Polymeric Papermaking Fabric With Airflow Channels for Tissue Drying
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Solution Overview
Problem
Conventional manufacturing processes for papermaking fabrics are time-consuming, expensive, and inefficient, leading to high capital and operational costs, and the resulting fabrics do not achieve the quality and productivity levels of advanced tissue manufacturing technologies like TAD and ATMOS.
Innovation Solution
The use of extruded polymeric netting material, laminated to woven fabric layers, creates a structuring fabric with airflow channels that enhance drying efficiency and reduce energy consumption, allowing for high-quality tissue production at lower costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing processes are used for papermaking fabrics, then the fabrics can be produced, but the production is time-consuming and expensive with high capital and operational costs
Solution Approach 1:
The patent changes the manufacturing parameters by using extruded polymeric netting material instead of traditional woven fabrics, and by modifying the drying process parameters to achieve high-quality tissue production more efficiently
Solution Approach 2:
The patent employs composite materials by combining extruded polymeric netting with woven fabric layers, creating a structuring fabric that improves both manufacturing efficiency and product quality
2Use of energy by moving object
If conventional fabrics are used, then the manufacturing process is simple, but the drying efficiency is low and energy consumption is high
Solution Approach 1:
The patent utilizes porous materials by incorporating extruded polymeric netting with controlled porosity and airflow channels, which enhances drying efficiency while reducing energy consumption through improved air circulation
Solution Approach 2:
The patent modifies the fabric structure parameters by using extruded netting with specific pore sizes and airflow channel configurations, optimizing the balance between drying efficiency and energy consumption
3Manufacturing precision
If traditional fabric structures are used, then the manufacturing cost is high, but the quality and productivity levels are insufficient for advanced tissue manufacturing
Solution Approach 1:
The patent changes the material parameters by using extruded polymeric netting with controlled dimensions and properties, achieving high tissue quality at lower manufacturing costs through optimized material specifications
Solution Approach 2:
The patent creates composite structures by combining extruded polymeric netting layers with woven fabric supports, achieving the desired tissue quality and productivity while maintaining cost-effectiveness through material composite design
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 approach reduces material costs, improves productivity, and achieves high-quality tissue production with low capital and operational expenses, surpassing the performance of conventional technologies.
Implementation Method 1
a first layer made of extruded polymer... a second layer made of woven fabric that supports the first layer, wherein the first layer is bonded to the second layer
Implementation Method 2
creates a structuring fabric with airflow channels that enhance drying efficiency
Data Source
AI summary
A fabric or belt for a papermaking machine including a first layer that defines a web contacting surface and a second layer that supports the first layer. The first layer is made of extruded polymer and includes a plurality of first elements aligned in a first direction, a plurality of second elements aligned in a second direction and extending over the plurality of first elements, and a plurality of open portions defined by the plurality of first and second elements. The second layer is made of woven or nonwoven fabric. The first layer is bonded to the second layer so that the first layer extends only partially through the second layer and an interface formed between the first and second layers includes bonded and unbonded portions and airflow channels that extend in a plane parallel to the first and second layers.