Composite Yarn Structure for Low-Dusting Sustainable Press Felts
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Solution Overview
Problem
Existing yarns used in press felts cause dusting during weaving and contribute to microplastic pollution, while lacking sustainability and high mechanical performance.
Innovation Solution
A yarn comprising a plurality of monofilaments twisted together with a multifilament made from bio-based materials, such as cellulose-based or biopolyamide, providing a core for strength and a densifying effect without sacrificing mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If spun yarn is used to densify the felt and create fast start-up, then the felt structure is improved, but dusting increases during weaving
Solution Approach 1:
The patent applies composite materials by combining monofilaments with a multifilament sheath made of bio-based material. This composite structure provides the densifying effect needed for felt structure while the smooth monofilament core reduces dusting during weaving, resolving the contradiction between felt structure stability and dusting generation.
2Strength
If conventional fossil-based materials are used, then mechanical performance is maintained, but sustainability decreases and microplastic pollution increases
Solution Approach 1:
The patent changes the material parameter from fossil-based synthetic fibers to bio-based materials for the multifilament sheath. This substitution maintains the necessary mechanical performance while improving sustainability and reducing microplastic pollution, as the bio-based materials are derived from renewable resources and are more environmentally friendly.
3Productivity
If multifilament is added to densify the felt, then fast start-up is achieved, but carbon footprint increases
Solution Approach 1:
The patent changes the material composition parameter by using bio-based materials with lower carbon footprints for the multifilament sheath. This allows the felt to achieve fast start-up and good nip dewatering through the densifying effect of the multifilament while simultaneously reducing the overall carbon footprint compared to conventional fossil-based materials.
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 yarn offers reduced carbon footprint, less dusting during weaving, and extended product lifetime by maintaining felt structure openness, while maintaining mechanical performance.
Implementation Method 1
a plurality of monofilaments (101, 102, 103, 104) twisted together
Implementation Method 2
a multifilament (105) wound around the plurality of monofilaments (101, 102, 103, 104)
Data Source
Figure 1
AI summary
According to an example aspect of the present invention, there is provided a yarn (100) comprising: a plurality of monofilaments (101 102, 103, 104) twisted together, and a multifilament or a spun yarn (105) wound around the plurality of monofilaments (101, 102, 103, 104), wherein the multifilament or the spun yarn (105) comprises a bio-based material, a recycled bio-based material or a recycled synthetic material.