Thermally sprayed protective coating for industrial and engineered fabrics

A method for forming an industrial fabric or belt, comprising the steps of:

• providing a base support structure for an industrial fabric;
• and applying at least one coating or layer directly or indirectly on said base support structure by a thermal spray process in accord with structural design requirements for the industrial fabric or belt:
• wherein the industrial fabric or belt is a long nip press belt for a papermaking machine, and
• wherein said thermally sprayed coating comprises a thermoplastic resin and/or a thermoset resin, and
• wherein said base support structure includes a resin layer, said resin layer having an outer layer with grooves, cavities, or voids, and
• wherein said thermally sprayed coating conforms to and maintains said resin layer's grooves, cavities, or voids, and
• wherein said coating has a thickness of at least 0.1 mm.

An improved long nip press belt comprising:

• a base support structure for the industrial fabric or belt;
• and
• at least one thermally sprayed coating or layer provided on said base support structure in accord with structural design requirements for the industrial fabric or belt, wherein the improvement consists of applying said coating or layer by a thermal spray process, wherein said thermally sprayed coating comprises a thermoplastic resin and/or a thermoset resin, and
• wherein said base support structure includes a resin layer, said resin layer having an outer layer with grooves, cavities, or voids, and wherein said thermally sprayed coating conforms to and maintains said resin layer's grooves, cavities, or voids, and wherein said coating has a thickness of at least 0.1 mm.

An improved industrial fabric or long nip press belt for a nonwoven manufacturing machine comprising:

• a base support structure for the industrial fabric or belt;
• and
• at least one thermally sprayed coating or layer provided on said base support structure in accord with structural design requirements for the industrial fabric or belt and, wherein the improvement consists of applying said coating or layer by a thermal spray process, wherein said coating further includes functional organic or inorganic or metallic particles or a combination thereof being nanometric size or larger and distributed substantially uniformly throughout said coating;
• wherein the industrial fabric or belt is for a nonwoven manufacturing machine, and
• wherein said thermally sprayed coating comprises a thermoplastic resin and/or a thermoset resin, and
• wherein said base support structure includes a resin layer, said resin layer having an outer layer with grooves, cavities, or voids, and
• wherein said thermally sprayed coating conforms to and maintains said resin layer's grooves, cavities, or voids, and wherein said coating has a thickness of at least 0.1 mm.