Etched Metal Web Support for High-Freedom Nonwoven Patterning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for applying patterns to nonwoven substances using mark-welded wires or resin patterns face limitations in patterning freedom and durability, while fabric patterning is restricted to geometric designs.
Innovation Solution
A method involving a metal web support with etched recesses, convexities, and water conduction holes is used, allowing for the formation of a cylindrical shape by welding the edges, enabling high patterning freedom and durability by forming the recesses and convexities on a flat metal base material before shaping it into a cylindrical main body section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a mark is welded on a wire in accordance with the pattern, then the pattern can be applied to the nonwoven substance, but the welded mark is hard to attach and may remove disadvantageously
Solution Approach 1:
The patent replaces the mechanical welding system with a chemical etching system. Instead of welding marks onto wires, the invention uses etching to directly form the pattern on the metal base material surface. This substitution eliminates the attachment problems of welded marks while maintaining pattern durability through integral formation with the base material.
Solution Approach 2:
The patent performs the pattern formation action in advance by etching the pattern directly onto the metal base material before the nonwoven substance is processed. This preliminary action ensures the pattern is already integrated into the support structure, eliminating subsequent attachment issues and ensuring durability throughout the manufacturing process.
2Adaptability or versatility
If a resin is formed into a pattern shape corresponding to the pattern, then the patterning freedom is high, but the resin may remove disadvantageously when a high-pressure water stream is repeatedly jetted
Solution Approach 1:
The patent changes the material parameter from resin to metal, and the formation method from molding to etching. This parameter change maintains the high patterning freedom of resin (since etching can create complex patterns) while dramatically improving durability under high-pressure water jetting, as metal etched patterns are integral to the base material and cannot be removed by water pressure.
Solution Approach 2:
The invention uses a metal base material with etched patterns instead of resin patterns. The etched metal structure creates a composite-like functionality where the pattern is part of the base material itself, combining the durability of metal with the patterning flexibility previously only achievable with resin.
3Device complexity
If fabric for patterning is used, then the structure is simple, but the pattern is limited to a geometrical pattern such as a grating or a houndstooth check, so the patterning freedom is disadvantageously low
Solution Approach 1:
The patent replaces the mechanical fabric structure with a chemical etching process on metal. This substitution maintains structural simplicity (a single metal piece instead of layered fabric) while dramatically increasing patterning freedom, as etching can create any pattern design directly on the metal surface without being constrained to geometric patterns.
4Adaptability or versatility
If the recess and the convexity are formed on the metal base material by etching, then the patterning freedom is high and the durability is excellent, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the pattern formation process with the base material preparation process by using etching to directly create the pattern on the metal surface. This merging eliminates the need for separate pattern attachment steps, and the added etching complexity is offset by the elimination of multiple assembly operations, resulting in a streamlined manufacturing process with high patterning freedom and excellent durability.
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 solution provides a web support with excellent durability and flexibility to handle various patterns, resisting deformation and abrasion, while ensuring accurate pattern application and easy release of the nonwoven substance.
Implementation Method 1
A spunlace method that a high-pressure water stream onto a web obtained by laminating fibers and spreading the fibers into a sheet to manufacture a nonwoven substance
Implementation Method 2
a step for forming, by etching, a recess and a convexity corresponding to the pattern on a front surface of the base material
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The purpose of the present invention is to provide a web support with a high degree of patterning freedom and excellent durability, a production method therefor, and a patterning method. The web support (10) is used when applying a pattern to a nonwoven substance by jetting a high-pressure water stream on a web. The web support (10) production method comprises: a step of preparing a flat metal base material (16); a step for forming, by etching, a first water conduction hole (14) and second water conduction hole (15) that pass through the front surface of the base material (16) to the back surface, and a recess (12) on the front surface of the base material (16) that includes the first water conduction hole (14) and that corresponds to the pattern; and a step for forming the base material (16) into a cylindrical main body section (11) by welding the edges of the base material (16) to each other.