Fiber Cement Felt Weave Pattern Eliminates Needling
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Solution Overview
Problem
The needling process in fiber cement felt production damages machine and cross-machine direction yarns, reducing the tensile strength of the felt, and the use of batt layers is undesirable.
Innovation Solution
A fiber cement felt with a predetermined weave pattern incorporating top, middle, and bottom machine direction yarns, along with cross-machine direction yarns, where at least some of the machine direction yarns are effect yarns, eliminating the need for batt layers and the needling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a batt layer is added to the fabric to assist in slurry pick-up, then the slurry retrieval capability is improved, but the manufacturing complexity increases and the needling process damages yarns reducing tensile strength
Solution Approach 1:
The invention removes the batt layer from the felt structure, eliminating the need for the needling process entirely. The base fabric alone performs both slurry pick-up and maintains tensile strength, resolving the contradiction by extracting the problematic component that caused yarn damage.
Solution Approach 2:
The base fabric is designed to perform multiple functions: it provides structural integrity for tensile strength and simultaneously enables slurry pick-up through its porous structure and surface properties. This multi-functionality eliminates the need for a separate batt layer, resolving the contradiction between ease of manufacture and strength.
2Stability of the object's composition
If a needling process is used to connect the base fabric and batt layer, then the structural integrity is improved, but the yarns are damaged reducing tensile strength in both directions
Solution Approach 1:
The invention eliminates the needling process by removing the batt layer entirely. The base fabric maintains structural integrity through its own woven or non-woven structure without requiring mechanical interlocking, thus preventing yarn damage and preserving tensile strength.
Solution Approach 2:
The base fabric serves itself by providing both structural integrity and slurry handling capabilities without requiring additional layers or processes. The fabric's inherent properties enable it to maintain structural stability while avoiding the harmful needling process.
3Ease of operation
If batt layers are used on the fabric, then the slurry retrieval is improved, but the device complexity and production steps increase
Solution Approach 1:
The invention removes the batt layer component entirely, simplifying the felt structure to just the base fabric. This extraction eliminates the complexity of layering and needling while the base fabric's properties continue to enable effective slurry retrieval.
Solution Approach 2:
The base fabric is designed to universally perform both structural support and slurry retrieval functions. By making the base fabric multi-functional, the invention eliminates the need for separate batt layers, thereby reducing device complexity while maintaining operational effectiveness.
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
This approach enhances tensile strength in both directions without the need for batt layers or the needling process, simplifying production and improving fiber cement felt properties.
Implementation Method 1
As the slurry is conveyed, moisture contained therein drains through openings in the fabric
Implementation Method 2
Moisture removal is typically augmented by the application of vacuum to the slurry through the fabric (usually via a suction box located beneath the porous fabric)
Data Source
AI summary
The present invention is directed to a fiber cement felt comprising repeat units, each of which includes top, middle, and bottom machine direction yarns and cross-machine direction yarns interwoven with the top, middle, and bottom machine direction yarns in a predetermined weave pattern. The top, middle, and bottom machine direction yarns may comprise effect yarns and linear yarns without the need for a batt layer.