Treadmill belt

Abstract

An endless treadmill includes a bottom-ply fabric that at least partially forms a bottom surface of the belt that is for sliding across a treadmill deck. The bottom-ply fabric has warp yarns that at least partially form the bottom surface of the belt, with a large number of these warp yarns, and preferably all of these warp yarns, being less than about 1000 denier, or more preferably about 500 denier or smaller. In addition, the warp yarns that at least partially form the bottom surface of the belt are twisted about 2.5 complete turns per inch, or less. A solid lubricant composition is preferably impregnated in the bottom-ply fabric. The solid lubricant composition includes a wax mixture and it optionally further includes a lower viscosity lubricant, such as silicone. The wax mixture may include a vegetable wax and a mineral wax, such as a mixture of paraffin wax and carnauba wax.

Description

BACKGROUND OF THE INVENTION

[0001] The present inventions relate to belts and belt lubricants, and more particularly to lubricated, endless belts for treadmills.

[0002] 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.

[0003] 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.

[0004] 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.

[0005] 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.

[0006] 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.

[0007] 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.

[0008] 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 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. 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 weave. 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.

[0009] 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

[0010] One aspect of the present invention is the provision of belt materials and/or belts that provide an improved balance of properties, and methods of making and using the belts and/or belt materials. A more specific aspect of the present invention is the provision of endless treadmill belts that are each for extending around and sliding across a treadmill deck, and that provide an improved balance of properties. Preferably the improved balance of properties results from fabric(s) of the belts and/or lubricant(s) impregnated in the belts. One aspect of the present invention is the fabric(s) which are preferably, but not limited to being, bottom-plies of the belts, and another aspect of the present invention is the lubricant(s) which are preferably, but not limited to being, impregnated in the bottom-plies of the belts.

[0011] In accordance with one aspect of the present invention, an endless treadmill belt is preferably multi-ply and includes a bottom-ply fabric that at least partially forms a bottom surface of the belt, and the bottom surface is for sliding across a treadmill deck. In accordance with one example of this aspect, the bottom-ply fabric has warp yarns that at least partially form the bottom surface of the belt, with a large number of these warp yarns, and preferably all of these warp yarns, being less than about 1000 denier, or more preferably about 500 denier or smaller. In accordance with this same or another example of this aspect, the warp yarns that at least partially form the bottom surface of the belt are twisted about 2.5 complete turns per inch, or less.

[0012] In accordance with one aspect of the present invention, a lubricant coating composition is preferably impregnated into the bottom surfaces of the endless treadmill belts that are for sliding across the decks of treadmills. In accordance with one aspect of the present invention, the lubricant includes a wax mixture and it optionally further includes a lower viscosity lubricant, such as a silicone lubricant. The wax mixture is preferably a mixture of at least one vegetable wax and at least one mineral wax. In accordance with the exemplary embodiment of the present invention, the vegetable wax is carnauba wax, and the mineral wax is paraffin wax. Preferably the lubricant is a substantially uniformly dispersed mixture.

[0013] In accordance with one example of the present invention, the lubricant coating composition impregnated in an endless treadmill belt is at least substantially solid. Such solid lubricant coating compositions are preferably formed from liquid lubricant compositions that include solvents. In some of the embodiments of the present invention, the solvents are substantially entirely volatilized after the liquid lubricant is applied to the belt material from which endless belts are formed, and after volatilization of the solvents, the belt material is cut into lengths from which endless belts are formed.

[0014] Each of the endless treadmill belts of the present invention is preferably used in combination with a deck, so that the belt extends around and slides across the deck. The combination preferably further includes a frame to which the deck is mounted, pulleys rotatably mounted to the frame and around which the belt extends, and a motor mounted to the frame and operative for causing the belt to travel relative to the deck, so that the bottom surface of the belt slides across an upper surface of the deck. The improved balance of properties according to one aspect of the present invention pertains to there being an acceptably low coefficient of friction at the interface between the bottom surface of the belt and the upper surface of the deck.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] 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:

[0016] 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;

[0017] 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;

[0018] 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;

[0019] 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; and

[0020] FIG. 5 is a chart illustrating the performance of the belt of the exemplary embodiment of the present invention as compared to a conventional, comparable belt.

