Papermaking Felt Joint Spacing for Stability
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Solution Overview
Problem
Papermaking felts with laminate structures using hollow woven base fabrics have poor productivity, and those with plain woven base fabrics face risks of joint opening during batt fiber layer attachment or use, leading to decreased productivity and stability issues.
Innovation Solution
A papermaking felt with a laminate structure using 2 or more plain weave base fabrics, where the distance between joint portions in the MD direction is set within specific ranges to ensure strength and prevent joint opening, allowing for stable bonding and improved productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hollow woven base fabrics are used in laminate structure papermaking felts, then smoothness and running stability are improved, but productivity decreases due to custom manufacturing requirements
Solution Approach 1:
The base fabric is divided into multiple fabric pieces that are joined together to form an endless base fabric. This segmentation allows standard fabrics to be combined to achieve the required length without custom manufacturing, improving productivity while maintaining running stability through proper joining techniques.
Solution Approach 2:
Multiple fabric pieces are merged together through joining their end portions to create an endless base fabric. This combining approach enables the use of standard fabrics in modular units that can be assembled to meet various length requirements, resolving the contradiction between customization and productivity.
2Productivity
If plain woven base fabrics are used in papermaking felts, then productivity improves through standardized manufacturing, but joint portions may open during batt fiber layer attachment or use
Solution Approach 1:
The end portions of the base fabrics are joined together before the batt fiber layer is attached. This preliminary action ensures that the joints are formed and strengthened in advance, preventing them from opening during subsequent batt fiber layer attachment or felt use, while maintaining productivity through standardized joining processes.
Solution Approach 2:
Overlapping portions are provided at the joints of the base fabrics to cushion and distribute stresses. This beforehand cushioning prevents the joints from opening under load during batt fiber layer attachment or felt operation, maintaining joint strength while using standardized plain woven fabrics.
3Reliability
If the maximum distance between joint portions is reduced to 750 cm or less, then joint opening is prevented, but manufacturing complexity increases
Solution Approach 1:
The distance between joint portions is controlled within a specific range (maximum 750 cm or less) to prevent joint opening. This parameter change optimizes the balance between joint strength and manufacturing simplicity, as the standardized joining process remains the same while only the spacing parameter is constrained.
Data Source
AI summary
A papermaking felt with two or more plain weave base fabrics that can be bonded to each other. The joint portions do not open when a batt fiber layer is attached or when the felt is used. The papermaking felt can be made from an MD yarn material in the felt running direction (MD direction) and a CD yarn material in the felt cross-direction (CD direction), including a combination with two or more base fabrics directly overlapped with each other, which have a joint portion wherein the MD direction end portions are joined which include a first MD direction end portion and a second MD direction end portion wherein, with regard to the base fabrics having all included joint portions. The equations (1) and (2) below are satisfied when the maximum distance in the MD direction between the joint portions of the base fabrics is x (cm) and the minimum distance thereof is y (cm): x≤750 (1); and 51≤y (2).