Infinity Coil Fabric Structure for Uniform Seam Thickness

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Solution Overview

Problem

Industrial fabrics used in papermaking and nonwovens often face issues with seam thickness variations leading to product marking and potential seam failure due to differences in caliper and construction, and existing solutions like spiral link coils are stiff, costly, and prone to failure.

Innovation Solution

The use of infinity coil elements, shaped like figure-eight curves, which are interdigitated to form a continuous fabric with uniform characteristics across the length and width, eliminating the need for additional stiffening materials and reducing the risk of seam failure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional spiral link coils are used to form seams, then seam strength is improved, but fabric stiffness increases and cost increases

Engineering Contradiction:

Improveseam strengthVSAvoidfabric stiffness

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Instead of using rigid spiral link coils that create stiffness, the patent inverts the approach by using flexible seaming loops made from the same fabric material. The seaming loops are formed by reversing the knitting direction and using the fabric's own structure to create the seaming mechanism, eliminating the need for stiffening materials while maintaining seam strength.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent applies homogeneity by making the seaming loops from the same fabric material as the main body. This ensures uniform flexibility, appearance, and mechanical properties throughout the entire fabric, eliminating the stiffness and visual discontinuity caused by heterogeneous seaming materials like spiral link coils.

Inventive Principle:

Principle #33Homogeneity

2Ease of manufacture

If seaming loops are formed from warp yarns, then seam formation is enabled, but thickness variation occurs at the seam area

Engineering Contradiction:

Improveseam formationVSAvoidthickness uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent changes the parameter of loop formation by creating seaming loops that extend beyond the fabric edges rather than forming loops within the fabric structure. This external loop formation method allows the seam to be constructed from the same material without creating thickness variations, as the loops are formed by extending yarns outward and knitting them in reverse direction.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If spiral link coils are used for seaming, then seam durability is improved, but risk of belt unzip increases

Engineering Contradiction:

Improveseam durabilityVSAvoidresistance to unzip

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent merges the seaming function with the fabric structure itself by using the same continuous yarns that form the fabric body to create the seaming loops. This integration ensures that the seam and fabric move as a unified structure, eliminating the risk of differential movement that causes spiral link coils to unzip, while maintaining durability through the continuous yarn construction.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11619001B2Infinity shape coils for industrial fabrics

Publication Date: 2023.04.04 ALBANY INT CORP

AI summary

An industrial fabric/belt including spiral coils shaped as a symbol for infinity or a lemniscate, i.e., infinity elements, are joined to each other with a pintle. A fabric element is configured as a continuous loop to form an industrial fabric employing a plurality of infinity coil elements.