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.

[0027] 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. 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° to 160° C., or more specifically about 100° 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 an “overlap splice,” meaning that it is formed by peeling back plies at the opposite ends of the section of belt material and then overlapping and sealing the peeled plies.

[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 preferably includes an effective amount of relatively fine and/or low twist warp yarns. As used herein, the term “warp yarn” refers to those yarns within a given layer which extend in the longitudinal direction, i.e., along the length of the belt 121. Correspondingly, as used herein, the term “weft yarns” refers to those yarns within a given layer that extend in the transverse direction, i.e. across the belt 121. Although not wishing to be bound by theory, theoretically the incorporation of relatively fine and/or low twist warp yarn into the bottom ply 136 decreases the coefficient of friction between the bottom surface 142 of the belt 121 and the deck 26 (FIG. 1).

[0035] Accordingly, an effective amount of the warp yarns within the bottom ply 136 preferably have a relatively fine denier, such as a denier of less than about 1000, and, more preferably, a denier of about 500 or smaller. As an additional example, an effective amount of the warp yarns within the bottom ply 136 can have a denier ranging from about 150 to 500. In accordance with the exemplary embodiment of the present invention, preferably 100% of the warp yarns of the fabric of the bottom ply 136 are the relatively fine denier yarn.

[0036] The warp yarns of the bottom ply 136 preferably additionally or alternatively possess low twist, such as a twist of less than about 2.5 complete turns per inch, and most preferably twist ranging from about 1.5 to 2.0 complete turns per inch. Regarding the warp yarns of the bottom ply 136, a twist of about 2.0 complete turns per inch may be most preferred for facilitating weaving, whereas a twist of about 1.5 complete turns per inch may be most preferred for reducing the friction generated between the bottom ply 136 and the deck 26 (FIG. 1) while the treadmill is in operation.

[0037] In accordance with the exemplary embodiment of the present invention, the bottom ply 136 warp yarns preferably are formed from polyethylene terephthalate, they are about 500 denier or smaller, and each is twisted about 1.5 to 2.0 complete turns per inch; the bottom ply 136 weft yarns are preferably formed from monofilament fiber, and the monofilament weft yarns each preferably have a diameter of about 0.25 mm; the fabric of the bottom ply 136 is preferably a plain weave; and the bottom ply 136 fabric has 45×50 yarns per inch (i.e., 45 warp ends per inch and 50 weft ends per inch). One exemplary commercially available fabric for use in the bottom ply 136 is Style No. 930388, produced by Milliken & Company of Spartanburg, S.C.

[0038] In accordance with an alternative embodiment of the present invention, the fabric of the bottom ply 136 is a twill weave, preferably a 2/1 twill weave. In embodiments including 2/1 twill weaves, the warp yarn preferably 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 (FIG. 1).

[0039] As mentioned above, the relatively fine size and/or the low twist of the warp yarns in the bottom ply 136 are believed to reduce 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 further 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.

[0040] In accordance with the exemplary embodiment of the present invention, the solid lubricant composition 143 preferably includes a mixture of two or more relatively higher viscosity lubricants optionally along with one or more relatively lower viscosity lubricants, with the lower viscosity lubricant(s) having lower viscosity than the higher viscosity lubricant(s). The mixture of two or more higher viscosity lubricants within the solid lubricant composition 143 preferably includes a mixture of two or more waxes. The mixture of two or more waxes preferably includes at least one vegetable wax and at least one mineral wax. Exemplary vegetable waxes include carnauba wax, candelilla wax, bayberry wax and wax derived from sugar cane. In accordance with the exemplary embodiment, the vegetable wax is carnauba wax. Exemplary mineral waxes include earth waxes, such as ozocerite, ceresin and montan waxes, and petroleum waxes, such as paraffin and microcrystalline wax. In accordance with the exemplary embodiment, the mineral wax is paraffin wax.

