Papermaking Press Section with Composite Fabric for Low-Energy Drying
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Solution Overview
Problem
Existing papermaking processes, such as TAD and ATMOS, face high capital costs, high energy consumption, and lower productivity due to limitations in fabric design and web transfer efficiency, resulting in suboptimal quality and output compared to conventional dry crepe processes.
Innovation Solution
A novel press section for papermaking machines incorporating a structuring fabric with extruded polymer netting laminated to a woven structure, allowing for improved airflow in the X-Y plane and reduced energy consumption, combined with a dewatering fabric and steam heated cylinder to enhance web drying efficiency and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional TAD or ATMOS processes are used, then high-quality tissue paper with high bulk can be produced, but capital costs and energy consumption are high
Solution Approach 1:
The patent employs a porous forming fabric with controlled void volume and air permeability to enable efficient water removal and airflow through the web during drying. The fabric's porous structure allows hot air to penetrate and dry the web from both sides simultaneously, reducing energy consumption while maintaining high bulk tissue quality
Solution Approach 2:
The patent uses a composite structuring fabric combining a woven fabric base with an overlaid polymer layer. This composite structure provides both mechanical strength and controlled porosity, enabling efficient dewatering and drying while reducing capital costs compared to conventional TAD equipment
2Manufacturing precision
If conventional TAD or ATMOS processes are used, then high-quality tissue paper with high bulk can be produced, but production rates are low
Solution Approach 1:
The patent implements a continuous drying process where the web passes through a heated drying zone without interruption. The forming fabric continuously conveys the web through the drying section, maintaining steady-state operation and maximizing production rate while ensuring consistent high-quality output
Solution Approach 2:
The patent extracts water from the web in multiple stages: initial dewatering on the forming fabric, intermediate pressing, and final drying. This multi-stage water removal approach accelerates the overall process and increases production rate while maintaining product quality
3Reliability
If forming fabrics with larger diameter monofilaments are used on the wear side, then wear resistance and drainage are improved, but fiber and filler retention may be compromised
Solution Approach 1:
The patent employs a forming fabric with different monofilament diameters on different sides: larger diameter monofilaments on the wear side for wear resistance and drainage, and finer yarns on the sheet side for fiber and filler retention. This local differentiation of properties resolves the contradiction between wear resistance and fiber retention
4Reliability
If triple layer fabrics are used instead of single layer fabrics, then dimensional stability, wear potential, drainage, and fiber support are improved, but device complexity increases
Solution Approach 1:
The patent uses a triple layer forming fabric composed of two single layer fabrics bound together by binder yarns. This composite structure provides enhanced dimensional stability, wear resistance, and drainage while maintaining manageable complexity through standardized manufacturing processes
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 achieves high-quality, high-bulk tissue paper with reduced capital costs and energy consumption, matching the performance of TAD technology while improving production rates.
Implementation Method 1
a drying section for drying the partially dewatered paper web, the drying section comprising: (i) a second press element with the inside surface of the structuring fabric in contact with the second press element; (ii) a steam heated cylinder; and (iii) a second nip, formed between the structuring fabric in contact with the second press element and the steam heated cylinder, in which the partially dewatered paper web is pressed and transferred to the steam heated cylinder
Implementation Method 2
a press section for pressing the partially dewatered paper web, the press section comprising: (i) the first press element with an inside surface of the dewatering fabric in contact with the first press element; (ii) a structuring belt with an inside surface of the structuring belt in contact with a suction element; and (iii) a first nip, formed between the dewatering fabric in contact with the first press element and the structuring belt in contact with the suction element
Data Source
Figure 1
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AI summary
A machine or apparatus for producing structured tissue or towel using a press section.