Patterned Papermaking Belt with Deflection Conduits
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Solution Overview
Problem
Conventional papermaking processes struggle to produce paper products with high strength, absorbency, and flexibility, often requiring a trade-off between these properties, and traditional drying methods limit the production speed of structured paper with distinct density regions.
Innovation Solution
A papermaking belt with a patterned framework featuring a continuous network region and discrete deflection conduits, where the conduits are surrounded by tessellating unit cells with varying land area densities, allows for differential fiber deflection and water removal, creating a paper web with high density regions and low density domes, enhancing structural rigidity and absorbency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional papermaking processes use traditional drying methods, then production speed is limited, but structured paper with distinct density regions can be produced
Solution Approach 1:
The papermaking belt is divided into distinct regions: a continuous network region and discrete deflection conduit regions. This segmentation allows different areas to perform different functions - the continuous network provides structural support while the deflection conduits create dome structures, enabling structured paper formation without requiring slow traditional drying methods
Solution Approach 2:
The belt provides different local qualities through its patterned framework - areas with deflection conduits create low-density dome regions, while the continuous network region creates high-density structural regions. This local differentiation of properties allows the paper to achieve both speed and quality by having different regions optimized for different functions
2Strength
If softness and absorbency are increased in paper web, then strength decreases
Solution Approach 1:
The paper web is created with different local qualities through the patterned framework - the continuous network region provides high strength and structural integrity, while the dome regions provide softness and absorbency. This spatial differentiation allows both contradictory properties to coexist in different parts of the same paper web
Solution Approach 2:
The paper web functions as a composite structure combining two distinct regions: a continuous network region acting as the structural framework and dome regions providing functional properties. This composite approach allows the paper to exhibit both high strength from the network and high softness/absorbency from the domes
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 enables the production of paper products with increased strength, absorbency, and flexibility, while maintaining high caliper and density differences, allowing for faster drying and improved product performance comparable to through-air-dried processes.
Implementation Method 1
the papermaking fibers deflected into the conduits become rearranged upon the application of a differential fluid pressure
Implementation Method 2
as the paper slurry is fed onto a surface of a traveling endless wire where the initial dewatering occurs
Data Source
AI summary
The present disclosure is directed toward a papermaking belt having an embryonic-web-contacting surface for carrying an embryonic web of paper fibers and a non-embryonic-web-contacting surface opposite the embryonic-web-contacting surface. The papermaking belt has a patterned framework having a continuous network region and a plurality of discrete deflection conduits isolated from one another by the continuous network region. The continuous network region has a pattern formed therein by a plurality of tessellating unit cells. Each cell has a center and at least two continuous land areas extending in at least two directions from the center. At least one of the continuous land areas at least bifurcates to form a continuous land area portion having a first width before the bifurcation and at least two continuous land area portions having a second width after the bifurcation.