Machine Felt Manufacturing with Auxiliary Substrate Web
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Solution Overview
Problem
Existing methods for manufacturing machine felts of finite length face challenges in achieving uniform yarn distribution and transverse strength, leading to non-uniform properties and difficulties in installation, particularly in the press section of paper machines.
Innovation Solution
A method involving the use of an auxiliary substrate web with laser-absorbing properties, where longitudinal yarns are connected and wound helically to form a tube, which is then compressed into a flattened structure with exposed yarn loops, allowing for uniform yarn spacing and integration of transverse yarn layers for enhanced strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If longitudinal yarns are wound helically to form a tube and then compressed into a flattened tube, then transverse strength is improved, but the yarn arrangement becomes complex and manufacturing precision is difficult to maintain
Solution Approach 1:
The patent applies preliminary action by pre-arranging longitudinal yarns in parallel on the auxiliary substrate web before winding. This ensures uniform yarn distribution is established in advance, preventing displacement during subsequent compression and needle felting processes, thereby maintaining manufacturing precision while achieving the desired transverse strength through the flattened tube configuration.
2Strength
If the tube is compressed into a flattened tube with mutual abutment of inner sides, then transverse strength is enhanced, but yarn displacement occurs during manufacturing
Solution Approach 1:
The auxiliary substrate web serves as an intermediary that holds longitudinal yarns in fixed positions during the winding and compression processes. This mediator prevents yarn displacement by providing a stable base structure, allowing the tube to be compressed into a flattened configuration while maintaining yarn position stability throughout manufacturing.
3Manufacturing precision
If auxiliary substrate web is used to hold longitudinal yarns, then yarn distribution uniformity is improved, but device complexity increases
Solution Approach 1:
The auxiliary substrate web is discarded after serving its temporary purpose of holding longitudinal yarns in uniform distribution. The web is completely destroyed during the needle felting process, where fibers penetrate and interlock the yarns in place. This allows the use of a simple auxiliary structure that enables precise yarn distribution without requiring complex permanent manufacturing equipment.
4Adaptability or versatility
If longitudinal yarns are spaced apart to form loops at front ends, then coupling capability is improved, but transverse strength in edge regions is reduced
Solution Approach 1:
The patent applies local quality by creating different yarn configurations in different regions of the machine felt. At the front ends, longitudinal yarns are spaced apart to form loops for coupling, while in the main body regions, the yarns are arranged to provide uniform transverse strength. This localized differentiation allows the felt to possess both coupling capability and adequate transverse strength in different areas as needed.
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 ensures uniform yarn distribution and properties across the machine felt surface, preventing yarn displacement during manufacturing and improving transverse strength, while allowing for easy coupling and installation in paper machines.
Implementation Method 1
at least in part a material is used that has the property of absorbing laser energy and of being capable of being brought by means of laser energy, at least superficially and at least partially, to melting temperature
Implementation Method 2
the yarns are brought together with the auxiliary substrate web in its longitudinal direction and connected to one another by the action of a laser beam
Implementation Method 3
being capable of being brought by means of laser energy, at least superficially and at least partially, to melting temperature
Data Source
AI summary
A method for manufacturing a machine felt. Firstly a tube having a longitudinal yarn layer is manufactured with a peripheral length double the length of the machine felt, and a width that corresponds to the width of the machine felt. The tube is compressed into a flattened tube with the formation of longitudinal yarn loops which are exposed by the removal of fibers of a fiber batt layer. An auxiliary substrate web is manufactured with a width that is less than that of the machine felt; for the longitudinal yarns and/or for the auxiliary substrate web, a material is used that absorbs laser energy; the longitudinal yarns are brought together with the auxiliary substrate web and connected by a laser beam; the auxiliary substrate web is helically wound until the tube is formed; and upon exposure of the longitudinal yarn loops, the auxiliary substrate web(s) are also removed.