Papermaking Fabric Segmented Weave for Fiber Retention
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Solution Overview
Problem
Existing papermaking fabrics with a single layer structured surface are inadequate for forming structured paper sheets due to poor fiber retention and insufficient wear resistance, as they require larger yarn diameters and greater distances to ensure permeability and wear resistance, compromising fiber retention capabilities.
Innovation Solution
A papermaking fabric with a top weave structure that forms repeated fiber compression and support areas, where fiber support areas are recessed relative to compression areas, and separated by them, providing improved fiber retention and wear resistance through a plain weave structure that allows for efficient dewatering and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If single layer structured fabrics are used as forming fabrics, then permeability and wear resistance are improved, but fiber retention capability deteriorates
Solution Approach 1:
The fabric is divided into two separate layers: a top layer with structured surface for permeability and wear resistance, and a bottom layer with fine mesh for fiber retention. Each layer performs its specific function independently, resolving the contradiction between wear resistance and fiber retention.
Solution Approach 2:
The invention uses a composite structure combining two different fabric layers with distinct properties. The top layer uses larger yarns for durability and permeability, while the bottom layer uses finer yarns for fiber retention, creating a composite material system that achieves both requirements simultaneously.
2Object-generated harmful factors
If single layer structured fabrics are used as forming fabrics, then permeability is improved, but fiber retention capability deteriorates
Solution Approach 1:
The fabric is divided into two separate layers: a top layer with structured surface for permeability and wear resistance, and a bottom layer with fine mesh for fiber retention. Each layer performs its specific function independently, resolving the contradiction between wear resistance and fiber retention.
Solution Approach 2:
Different regions of the fabric have different properties optimized for their specific functions. The top layer has larger openings and coarser yarns for permeability, while the bottom layer has finer mesh for fiber retention, achieving local optimization of both contradictory requirements.
3Strength
If larger yarn diameters are used to ensure wear resistance and permeability, then wear resistance and permeability are improved, but fiber retention capability deteriorates
Solution Approach 1:
The fabric is divided into two separate layers: a top layer with structured surface for permeability and wear resistance, and a bottom layer with fine mesh for fiber retention. Each layer performs its specific function independently, resolving the contradiction between wear resistance and fiber retention.
Solution Approach 2:
The invention uses a composite structure combining two different fabric layers with distinct properties. The top layer uses larger yarns for durability and permeability, while the bottom layer uses finer yarns for fiber retention, creating a composite material system that achieves both requirements simultaneously.
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 fabric achieves enhanced fiber retention and wear resistance, enabling the production of structured paper sheets with improved bulk and tensile strength, while maintaining sufficient air permeability for effective dewatering.
Implementation Method 1
maintaining sufficient air permeability for effective dewatering
Data Source
AI summary
A papermaking fabric for fibrous web forming or processing machines extends in MD and CD-directions and includes top and bottom fabric layers bound by binder yarns. The top layer is a web contacting side with top weave structures having interwoven first MD and first CD-yarns. The bottom layer is a machine contacting side with bottom weave structures having interwoven second MD and second CD-yarns. The top weave structure has repeats and forms fiber compression areas and fiber support areas recessed in thickness direction of the fabric relative to the fiber compression areas on the web side and fiber support areas separated by fiber compression areas or vice versa. A fiber compression area has adjacent top MD-floats on the web side or adjacent top CD-floats on the web side and a fiber support area has first MD and first CD-yarns interwoven in plain weave.