Discretized Patterned Belt for Permeability and Stress Control
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Solution Overview
Problem
Existing texturing belts face limitations in pattern complexity, permeability loss, and structural integrity due to continuous lattices, leading to inefficiencies and premature failure from stress concentrations and delamination.
Innovation Solution
A texturing belt with a first layer and a second layer comprising non-adjoining subunits that form a pattern element, allowing for complex patterns without significant permeability loss and reducing stress concentrations by decoupling the second layer from bending forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If continuous lattices are used to create complex patterns, then pattern complexity is improved, but permeability is reduced
Solution Approach 1:
The continuous lattice pattern is segmented into discrete, non-adjoining subunits that are distributed across the belt surface. This segmentation allows the pattern to achieve visual complexity while maintaining open spaces between subunits, thereby preserving air and water permeability through the belt structure.
2Device complexity
If continuous lattices are used to create complex patterns, then pattern complexity is improved, but structural integrity is reduced
Solution Approach 1:
The continuous lattice is divided into discrete, non-adjoining subunits. This segmentation eliminates stress concentration points that would occur in continuous structures, preventing delamination and stress cracking while maintaining the desired pattern complexity.
Solution Approach 2:
The harmful continuous connections between lattice elements are extracted and removed, leaving only the necessary discrete subunits. This removal of continuous material eliminates the pathways for stress propagation and delamination while preserving the pattern's visual and functional complexity.
3Ease of operation
If belt speed is reduced to avoid turbulence, then sheet control is improved, but productivity is reduced
Solution Approach 1:
The continuous lattice structure that causes turbulence and sheet control issues is extracted and replaced with discrete subunits. This removal of continuous obstructions allows sheet to flow smoothly at higher speeds while maintaining control, thereby resolving the contradiction between operational ease and productivity.
4Ease of operation
If vacuum levels are increased to hold sheet in place, then sheet control is improved, but energy consumption is increased
Solution Approach 1:
The continuous lattice structure that requires high vacuum levels for sheet control is extracted and replaced with discrete subunits. This design change reduces the vacuum force needed to hold the sheet in place, thereby lowering energy consumption while maintaining adequate sheet control.
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 belt achieves increased permeability, reduced stress concentrations, and improved durability by transferring stress to the first layer, enabling efficient production of textured products with complex patterns.
Implementation Method 1
The second layer comprises two or more non-adjoining subunits deposited on the top surface of the first layer
Implementation Method 2
Bonding can be chemical or thermal, or a combination of both
Implementation Method 3
Bonding can be chemical or thermal, or a combination of both
Data Source
AI summary
The invention relates to an industrial fabric, such as a texturing belt, used to create three-dimensional structures in a product produced thereon, e.g., in the papermaking field, such as for fiber products, and in nonwoven processes. The invention concerns a texturing belt that can impart an endless variety of complex patterns utilizing discretization, such as, wherein individual subunits that comprise a pattern element are not connected, and therefore do not act as a stressed member of the texturing belt.