Bio-based Thermoplastic Elastomer Press Felt for Paper Machines
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Solution Overview
Problem
Conventional press felts used in paper and cardboard machines are made from fossil-based materials, leading to high carbon footprints and environmental concerns, while maintaining mechanical performance is a challenge in transitioning to sustainable alternatives.
Innovation Solution
Development of press felts incorporating thermoplastic elastomer fibers and yarns originating from bio-based and carbon-dioxide based raw materials, combined with polyamide fibers, to reduce fossil-based material usage without compromising mechanical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If press felts are made from fossil-based materials, then mechanical performance is maintained, but carbon footprint increases and sustainability deteriorates
Solution Approach 1:
The patent changes the material composition parameter by incorporating thermoplastic elastomer fibers from bio-based and carbon-dioxide based raw materials into the press felt structure. This substitution reduces the fossil-based content while maintaining the mechanical performance through careful selection of fiber properties and composition ratios.
Solution Approach 2:
The patent creates a composite material system combining thermoplastic elastomer fibers (from bio-based and CO2-based sources) with traditional polyamide fibers in the press felt. This composite approach allows the sustainable TPE fibers to replace fossil-based materials while the polyamide component ensures mechanical performance requirements are met.
2Object-affected harmful factors
If thermoplastic elastomer fibers from bio-based materials are used, then sustainability is improved, but mechanical performance may be compromised
Solution Approach 1:
The patent employs composite materials by combining thermoplastic elastomer fibers from sustainable sources with traditional polyamide fibers. The TPE fibers contribute to sustainability and elastic properties, while the polyamide fibers provide structural strength and mechanical performance, creating a synergistic composite that meets both environmental and mechanical requirements.
Solution Approach 2:
The patent applies local quality by assigning different functions to different fiber components within the press felt. The thermoplastic elastomer fibers provide elasticity and sustainability benefits in specific regions, while polyamide fibers provide structural support and mechanical strength in other regions, allowing each material to optimize its local function.
3Productivity
If elastic TPE fibers are added to improve nip-dewatering, then dewatering performance is improved, but device complexity increases
Solution Approach 1:
The patent applies multi-functionality by using thermoplastic elastomer fibers that simultaneously provide elastic recovery for improved nip-dewatering performance and contribute to the overall structural integrity of the press felt. The same TPE fibers serve multiple functions, reducing the need for additional specialized components and thereby limiting complexity increase.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The use of bio-based and carbon-dioxide based thermoplastic elastomer fibers in press felts results in a more sustainable option with reduced carbon footprint, maintaining or exceeding the mechanical properties of conventional felts, including excellent machine runnability, high sheet dry content, and smooth surface properties.
Implementation Method 1
The TPE fiber layer compresses in the nip and recovers quickly after improving the nip-dewatering
Data Source
AI summary
A press felt for use in paper, cardboard or tissue machines has at least one base fabric (110), and fiber layers (120, 121) attached to the base fabric (110). The press felt fiber layers (120, 121) include thermoplastic elastomer fibers of thermoplastic elastomer originating from bio-based raw material and/or carbon-dioxide based raw material.