Porous Press Fabric with Controlled Plasticized Surface
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing paper machine clothing technologies face challenges in achieving smoothness and uniformity while maintaining wear resistance, as methods like polymeric coatings and fine fibers often damage fibers and lead to non-uniform pressure distribution and sheet marking.
Innovation Solution
The use of plasticizers, combined with heat and pressure treatment, to enhance fiber bonding and create a smooth, porous surface on press fabrics, allowing for controlled permeability and improved wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If polymeric coating is applied to smooth the fabric surface, then sheet smoothness is improved, but fiber damage occurs and wear resistance deteriorates
Solution Approach 1:
The patent replaces the mechanical grinding process with a chemical treatment process. Instead of mechanically grinding the fabric surface to achieve smoothness (which damages fibers), the invention uses a chemical composition containing acids, bases, or salts that react with the fiber surface to create smoothness chemically, thereby eliminating mechanical fiber damage while maintaining wear resistance
Solution Approach 2:
The patent changes the surface properties of fibers through chemical parameter changes. By applying chemical compositions with specific pH levels and chemical concentrations, the fiber surface undergoes chemical modification that alters its surface roughness and morphology, achieving smoothness without mechanical removal of fiber material
2Manufacturing precision
If water based coating is applied to porous substrate, then surface coating is achieved, but coating penetration control becomes difficult
Solution Approach 1:
The patent replaces the water-based coating process with a vapor-phase or aerosol-phase chemical treatment process. The active chemical components are delivered in a controlled vapor or aerosol form that can be precisely directed and controlled, preventing uncontrolled penetration into the porous substrate while ensuring uniform surface coverage
Solution Approach 2:
The patent introduces a carrier gas or aerosol medium as an intermediary between the chemical composition and the fabric substrate. This intermediary allows for precise control of chemical delivery, enabling the active ingredients to reach the surface without excessive penetration into the porous structure
3Manufacturing precision
If fine fibers are used to create smooth surface, then sheet smoothness is improved, but wear resistance substantially reduces
Solution Approach 1:
The patent changes the surface morphology of existing fibers through chemical treatment rather than relying on fine fiber selection. The chemical composition modifies the fiber surface to reduce roughness and create smoothness, achieving the same effect as using fine fibers without sacrificing the mechanical strength and wear resistance of the fiber bulk structure
Solution Approach 2:
The patent replaces the mechanical approach of selecting and using fine fibers with a chemical surface modification approach. Instead of mechanically choosing finer fibers (which inherently have lower strength), the invention uses chemical treatment to smooth the surface of existing fibers, preserving their wear resistance while achieving smoothness
4Manufacturing precision
If rubber or resin emulsion is applied to smooth surface layer, then surface smoothness is improved, but permeability control becomes problematic and surface layer wears away over time
Solution Approach 1:
The patent replaces the application of rubber or resin emulsions with direct chemical treatment of the fiber surface. Instead of coating the surface with additional polymeric materials (which can wear away), the invention modifies the fiber surface chemistry and morphology directly, creating a durable smooth surface that is integral to the fiber structure itself
Solution Approach 2:
The patent achieves surface smoothness through chemical parameter changes of the fiber surface rather than through polymeric coating. The chemical composition alters the surface properties of the fibers themselves, creating a smooth surface that maintains the original fiber's durability and permeability characteristics without adding wear-prone coating layers
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 process results in fabrics with enhanced smoothness and uniformity, ensuring consistent pressure distribution and increased wear resistance, reducing sheet marking and improving paper dryness without the need for additional coatings or chemicals.
Implementation Method 1
treating the one or more layers of batt with a plasticizer sufficient enough to lower the glass transition temperature of both polymers of the polymeric bicomponent fibers by 40-60°C
Implementation Method 2
applying heat and/or pressure to the treated layers to cause fiber flattening and densification of the entire layers of batt
Implementation Method 3
applying heat and/or pressure to the treated layers to cause fiber flattening and densification of the entire layers of batt
Data Source
Figure 1
AI summary
The present invention relates to a process of obtaining an industrial fabric with porous and controlled plasticized surface and an industrial fabric with the mentioned characteristics thereof. The invention also relates to an industrial fabric such as press fabric for use in the press section of a paper machine with enhanced aesthetic properties by the use of plasticizers and optional heat and/or pressure treatment.