Papermaking felt and method for manufacturing the same
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Solution Overview
Problem
Existing papermaking felts manufactured by overlapping and welding end regions often suffer from poor smoothness, particularly at the welded portions, which can result in visible marks and inadequate compressibility.
Innovation Solution
The papermaking felt is designed with a configuration where the thickness of the welded portion is adjusted to be between 50% to 95% of the non-welded portion's thickness, achieved by overlapping and welding end regions without removing yarn materials, ensuring the welded portion's thickness equals the material portion's thickness under pressure, thus enhancing smoothness and compressibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If end regions are overlapped and welded without removing yarn materials, then manufacturing efficiency is improved, but the thickness of welded portion becomes greater than material portion, causing poor smoothness and visible marks
Solution Approach 1:
The invention changes the thickness parameter of the welded portion by controlling the overlap length and welding pressure, making the welded portion thickness (x) equal to or slightly less than the material portion thickness (y) according to the formula x≤y. This parameter optimization resolves the contradiction by allowing efficient welding without yarn removal while maintaining smooth surface quality.
2Strength
If welded portion thickness is increased to ensure structural integrity, then strength is improved, but smoothness deteriorates due to visible welded portion marks
Solution Approach 1:
The invention optimizes the thickness parameter within a specific range (x≤y) to balance strength and smoothness. By controlling the overlap length and welding conditions, the welded portion maintains sufficient structural integrity while avoiding excessive thickness that would cause visible marks, thus resolving the contradiction between strength and smoothness.
3Manufacturing precision
If welded portion thickness is reduced to improve smoothness, then surface quality is improved, but compressibility and dewatering property deteriorate
Solution Approach 1:
The invention sets the thickness parameter within an optimal range (x≤y) rather than minimizing it excessively. This ensures the welded portion is thin enough for smoothness but thick enough to maintain compression recovery characteristics and dewatering property, resolving the contradiction between smoothness and functional reliability.
4Manufacturing precision
If yarn materials are removed from overlapped portion to reduce thickness, then smoothness is improved, but manufacturing complexity and time increase
Solution Approach 1:
Instead of removing yarn materials to reduce thickness (conventional approach), the invention inverts the approach by controlling the welding parameters (overlap length, pressure, temperature) to achieve the desired thickness directly during welding. This eliminates the need for separate yarn removal steps, reducing manufacturing complexity while maintaining smoothness.
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 configuration results in a papermaking felt with improved smoothness, eliminating welded portion marks and base fabric marks, while maintaining efficient manufacturing by avoiding the need to remove yarn materials, thereby enhancing the overall performance and productivity.
Implementation Method 1
said overlapped portion is welded without removing a part or all of the MD yarn material or the CD yarn material in said overlapped portion
Implementation Method 2
at least one of the MD yarn material or the CD yarn material of at least one base fabric is a thermoplastic resin having a heat resistant temperature of 60°C to 200°C and a melting point of 80°C to 300°C
Data Source
Figure 1~3(B)
Figure 4~5(B)
AI summary
[Problem to be solved] To provide a papermaking felt excellent in smoothness of a joined portion (no welded portion mark or base fabric mark is generated) , and an efficient manufacturing method thereof. the average thickness of the welded portion is 50% or more and 95% or less of the average thickness before welding.