Additive-Manufactured Tile Deflection Member for Durable Fibrous Webs

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing deflection members used in papermaking and nonwoven production face challenges in terms of size, durability, and endurance under extreme processing conditions, limiting the commercialization of additive manufacturing processes for producing fibrous webs.

Innovation Solution

A deflection member comprising a reinforcing member and patterned framework of tiles, fastened together using stitching or other fastening elements, which are manufactured via additive manufacturing to provide a three-dimensional topography for fibrous web formation, capable of withstanding the demands of commercial papermaking and nonwoven web making machines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If additive manufacturing is used to produce deflection members, then manufacturing flexibility and design freedom are improved, but size and durability are insufficient for commercial papermaking machines

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoiddurability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The deflection member is divided into multiple modular tiles that can be independently manufactured via additive manufacturing and then assembled together. Each tile is a discrete unit that can be produced with precise geometric control, and the modular assembly allows the overall structure to achieve both manufacturing flexibility and structural durability through standardized connections between tiles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The deflection member employs composite construction combining additively manufactured tile structures with appropriate materials selected for their durability and mechanical properties. The composite approach integrates the design freedom of additive manufacturing with materials engineered to withstand the extreme temperatures, tensions, and pressures of commercial papermaking processes.

Inventive Principle:

Principle #40Composite materials

2Productivity

If deflection members are made larger to fit commercial papermaking machines, then productivity is improved, but durability under extreme conditions deteriorates

Engineering Contradiction:

Improvescale of productionVSAvoidendurance under extreme conditions

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Rather than manufacturing one large deflection member that would be difficult to ensure durability, the system segments the large-scale component into multiple smaller tiles. Each tile maintains manageable dimensions for reliable additive manufacturing and material performance, while the assembled configuration achieves the large scale needed for commercial papermaking machine productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The deflection member transitions from a traditional two-dimensional belt structure to a three-dimensional modular tile assembly. This dimensional change allows the system to achieve large surface area for high productivity while maintaining the structural integrity of individual tiles through vertical stacking and modular arrangement, enabling durability to be preserved despite increased overall scale.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS12448732B2Deflecting member for making fibrous structures

Publication Date: 2025.10.21 PROCTER & GAMBLE CO

AI summary

A deflection member that includes a reinforcing member and a plurality of tiles fastened to the reinforcing member.