Papermaking Belt Patterned Framework Dewatering
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Solution Overview
Problem
Conventional papermaking processes using conventional drying methods operate at low speeds to sufficiently dewater paper webs, limiting the production of high caliper, low density paper products with distinct structural regions.
Innovation Solution
A papermaking belt with a patterned framework featuring continuous network regions and discrete deflection conduits, along with pores that enhance dewatering capability, allowing for the production of high caliper paper products without additional dewatering felt or compression nips, by optimizing fiber orientation and water removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional drying methods are used, then paper webs can be dried, but the process operates at low speeds limiting productivity
Solution Approach 1:
The papermaking belt incorporates a porous framework structure with controlled porosity to enable rapid water removal from the paper web. The porous material allows water to pass through efficiently while maintaining belt strength and structural integrity, resolving the contradiction between fast production speed and adequate dewatering time.
Solution Approach 2:
The belt is divided into distinct functional regions including deflection conduits, capillary channels, and dewatering zones. This segmentation allows different parts of the belt to perform specialized functions - deflection conduits for fiber orientation, capillary channels for water transport, and dewatering zones for rapid moisture removal - enabling high-speed operation with effective dewatering.
2Volume of moving object
If high caliper paper products are produced, then paper thickness and absorbency are improved, but dewatering becomes more difficult
Solution Approach 1:
The belt design incorporates three-dimensional deflection conduits that extend vertically through the belt structure, creating Z-direction fiber orientation. This dimensional approach allows fibers to be arranged in multiple directions simultaneously, maintaining high caliper while facilitating water removal through the belt's porous structure.
Solution Approach 2:
Capillary channels act as intermediary structures between the paper web and the dewatering surface. These channels provide dedicated pathways for water to travel from the high-caliper paper web through the belt framework, enabling efficient dewatering without compromising paper thickness or absorbency.
3Strength
If fiber orientation in Z-direction is maximized, then caliper and structural rigidity are improved, but dewatering efficiency decreases
Solution Approach 1:
The belt combines multiple material properties and structural features - a porous framework for strength, deflection conduits for fiber orientation, and capillary channels for water transport. This composite structure achieves Z-direction fiber orientation for rigidity while maintaining high dewatering rates through the integrated capillary channel system.
Solution Approach 2:
The capillary channels utilize capillary action (a hydraulic principle) to actively draw water away from the paper web through the belt structure. This passive hydraulic system enables rapid dewatering without interfering with the Z-direction fiber orientation and structural rigidity provided by the deflection conduits.
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 enables efficient dewatering and production of paper products with high caliper and low density, maintaining structural integrity and absorbency, while operating at speeds comparable to through-air-drying processes.
Implementation Method 1
A plurality of non-random distinct pores is disposed within the continuous network region... as water is removed from the aqueous slurry of cellulosic fibers
Implementation Method 2
The papermaking fibers deflected into the conduits become rearranged upon the application of a differential fluid pressure
Data Source
AI summary
A papermaking belt for carrying an embryonic web of paper fibers is disclosed. The papermaking belt has an embryonic web contacting surface and a non-embryonic web contacting surface opposite thereto. The papermaking belt also has a reinforcing structure having a patterned framework disposed thereon and a plurality of non-random distinct pores disposed within the continuous network region. The patterned framework has a continuous network region and a plurality of discrete deflection conduits. The deflection conduits are isolated one from another by the continuous network region. Each of the pores has an opening disposed at a predetermined location upon the embryonic web contacting surface and an opening disposed at a predetermined location upon the non-embryonic web contacting surface. Each of the pores defines a single pathway between the embryonic web contacting surface and the non-embryonic web contacting surface.