Rotary Screen Patterning for Wide Papermachine Fabrics
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Solution Overview
Problem
Existing methods for applying topographical patterns to papermachine fabrics are limited by screen width restrictions, leading to time-consuming and labor-intensive processes that require precise alignment, making it difficult to achieve complex patterns over the entire fabric width.
Innovation Solution
A method using a rotary screen that moves relative to the fabric to apply a topographical polymer pattern in sections or continuously, ensuring an offset of 0.1 mm or less, allowing for accurate and efficient application of patterns over the entire fabric width, using polymers with viscosities up to 150,000 cP and patterns with heights up to 1.0 mm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a rotary screen is used to apply topographical patterns to papermachine fabric, then pattern application is efficient and durable, but the screen width restricts the fabric width that can be processed
Solution Approach 1:
The fabric width is divided into multiple sections, each covered by a separate rotary screen. Multiple screens are arranged side-by-side to collectively cover the entire fabric width, allowing each screen to operate independently while contributing to the overall pattern application across the full fabric width.
2Area of stationary object
If stencil printing is used to cover entire fabric width, then full width coverage is achieved, but the process is time-consuming and requires complex alignment
Solution Approach 1:
The rotary screens operate continuously as the fabric passes through, applying patterns in a continuous manner rather than in discrete, time-consuming stencil printing steps. The rotation of the screens maintains constant contact with the moving fabric, enabling uninterrupted pattern application across the entire width.
3Area of stationary object
If section-by-section printing is used to cover wide fabric, then full width coverage is achieved, but pattern alignment and matching becomes complex
Solution Approach 1:
Multiple rotary screens are merged into a single integrated system that operates simultaneously across the fabric width. The screens are positioned and synchronized to work together as one unified pattern application system, eliminating the alignment issues that arise from sequential section-by-section printing.
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
Enables the production of durable, high-quality paper with accurately aligned topographical patterns, improving efficiency and reducing alignment challenges, allowing for continuous or semi-continuous application of patterns with precise control and repeatability.
Implementation Method 1
a topographical polymer pattern is produced by a rotary screen (28)
Data Source
AI summary
A method for creating a pattern on or in an fabric, comprising producing a topographical polymer pattern on or in a papermachine fabric using a rotary screen. A fabric, comprising a papermachine fabric including a topographical polymer pattern as an external or internal feature. The instant abstract is neither intended to define the invention disclosed in this specification nor intended to limit the scope of the invention in any way.