[0041] The higher viscosity lubricant mixture within a first version of the solid lubricant composition 143 preferably includes at least about 30 weight percent vegetable wax, based on the weight of the solid lubricant composition (“bosc”). More specifically, the first version of the solid lubricant composition 143 preferably includes from about 30 weight percent to about 70 weight percent vegetable wax, bosc. Even more specifically, in accordance with the exemplary embodiment of the present invention, the first version of the solid lubricant composition 143 includes about 50 weight percent vegetable wax, bosc.

[0042] The higher viscosity lubricant mixture within the first version of the solid lubricant composition 143 preferably includes no more than about 70 weight percent mineral wax, bosc. The first version of the solid lubricant composition 143 preferably includes from about 30 weight percent to about 70 weight percent mineral wax, bosc. Even more specifically, in accordance with the exemplary embodiment of the present invention, the first version of the solid lubricant composition 143 includes about 50 weight percent mineral wax, bosc.

[0043] Pre-formed higher viscosity lubricant mixtures suitable for use in the present invention are readily commercially available. For example, one commercially available higher viscosity lubricant mixture is available from S.C. Johnson of Racine, Wis. under the trade name Johnson Paste Wax™. Johnson Paste Wax™ includes carnauba wax, paraffin wax, and a petroleum distillate solvent.

[0044] As noted above, the solid lubricant composition 143 optionally includes at least one lower viscosity lubricant. 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 is a silicone lubricant or a mixture of 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.

[0045] The lower viscosity lubricant can be included in the solid lubricant composition 143 in any amount providing sufficient lubricity without detrimentally impacting the cohesion of the resulting solid lubricant composition 143. Lower viscosity lubricants generally exhibit a lower coefficient of friction than higher viscosity lubricants. However, lower viscosity lubricants can impact coating cohesion/adhesive properties. Consequently, a second version of the solid lubricant composition 143 preferably includes significantly greater amounts of the higher viscosity lubricant than the lower viscosity lubricant. For example, the weight ratio of the higher viscosity lubricant mixture to the lower viscosity lubricant may be 2:1 or higher, such as a ratio of about 2.3:1.

[0046] Accordingly, the second version of the solid lubricant composition 143 preferably includes no more than about 40 weight percent of the lower viscosity lubricant, bosc. More specifically, the second version of the solid lubricant composition 143 preferably includes from about 20 to 40 weight percent of the lower viscosity lubricant, bosc. Even more specifically, in accordance with the exemplary embodiment of the present invention, the second version of the solid lubricant composition 143 includes about 29 to 30 weight percent of the lower viscosity lubricant, bosc.

[0047] The second version of the solid lubricant composition 143 incorporating the optional lower viscosity preferably includes from about 30 to 70 weight percent vegetable wax, from about 30 to 70 weight percent mineral wax and from about 20 to 40 weight percent low viscosity lubricant, bosc. More specifically, the second version of the solid lubricant composition preferably includes about 35 weight percent vegetable wax, about 35 weight percent mineral wax, and about 30 weight percent low viscosity lubricant, bosc. Even more specifically, the second version of the solid lubricant composition 143 preferably includes about 36 weight percent vegetable wax, about 35 weight percent mineral wax, and about 29 weight percent low viscosity lubricant, bosc.

[0048] 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. 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.

[0049] The liquid lubricant composition may be formed by dispersing or dissolving appropriate amounts of the higher viscosity lubricant mixture and the optional lower viscosity lubricant in solvent. The solvent may be any organic solvent capable of dispersing the higher viscosity lubricant mixture and optional lower viscosity lubricant. The liquid lubricant composition is preferably formed by initially combining the higher viscosity lubricant mixture and the optional lower viscosity lubricant with the solvent(s) and agitating the mixture at high speed for a suitable amount of time, such as about 5 minutes.

