of any woven fabric
exhibiting sufficient durability and flexibility, such as a woven
fabric formed from polyester yarns, particularly multifilament
polyester yarns having a denier of about 1000. As used herein, the
term "yarn" refers to any continuous strand of textile fibers,
filaments or material in a form suitable for knitting, weaving, or
otherwise intertwining to form a textile fabric. In accordance with
the exemplary embodiment of the present invention, it is preferred
for all of the fabrics of the belt 121 to be constructed solely of
man-made filaments/fibers, although natural fibers may be used in
alternative embodiments.
[0033] The intermediate ply/adhesive 138 is preferably formed from
an elastomeric material. In accordance with the exemplary
embodiment of the present invention, the intermediate ply/adhesive
138 is formed from a cured elastomeric material, such as a cured
polyurethane.
[0034] The bottom ply 136 may be formed from any fabric providing
sufficient strength, durability and frictional properties to the
resulting belt construction. In accordance with the exemplary
embodiment of the present invention, the fabric of the bottom ply
136 is preferably lofty. Although not wishing to be bound by
theory, it is believed that the incorporation of a bottom ply 136
exhibiting sufficient loftiness/bulkiness reduces the noise
resulting from friction between the bottom surface 142 and the deck
26 (FIG. 1) while the treadmill is in operation.
[0035] In accordance with the exemplary embodiment of the present
invention, the bottom ply 136 is formed from a lofty woven fabric
that includes an effective amount of textured synthetic yarns in at
least the warp direction. As used herein, the term "textured" yarn
refers to yarns having increased bulk in comparison to comparable
yarns which have not been subjected to a texturizing process. Hence
the terms "bulky" and "textured" are used interchangeably
throughout the remainder of the application. Textured yarns are
generally characterized by the presence of crimps or random loops
down the length of the yarn. Advantageously the bottom ply 136
includes textured synthetic continuous filament yarns in the warp
and/or weft direction, particularly continuous multifilament yarns.
In accordance with the exemplary embodiment of the present
invention, at least a portion of the warp and/or weft yarns within
the bottom ply 136 are formed from textured polyester continuous
filament yarns, and preferably all of the yarns of the bottom ply
are textured polyester continuous filament yarns.
[0036] As known in the art, bulk and/or crimp may be imparted to
continuous filament yarns by a variety of texturing processes,
including false twist texturing, air entangling and the like. In
accordance with the exemplary embodiment of the present invention,
a preferred lofty/bulky fabric for use in the bottom ply 136 is
continuous filament polyester fabric Style No. 930392 available
from Milliken & Company of Spartanburg, S.C.
[0037] In accordance with alternative embodiments of the present
invention, yarns formed from staple fibers, such as synthetic
staple fibers, are used either in conjunction with or in lieu of
the bulky continuous filament yarns described above. For example,
the bottom ply 136 may be formed entirely from synthetic staple
filament yarns. Alternatively, the bottom ply 136 may include a
mixture of yarns formed from staple and textured continuous
filaments. In such alternative embodiments, the synthetic staple
yarn is preferably formed from polyester.
[0038] In accordance with the exemplary embodiment of the present
invention, the bottom ply 136 is preferably formed from a twill
weave. Alternatively, the bottom ply 136 may be formed from a plain
weave. More specifically, preferred fabric specifications of the
bottom ply 136, in accordance the exemplary embodiment of the
present invention, are provided below: [0039] the fabric of the
bottom ply 136 is a twill weave, preferably a 2/1 twill weave,
meaning that where the bottom surface 142 of the upper run engages
the deck 26 (FIG. 1), for each warp yarn, the warp yarn passes
under two weft yarns for every weft yarn it passes over, so that
the long, floating portions of the warp yarns contact the upper
surface of the deck 26 that the belt slides across, with the belt
traveling in the direction in which the warp yarns extend; [0040]
the weft and warp yarns of the fabric of the bottom ply 136 are
about 300 denier yarns; and the fabric of the bottom ply 136 has
about 73.times.40 yarns per inch (i.e., 73 warp ends per inch in
the lateral direction, and 40 weft ends per inch in the
longitudinal direction).
[0041] Belts 121 formed in accordance with the exemplary embodiment
of the present invention preferably exhibit an elasticity
differential between the plies. More particularly, the fabric of
the bottom ply 136 can be stretched more easily than the fabric of
the top ply 134, and the fabric of the bottom ply 136 has a greater
range of elasticity than the fabric of the top ply 134. In theory,
the textured nature of the bottom ply 136 provides a relatively
higher stretchability and relatively larger range of elasticity.
That is, and very generally described, the bottom ply 136 exhibits
relatively greater "springiness" in the longitudinal direction than
the top ply 134, and the top ply 134 exhibits relatively greater
"stiffness" in the longitudinal direction than the bottom ply 136.
