Woven endless and needlepunched corrugator single facer belt

In a single-facer section of a corrugated board production line, said single-facer section being of the variety in which a belt is trained around at least two spaced rollers and forms an extended nip with a roll having uniformly spaced, peripheral teeth by running thereagainst, the improvement comprising an unlaminated single-facer belt, said unlaminated single-facer belt having:

• a single base structure, said base structure being in the form of an endless loop lacking a seam and having an inside and an outside, a machine, or running, direction and a cross-machine direction;
• said base structure being formed by machine-direction and cross-machine-direction yarns;
• at least one layer of staple fiber material needled into said outside of said base structure and extending at least partly therethrough;
• at least one layer of staple fiber material needled into said inside of said base structure;
• said base structure and said staple fiber material being impregnated with a polymeric resin material;
• and
• said yarns of said base structure, said staple fiber material and said polymeric resin material being of high-temperature-resistant materials.

In a single-facer section of a corrugated board production line, said single-facer section being of the variety in which a belt is trained around at least two spaced roller and forms an extended nip with a roll having uniformly spaced, peripheral teeth by running thereagainst, the improvement comprising an unlaminated single-facer belt, said unlaminated single-facer belt having:

• a single base structure, said base structure being in the form of an endless loop lacking a seam and having an inside and an outside, a machine, or running, direction and a cross-machine direction;
• said base structure being formed by machine-direction and cross-machine-direction yams;
• at least one layer of staple fiber material needled into said outside of said base structure and extending at least partly therethrough wherein said staple fiber material has an areal density relative to said base structure in the range from 3.0 to 30.0 oz/yd2;
• said base structure and said staple fiber material being impregnated with a polymeric resin material;
• and
• said yarns of said base structure, said staple fiber material and said polymeric resin material being of high-temperature-resistant materials.

In a single-facer section of a corrugated board production line, said single-facer section being of the variety in which a belt is trained around at least two spaced rollers and forms an extended nip with a roll having uniformly spaced, peripheral teeth by running thereagainst, the improvement comprising an unlaminated single-facer belt, said unlaminated single-facer belt having:

• a single base structure, said base structure being in the form of an endless loop lacking a seam and having an inside and an outside, a machine, or running, direction and a cross-machine direction;
• said base structure being formed by machine-direction and cross-machine-direction yarns;
• at least one layer of staple fiber material needled into said outside of said base structure and extending at least partly therethrough;
• said base structure and said staple fiber material being impregnated with a polymeric resin material wherein said polymeric resin material has an areal density relative to said base structure in the range from 1.0 to 15.0 oz/ft2;
• and
• said yarns of said base structure, said staple fiber material and said polymeric resin material being of high-temperature-resistant materials.

In a single-facer section of a corrugated board production line, said single-facer section being of the variety in which a belt is trained around at least two spaced rollers and forms an extended nip with a roll having uniformly spaced, peripheral teeth by running thereagainst, the improvement comprising an unlaminated single-facer belt, said unlaminated single-facer belt having:

• a single base structure, said base structure being in the form of an endless loop lacking a seam and having an inside and an outside, a machine, or running, direction and a cross-machine-direction;
• said base structure being formed by machine-direction and cross-machine direction yarns;
• at least one layer of staple fiber material needled into said outside of said base structure and extending at least partly therethrough;
• said base structure an said staple fiber material being impregnated with a polymeric resin material;
• said yarns of said base structure, said staple fiber material and said polymeric resin material being of high-temperature-resistant materials;
• and
• wherein said unlaminated single-facer belt has a rigidity in the range from 5% to 10%.

In a single-facer section of a corrugated board production line, said single-facer section being of the variety in which a belt is trained around at least two spaced rollers and forms an extended nip with a roll having uniformly spaced, peripheral teeth by running thereagainst, the improvement comprising an unlaminated single-facer belt, said unlaminated single-facer belt having:

• a single base structure, said base structure being in the form of an endless loop lacking a seam and having an inside and an outside, a machine, or running, direction and a cross-machine direction;
• said base structure being formed by machine-direction;
• said base structure being formed by machine-direction and cross-machine-direction yarns;
• at least one layer of staple fiber material needled into said outside of said base structure and extending at least partly therethrough;
• said base structure and said staple fiber material being impregnated with a polymeric resin material;
• and
• said yarns of said base structure, said staple fiber material and said polymeric resin material being of high-temperature-resistant materials wherein said unlaminated single-facer belt has a Z-direction compressibility in the range from 7% to 25%.