[0050] In accordance with the exemplary embodiment of the present invention, the first version of the solid lubricant composition 143 is formed from a first version of a liquid lubricant composition, and the second version of the solid lubricant composition 143 is formed from a second version of a liquid lubricant composition. Each of the first and second versions of the liquid lubricant composition preferably include an initial lubricant composition which is a mixture that preferably consists essentially of carnauba wax, paraffin wax and a petroleum distillate solvent. In accordance with the exemplary embodiment of the present invention, a suitable initial lubricant composition is available from S.C. Johnson of Racine, Wis., under the trade name Johnson Paste Wax™ That is, Johnson Paste Wax™ includes carnauba wax, paraffin wax, and a petroleum distillate solvent.

[0051] In accordance with the exemplary embodiment of the present invention, the second version of the liquid lubricant composition is preferably a substantially uniformly dispersed mixture including: the initial lubricant composition in an amount of about 64 weight percent, based on the weight of the liquid lubricant composition (“bolc”); a solvent, which is preferably mineral spirits, in an amount of about 31 weight percent, bolc; and the lower viscosity lubricant, which is preferably liquid silicone lubricant, in an amount of about 5 weight percent, bolc. In accordance with the exemplary embodiment of the present invention, the first version of the liquid lubricant composition is preferably a substantially uniformly dispersed mixture including: the initial lubricant composition in an amount of about 67 weight percent, bolc; and a solvent, which is preferably mineral spirits, in an amount of about 33 weight percent, bolc.

[0052] 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 lubricating composition to the fabric of 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° F.). The coated belt 121 preferably has solid lubricant composition 143 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.

[0053] Numerous advantages are associated with the belt 121 of the exemplary embodiment of the present invention. Advantageously, the belt 121 can be lubricated prior to splicing the belt, no relubrication is needed for the life of the belt, the belt lasts longer than conventional comparable belts, and the belt is “heavy-duty” such that it is well suited for treadmills used in spas or health clubs. As an example, the chart of FIG. 5 illustrates the performance of the belt 121 of the exemplary embodiment of the present invention as compared to a comparable belt. For FIG. 5, the two belts were run under substantially identical conditions, with the only difference being the differences in the belts themselves.

[0054] 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 un-waxed decks, or decks with substantially reduced wax quantity, wax will not substantially accumulate on rollers of the treadmills.

[0055] 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 substantially 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 143, with the lubricant 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. The small proportion of silicone lubricant in the lubricant composition 143 improves lubrication, but the proportion is preferably 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.

[0056] 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 lubricants 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.).

[0057] 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.

Claims

1. An endless treadmill belt for extending in a longitudinal direction around and traveling relative to a deck, the belt comprising:

a fabric that at least partially forms a bottom surface of the belt and is for sliding across the deck, with the fabric including a plurality of weft yarns extending in a lateral direction that is substantially perpendicular to the longitudinal direction, and a plurality of warp yarns extending in the longitudinal direction for slidingly engaging the deck, wherein each warp yarn of the plurality of warp yarns is less than about 1000 denier, and

an at least substantially solid lubricant is impregnated in the fabric and at least partially forming the bottom surface of the belt.

2. An endless treadmill belt according to claim 1, wherein the lubricant includes carnauba wax.

3. An endless treadmill belt according to claim 2, wherein the lubricant is a lubricant composition and the carnauba wax is present within the lubricant composition in amounts ranging from about 30 weight percent to about 70 weight percent.

4. An endless treadmill belt according to claim 1, wherein the lubricant includes a wax mixture.

5. An endless treadmill belt according to claim 4, wherein the wax mixture includes at least one vegetable wax and at least one mineral wax.

6. An endless treadmill belt according to claim 5, wherein the vegetable wax is selected from the group consisting of carnauba wax, candelilla wax, bayberry wax and wax derived from sugar cane.

7. An endless treadmill belt according to claim 5, wherein the vegetable wax is present within the lubricant composition in an amount of about 50 weight percent.

8. An endless treadmill belt according to claim 5, wherein the vegetable wax is present within the lubricant composition in an amount of about 36 weight percent.

9. An endless treadmill belt according to claim 5, wherein the mineral wax is selected from the group consisting of earth waxes and petroleum waxes.