More specifically, the bottom ply 136 has a lower modulus of
elasticity than the top ply 134, in the longitudinal direction.
Advantageously, the relatively greater "stiffness" of the top ply
134 compensates for the relatively greater "springiness" of the
bottom ply 136, so that the resulting belt 121 is not too "springy"
in the longitudinal direction.
[0042] As mentioned above, the bulkiness of at least the warp yarns
in the bottom ply 136 is believed to reduce noise associated with
the friction between the bottom surface 142 of the belt 121 and the
deck 26 (FIG. 1). In accordance with the exemplary embodiment of
the present invention, the coefficient of friction between the
bottom surface 142 of the belt 121 and the deck 26 is preferably
reduced by an at least substantially solid lubricant composition
143 that is impregnated in the fabric of the bottom ply 136 and is
proximate the bottom surface 142. As used herein, the term "solid"
means that the solvents employed within the corresponding liquid
lubricant composition, from which the solid lubricant composition
143 has been formed, have been substantially removed, such as by
volatization and the like. The solid lubricant composition 143 is
preferably a mixture, and most preferably is a substantially
uniformly dispersed mixture. In FIG. 4, the solid lubricant
composition 143 is schematically illustrated by stippling (i.e.,
dots and flicks) in the bottom ply 136.
[0043] In accordance with the exemplary embodiment of the present
invention, the solid lubricant composition 143 preferably includes
one or more higher viscosity lubricants, one or more lower
viscosity lubricants, and one or more binders, with the lower
viscosity lubricant(s) having lower viscosity than the higher
viscosity lubricant(s). Exemplary higher viscosity lubricants
preferably include waxes, such as natural and synthetic waxes.
Natural waxes include waxes derived from animal, vegetable and
mineral sources, as well as mixtures thereof. In accordance with
the exemplary embodiment of the present invention, the higher
viscosity lubricant is a vegetable wax, such as carnauba wax,
candelilla wax, bay berry wax, sugar cane wax and mixtures thereof.
Most preferably the vegetable wax is carnauba wax.
[0044] The solid lubricant composition 143 preferably includes no
more than about 60 weight percent of the higher viscosity
lubricant, based on the weight of the solid lubricant composition
("bosc"). More specifically, the solid lubricant composition 143
preferably includes from about 30 weight percent to about 60 weight
percent higher viscosity lubricant, bosc. Even more specifically,
in accordance with the exemplary embodiment of the present
invention, the solid lubricant composition 143 includes about 55
weight percent of the higher viscosity lubricant, bosc. In
alternative embodiments, the solid lubricant composition includes
about 52 weight percent of the higher viscosity lubricant,
bosc.
[0045] Suitable lower viscosity lubricants include silicones,
mineral oils, polyglycols, and mixtures thereof. In accordance with
the exemplary embodiment of the present invention, the lower
viscosity lubricant includes one or more silicone lubricants. In
accordance with the exemplary embodiment of the present invention,
the silicone lubricant is a polysiloxane, particularly a
polydimethlysiloxane. One exemplary silicone lubricant is Dow
Corning 200 Fluid, commercially available from the Dow Corning
Corporation of Midland Mich.
[0046] The lower viscosity lubricant can be included in any amount
providing sufficient lubricity without detrimentally impacting the
cohesion of the resulting solid lubricant composition 143. Lower
viscosity lubricants preferably exhibit a lower coefficient of
friction than higher viscosity lubricants. However, lower viscosity
lubricants can impact coating cohesion/adhesive properties.
Consequently, the solid lubricant composition 143 preferably
includes significantly higher amounts of the higher viscosity
lubricant than the lower viscosity lubricant. For example, the
weight ratio of the higher viscosity lubricant to lower viscosity
lubricant may be 2:1 or higher. Advantageously, the weight ratio of
the higher viscosity lubricant to lower viscosity lubricant may be
3:1 or higher, such as a ratio of about 3.33:1.
[0047] Accordingly, the solid lubricant composition 143 preferably
includes no more than about 30 weight percent of the lower
viscosity lubricant, bosc. More specifically, the solid lubricant
composition 143 preferably includes from about 10 weight percent to
about 30 weight percent of the lower viscosity lubricant, bosc.
Even more specifically, in accordance with the exemplary embodiment
of the present invention, the solid lubricant composition 143
includes about 16 weight percent of the lower viscosity lubricant,
bosc. In alternative embodiments of the present invention, the
solid lubricant composition 143 includes about 15 weight percent of
the lower viscosity lubricant, bosc.
[0048] The binder within the solid lubricant composition 143 serves
as an adhesive agent to provide bonding in the bottom ply 136.
