Laser-Engraved Structuring Belt for Soft, Low-Lint Tissue
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Solution Overview
Problem
Current manufacturing processes for papermaking fabrics are complex, costly, and inefficient, particularly in producing structured fabrics for tissue production, which affects the quality and cost of tissue products.
Innovation Solution
The development of a process using extruded polymeric netting to create fabrics, which are then laminated with woven fabric layers, offering improved airflow and reduced production costs compared to traditional weaving or welding methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional weaving or welding methods are used to manufacture papermaking fabrics, then the fabrics can be produced with traditional structures, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent replaces traditional mechanical weaving processes with a direct extrusion process that creates the fabric structure in a single operation. The extruded polymeric netting is formed by forcing molten polymer through a shaped die to create the three-dimensional structure, eliminating the need for complex weaving machinery and multiple processing steps.
Solution Approach 2:
The patent divides the fabric manufacturing into separate functional layers: an extruded polymeric netting layer providing the primary structure and airflow channels, and an optional woven or nonwoven fabric layer providing additional mechanical strength. This segmentation allows each layer to be optimized independently and simplifies the overall manufacturing process.
2Productivity
If traditional weaving methods are used to create structured fabrics, then the fabrics provide basic structural support, but production costs increase and productivity decreases
Solution Approach 1:
The patent incorporates the airflow channel structure directly into the extrusion die, so that the three-dimensional structure with integrated air channels is formed during the extrusion process itself, before the fabric reaches the paper machine. This preliminary formation of the structure eliminates subsequent processing steps and reduces manufacturing time and cost.
Solution Approach 2:
The patent changes the manufacturing parameters from traditional weaving (thread count, weave pattern, tension) to extrusion parameters (polymer viscosity, extrusion rate, die geometry, cooling rate). This parameter transformation enables continuous production at higher rates and reduces the complexity associated with traditional textile manufacturing.
3Manufacturing precision
If conventional forming fabrics are used in papermaking, then the fabrics provide basic drainage function, but the tissue product quality in terms of softness, bulk, and absorbency is limited
Solution Approach 1:
The patent creates regions of different porosity and structure within the same fabric. The extruded polymeric netting provides larger open areas for airflow and drainage, while the optional woven or nonwoven layers provide finer structure for fiber support. This local variation in structure quality enables simultaneous optimization of drainage, softness, and bulk without requiring an overly complex multi-layer construction.
4Manufacturing precision
If laser engraving is applied to structuring belts, then the belts achieve precise structural patterns for tissue formation, but the manufacturing process becomes more complex
Solution Approach 1:
The patent forms the precise structural pattern during the extrusion process itself by using a shaped die that directly creates the desired three-dimensional structure. This preliminary formation of the precise pattern eliminates the need for subsequent laser engraving or other secondary processing operations, thereby maintaining manufacturing precision while reducing process complexity.
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 results in higher quality tissue products with enhanced softness, bulk, and absorbency, while also reducing capital and operational costs, and improving productivity.
Implementation Method 1
a laser beam is used to engrave channels and/or patterns into a structuring belt
Implementation Method 2
an extruded polymeric layer is formed separately from a woven fabric layer, and the extruded polymeric layer is attached to the woven fabric layer
Data Source
AI summary
A tissue product including a laminate of at least two plies of a multi-layer tissue web, the tissue product having a softness value (HF) of 92.0 or greater, a lint value of 4.5 or less, and an Sdr of greater than 3.0.