10. An endless treadmill belt according to claim 5, wherein the mineral wax is paraffin wax.

11. An endless treadmill belt according to claim 5, wherein the mineral wax is present within the lubricant composition in amounts ranging from about 30 weight percent to about 70 weight percent.

12. An endless treadmill belt according to claim 5, wherein the mineral wax is present within the lubricant composition in an amount of about 50 weight percent.

13. An endless treadmill belt according to claim 5, wherein the mineral wax is present within the lubricant composition in an amount of about 35 weight percent.

14. An endless treadmill belt according to claim 1, wherein the lubricant is a lubricant composition which includes at least one higher viscosity lubricant and at least one lower viscosity lubricant, with the higher viscosity lubricant having a higher viscosity than the lower viscosity lubricant, and the lubricant composition being a substantially uniformly dispersed mixture.

15. An endless treadmill belt according to claim 14, wherein the lower viscosity lubricant is selected from the group of silicones, mineral oils, polyglycols and mixtures thereof.

16. An endless treadmill belt according to claim 14, wherein the lower viscosity lubricant includes a silicone lubricant.

17. An endless treadmill belt according to claim 14, wherein the lower viscosity lubricant is present in the lubricant composition in an amount ranging from about 20 weight percent to about 40 weight percent.

18. An endless treadmill belt according to claim 1, wherein each warp yarn of the plurality of warp yarns is about 500 denier or smaller.

19. An endless treadmill belt according to claim 1, wherein each warp yarn of the plurality of warp yarns is twisted, with each warp yarn of the plurality of warp yarns being twisted less than about 2.5 complete turns per inch.

20. An endless treadmill belt according to claim 19, wherein each warp yarn of the plurality of warp yarns is about 500 denier or smaller.

21. An endless treadmill belt according to claim 1, wherein each warp yarn of the plurality of warp yarns is twisted within a range of about 1.5 to about 2.0 complete turns per inch.

22. An endless treadmill belt according to claim 21, wherein each warp yarn of the plurality of warp yarns is about 500 denier or smaller.

23. An endless treadmill belt according to claim 1, wherein the belt is in combination with and extends around the deck, and the combination further comprises:

a frame to which the deck is mounted;

a pulley rotatably mounted to the frame and around which the belt extends, with the pulley carrying the belt; and

a motor mounted to the frame and operative for causing the belt to travel relative to the deck, so that the bottom surface of the belt slides across an upper surface of the deck.

24. An endless treadmill belt for extending in a longitudinal direction around and traveling relative to a deck, the belt comprising:

a fabric that at least partially forms a bottom surface of the belt and is for sliding across the deck, with the fabric including a plurality of weft yarns extending in a lateral direction that is substantially perpendicular to the longitudinal direction, and a plurality of warp yarns extending in the longitudinal direction for slidingly engaging the deck, wherein each warp yarn of the plurality of warp yarns is twisted, with each warp yarn of the plurality of warp yarns being twisted less than about 2.5 complete turns per inch, and

an at least substantially solid lubricant is impregnated in the fabric and at least partially forming the bottom surface of the belt.

25. An endless treadmill belt according to claim 24, wherein the lubricant is a lubricant composition having at least one vegetable wax and at least one mineral wax.

26. An endless treadmill belt according to claim 25, wherein the vegetable wax includes carnuaba wax.

27. An endless treadmill belt according to claim 25, wherein the vegetable wax is present within the lubricant composition in amounts ranging from about 30 weight percent to about 70 weight percent.

28. An endless treadmill belt according to claim 25, wherein the mineral wax is a petroleum wax selected from the group consisting of paraffin wax and microcrystalline wax.

29. An endless treadmill belt according to claim 25, wherein the mineral wax includes paraffin wax.

30. An endless treadmill belt according to claim 25, wherein the mineral wax is present within the lubricant composition in amounts ranging from about 30 to 70 weight percent.