Consequently, exemplary binders for use in the present invention
include any film forming polymer known in the art that is
compatible with the remaining components within the solid lubricant
composition 143 and provides sufficient bonding properties and
flexibility. Suitable binders include polyurethanes, acrylic
polymers, vinyl polymers, and the like, including mixtures and
copolymers thereof. In accordance with the exemplary embodiment of
the present invention, the binder is preferably polyurethane.
Suitable polyurethanes include both polyester polyurethanes and
polyether polyurethanes. In accordance with the exemplary
embodiment of the present invention, the polyurethane is a
polyester polyurethane. One suitable commercially available
polyester polyurethane is ESTANE.TM. 5712 F30 polyurethane from
Noveon, Inc. of Cleveland, Ohio.
[0049] The binder may be present in the solid lubricant composition
in any amount effective to provide sufficient bonding in the bottom
ply 136. For example, the binder may be present in the solid
lubricant composition 143 in an amount ranging from about 10 to 50
weight percent, bosc. Preferably, the solid lubricant composition
143 includes about 20 weight percent to about 30 weight percent
binder, bosc. More preferably, the solid lubricant composition 143
includes from about 25 weight percent to about 30 weight percent
binder, bosc, such as an amount of about 29 weight percent or about
28 weight percent.
[0050] In accordance with the exemplary embodiment of the present
invention, the solid lubricant composition may further include one
or more bonding agents, e.g. crosslinkers, to crosslink the binder
and further promote cohesion within the solid lubricant composition
143 and adhesion in the bottom ply 136. Any suitable crosslinker
known in the art for use in conjunction with a given binder may be
employed. Exemplary crosslinkers include isocyantes, such as
polyisocyanates and diisocyantes, peroxides, epoxies,
polyfunctional amides and mixtures thereof. In accordance with the
exemplary embodiment of the present invention, a polyisocyanate
crosslinking agent may be included in solid lubricant compositions
employing a polyurethane binder.
[0051] The crosslinker is included in the composition in amounts
effective to provide a sufficient amount of crosslinking within the
binder without imparting excessive stiffness to the resulting solid
lubricant composition 143. Preferably, the crosslinker is present
in the solid lubricant composition in amounts ranging from about
2.5 to 10 weight percent, bosc. In accordance with the exemplary
embodiment of the present invention, the crosslinker is preferably
present in an amount of about 4.9 weight percent, bosc.
[0052] In accordance with the exemplary embodiment of the present
invention, the solid lubricant composition is formed from a liquid
lubricant composition that is applied to, e.g. coated onto, the
bottom ply as a liquid lubricant composition. The solvents are then
removed from the liquid lubricant composition, typically by drying
and the like, preferably resulting in a layer of the solid
lubricant composition 143 substantially covering at least a portion
of the outermost surface of, and substantially impregnated into,
the fabric of the bottom ply 136.
[0053] The liquid lubricant composition may be formed by dispersing
or dissolving appropriate amounts of the higher viscosity
lubricant, the lower viscosity lubricant and a binder composition
in a lubricant solvent. The higher viscosity lubricant and lower
viscosity lubricant are normally incorporated into the liquid
lubricant composition in an undiluted form. The binder composition
preferably contains the binder polymer dispersed or dissolved in an
appropriate binder solvent. Suitable binder solvents include polar
organic solvents, such as acetone and methyl ethyl ketone ("MEK")
and mixtures thereof. In accordance with the exemplary embodiment
of the present invention, the binder solvent is a mixture of
acetone and MEK, particularly a mixture containing about 58 parts
acetone per about 42 parts MEK.
[0054] The lubricant solvent may be any organic solvent capable of
dispersing the higher and lower viscosity lubricants and binder
composition. The lubricant solvent is preferably a ketone based
solvent, such as cyclohexanone.
[0055] The liquid lubricant composition is preferably formed by
initially combining the higher and lower viscosity lubricants with
the lubricant solvent and heating the initial mixture to an
elevated temperature, such as a temperature of about 80.degree. C.
while the initial mixture is under low speed agitation. Upon
dissolution of the higher viscosity lubricant, the initial mixture
may be allowed to cool to a lower, yet elevated, temperature, such
as a temperature of about 55.degree. C. Upon cooling to the lower
temperature, the binder composition may be added, after which the
agitation speed may be increased and the liquid lubricant
composition may be agitated for a period of about 5 minutes. The
liquid lubricant composition is typically allowed to sit for at
least 24 hours, after which the liquid lubricant composition is
stirred and the viscosity is adjusted with an appropriate organic
solvent, such as acetone. The viscosity of the liquid lubricant
composition is preferably about 2500 cps (Brookfield viscosity
based on a 50 rpm spindle speed).
