Papermaking Belt With Extruded Polymer Layer for Airflow Control
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Solution Overview
Problem
Conventional manufacturing processes for papermaking fabrics are time-consuming, expensive, and inefficient, leading to high capital and operational costs, and the resulting fabrics do not achieve the quality and productivity levels of advanced tissue production methods like TAD and ATMOS due to limitations in airflow and structural design.
Innovation Solution
The use of extruded polymeric netting material as a first layer, laminated to a woven fabric layer, creating a fabric structure with airflow channels parallel to the layers, which enhances airflow and reduces the need for high air flow rates, thereby lowering energy consumption and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing processes are used for papermaking fabrics, then production costs are reduced, but quality and productivity levels are insufficient compared to advanced tissue production methods
Solution Approach 1:
The patent employs composite materials by combining a polymeric overlay layer with a woven fabric substrate. The polymeric layer (made from materials like polyethylene, polypropylene, or polyester) is bonded to the woven fabric to create a composite structure that achieves both high fabric quality with controlled airflow characteristics and high productivity suitable for advanced tissue production methods like TAD and ATMOS
Solution Approach 2:
The patent applies local quality by creating a polymeric overlay layer with specific local properties on the fabric surface. This overlay provides localized airflow resistance and structural characteristics that are different from the base woven fabric, enabling precise control over air flow rates and fabric performance to meet both quality and productivity requirements
2Difficulty of detecting and measuring
If conventional fabric structures are used, then manufacturing simplicity is maintained, but airflow characteristics are insufficient for advanced tissue production
Solution Approach 1:
The patent utilizes porous materials by incorporating a polymeric overlay layer with controlled porosity and airflow characteristics. This porous polymeric layer is bonded to the woven fabric substrate to create a composite structure that provides precise airflow control for advanced tissue production methods, enabling the fabric to function effectively in applications requiring specific air flow rates and patterns
3Productivity
If high air flow rates are required, then productivity is improved, but energy consumption increases
Solution Approach 1:
The patent applies parameter changes by modifying the fabric structure to include a polymeric overlay layer with specific physical parameters such as porosity, thickness, and permeability. These parameter changes enable the fabric to achieve optimal air flow characteristics that improve productivity while reducing the energy required for air movement, as the structured polymeric layer facilitates more efficient airflow patterns
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 allows for high-quality tissue production at lower costs and higher productivity rates, matching or exceeding the quality of TAD technology while reducing capital and operational expenses.
Implementation Method 1
The use of extruded polymeric netting material as a first layer, laminated to a woven fabric layer
Implementation Method 2
a first layer that is bonded to a second layer
Data Source
AI summary
A fabric or belt for a papermaking machine including a first layer that defines a web contacting surface and a second layer that supports the first layer. The first layer is made of extruded polymer and includes a plurality of first elements aligned in a first direction, a plurality of second elements aligned in a second direction and extending over the plurality of first elements, and a plurality of open portions defined by the plurality of first and second elements. The second layer is made of woven or nonwoven fabric. The first layer is bonded to the second layer so that the first layer extends only partially through the second layer and an interface formed between the first and second layers includes bonded and unbonded portions and airflow channels that extend in a plane parallel to the first and second layers.