31. An endless treadmill belt according to claim 24, wherein the lubricant is a lubricant composition which includes at least one higher viscosity lubricant and at least one lower viscosity lubricant, with the higher viscosity lubricant having a higher viscosity than the lower viscosity lubricant.

32. An endless treadmill belt according to claim 31 wherein the lower viscosity lubricant includes silicone lubricant.

33. An endless treadmill belt according to claim 31, wherein the lower viscosity lubricant is present in the lubricant composition in an amount ranging from about 20 weight percent to about 40 weight percent.

34. An endless treadmill belt according to claim 24, wherein each warp yarn of the plurality of warp yarns is twisted within a range of about 1.5 to about 2.0 complete turns per inch.

35. An endless treadmill belt for extending in a longitudinal direction around and traveling relative to a deck, the belt comprising:

a fabric that at least partially forms a bottom surface of the belt and is for sliding across the deck, and

an at least substantially solid lubricant composition impregnated in the fabric and at least partially forming the bottom surface of the belt, wherein the lubricant composition is a substantially uniformly dispersed mixture including wax and no more than about 40 weight percent of a silicone lubricant.

36. An endless treadmill belt according to claim 35, wherein the fabric includes a plurality of weft yarns extending in a lateral direction that is substantially perpendicular to the longitudinal direction, and a plurality of warp yarns extending in the longitudinal direction for slidingly engaging the deck, and wherein each warp yarn of the plurality of warp yarns is less than about 1000 denier.

37. An endless treadmill belt according to claim 35, wherein the fabric includes a plurality of weft yarns extending in a lateral direction that is substantially perpendicular to the longitudinal direction, and a plurality of warp yarns extending in the longitudinal direction for slidingly engaging the deck, and wherein each warp yarn of the plurality of warp yarns is twisted, with each warp yarn of the plurality of warp yarns being twisted less than about 2.5 complete turns per inch.

38. An endless treadmill belt for extending in a longitudinal direction around and traveling relative to a deck, the belt comprising:

a fabric that at least partially forms a bottom surface of the belt and is for sliding across the deck; and

an at least substantially solid lubricant composition impregnated in the fabric and at least partially forming the bottom surface of the belt, wherein the lubricant composition includes at least one vegetable wax, at least one mineral wax, and at least one silicone lubricant.

39. An endless treadmill belt according to claim 38 wherein the vegetable wax includes carnauba wax.

40. An endless treadmill belt according to claim 38, wherein the mineral wax includes paraffin wax.

41. An endless treadmill belt according to claim 38, wherein the lubricant composition mixture includes vegetable wax in an amount ranging from about 30 weight percent to about 40 weight percent, and mineral wax in an amount ranging from about 30 weight percent to about 40 weight percent.

42. An endless treadmill belt according to claim 38, wherein the silicone lubricant makes up no more than about 40 weight percent of the lubricant composition mixture.

43. An endless treadmill belt according to claim 38, wherein the belt is in combination with and extends around the deck, and the combination further comprises:

a frame to which the deck is mounted;

a pulley rotatably mounted to the frame and around which the belt extends, with the pulley carrying the belt; and

a motor mounted to the frame and operative for causing the belt to travel relative to the deck, so that the bottom surface of the belt slides across an upper surface of the deck.

44. A method of manufacturing, comprising:

lubricating a belt material by applying a liquid lubricant composition which includes at least one silicone lubricant to the belt material;

drying the liquid lubricant composition to form an at least substantially solid lubricant composition;

then cutting a section from the belt material so that the section includes opposite ends and opposite edges extending between the opposite ends, with the lubricating being carried out so that at least substantially all of a broad surface of the section is impregnated with the at least substantially solid lubricant composition, with the broad surface being substantially contiguous with and spanning between the ends and edges; and

splicing the ends together so that the section is endless and extends around a space, and the first broad surface faces the space.

45. A method according to claim 44, wherein lubricating the belt material includes lubricating a fabric of the belt material, such that the broad surface includes the fabric, and wherein the method further includes encircling a deck with the endless section and driving the endless section with a motor while the endless section is encircling the deck, so that the lubricated fabric slides across the deck.