[0056] In the embodiments of the present invention which further
include a crosslinking agent, a bonding agent composition may be
added to the liquid lubricant composition. The bonding agent
composition preferably includes the crosslinker dissolved or
suspended in an appropriate organic solvent. For example, the
bonding agent composition may include a polyisocyante crosslinking
agent dissolved or suspended within ethyl acetate. One exemplary
bonding agent composition is DESMODUR RC, commercially available
from Bayer Corporation of Pittsburgh, Pa., which contains about 30%
polyisocyanate in ethyl acetate. The bonding agent composition is
preferably added to the liquid lubricating composition at room
temperature under high speed agitation. The resulting liquid
lubricant composition is allowed to agitate at least about 3
minutes prior to use. As known in the art, the shelf life of
compositions containing bonding agents may be limited. Accordingly,
the bonding agent composition may be added to the liquid lubricant
composition either immediately prior to or a few hours before its
application to the fabric of the bottom ply 136.
[0057] The liquid lubricant composition is preferably applied to
the belt material using the equipment and processes described in
conjunction with the comparative embodiment described above. More
particularly, a coater, such as a knife coater, is used to apply
the liquid lubricant composition to the bottom ply of the belt
material and the coated belt material is subsequently dried. In
accordance with the exemplary embodiment of the present invention,
the various solvents within the liquid lubricant composition are
volatilized in the drying oven 52 (FIG. 3) following the coating
process, so that the resulting solid lubricant composition 143 is
impregnated in the fabric of the bottom ply 136. The solid
lubricant composition 143 is preferably at least substantially in
solid form at room temperature (e.g., 72.degree. F.). The coated
belt 121 preferably has solid lubricant composition coat weight
ranging from about 1 oz/sq. yd to about 5 oz/sq. yd. Most
preferably, the solid lubricant composition 143 is present in the
belt 121 in an amount of about 2.5 oz/sq. yd.
[0058] The endless belts 121 of the exemplary embodiment of the
present invention are preferably used in treadmills; nonetheless,
the belts 121 can also be used in a wide range of other
applications in which belts are used. In one example, the endless
belt 121 is used in a treadmill with an unwaxed deck (e.g., see the
deck 26 in FIG. 1). In another example, the belt 121 is used in a
treadmill with a waxed deck (e.g., see the wax 32 on the deck 26 in
FIG. 1), but advantageously the quantity of wax on the deck can be
substantially reduced as compared to the prior art. Since the
lubricated belts 121 are used with unwaxed decks, or decks with
substantially reduced wax quantity, wax will not substantially
accumulate on rollers of the treadmills.
[0059] Numerous other advantages are associated with the belts 121
of the exemplary embodiment of the present invention. For example,
since the belt lubricant 143 of the exemplary embodiment is at
least substantially solid after drying, migration of the lubricant
143 is substantially precluded. Also, due to the solid nature of
the lubricant 143, it can advantageously be applied to rolls of
belting material before sections are cut therefrom and spliced,
because the solid lubricant does not substantially interfere with
the splicing/adhesion. Additionally, the fabric of the bottom ply
136 is preferably saturated with the lubricant composition 143,
with the lubricant composition intimately impregnated in the fabric
bottom ply, and not just on the bottom surface, so that any loss of
lubricant from the belt is insubstantial. Preferably, the
binder/bonding agent in the lubricant composition 143 substantially
keeps the lubricant(s) on the belt 121 so that re-lubrication is
not necessary. The small proportion of silicone lubricant in the
lubricant composition 143 improves lubrication, but the proportion
is sufficiently small so that the lubricant composition 143 is
still substantially solid at room temperature. Advantageously, the
small proportion of silicone lubricant does not substantially
migrate or substantially interfere with belt splicing.
[0060] Many modifications and other embodiments of the inventions
set forth herein will come to mind to one skilled in the art to
which these inventions pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. For example, the lubricant compositions of the present
invention can be applied to many different types of belts, can be
used on items other than belts, and can be considered to be
isolated articles of manufacture (e.g., separate from any belts,
treadmills, etc.) For example, it is within the scope of the
present invention for the lubricant 143 of the present invention to
be used with (e.g. applied to and preferably impregnated into the
bottom surfaces of) conventional treadmill belts. Likewise, the
belts of the present invention can be used in combination with many
different types of lubricants or can be considered to be isolated
articles of manufacture (e.g., separate from any lubricant
etc.).
[0061] It is to be understood that the inventions are not to be
limited to the specific embodiments disclosed and that
modifications and other embodiments are intended to be included
within the scope of the appended claims. Although specific terms
are employed herein, they are used in a generic and descriptive
sense only and not for purposes of limitation.
* * * * *