Seam-Containing Web Structuring Belt for Tissue Production
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Solution Overview
Problem
Laminated web material structuring belts with seams suffer from delamination, insufficient seam strength, poor seam quality, and inefficiencies in drying and structure formation due to inadequate seam integration between the structuring and support layers, leading to durability and functional issues in web material production.
Innovation Solution
The development of laminated web material structuring belts with seams where at least one seam portion extends into the support layer or structuring layer, providing improved penetration and adhesion to enhance seam strength and integrity, allowing for better air permeability and effective structure imparting during the web material forming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If seams are used to connect ends of structuring and support layers, then the belt can be formed and operated, but delamination occurs and seam strength is insufficient
Solution Approach 1:
The seam material is embedded within the porous structure of the support layer, with portions extending into the support layer to create a nested configuration. This nesting prevents delamination by anchoring the seam within the layer structure rather than merely surface-level attachment.
Solution Approach 2:
The invention uses composite construction where the seam comprises multiple materials including seam material and bonding material in specific ratios (e.g., 30-70% seam material and 30-70% bonding material). This composite approach enhances both seam strength and adhesion to prevent delamination.
2Ease of manufacture
If seams are present in the belt, then the belt can be constructed from multiple layers, but discontinuities are created that impact durability
Solution Approach 1:
The seam material is nested within the porous support layer structure, creating a continuous integrated structure rather than a discontinuous seam. This nesting eliminates sharp transitions and creates a gradual integration that maintains durability while allowing multi-layer construction.
3Ease of manufacture
If seams are used to join layers, then the belt can be assembled, but poor seam quality results due to inadequate integration
Solution Approach 1:
The seam material is nested within the porous support layer with controlled penetration depth (e.g., 0.1-5.0 mm into the support layer). This nesting creates precise integration without requiring complex assembly procedures, maintaining both ease of manufacture and high seam quality.
Solution Approach 2:
The seam uses a composite of seam material and bonding material in controlled ratios to achieve optimal adhesion and integration quality. The bonding material specifically enhances the connection between layers while the seam material provides structural continuity.
4Ease of manufacture
If seams are present in the belt structure, then the belt can be formed from multiple layers, but drying efficiency is reduced
Solution Approach 1:
The seam material is nested within the porous support layer structure, maintaining the overall porosity and air permeability of the belt. This nesting allows air flow to pass through the seam region without significant resistance, preserving drying efficiency while enabling multi-layer construction.
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 solution enables the production of web materials with improved durability and efficiency, enabling faster processing speeds, higher temperatures, and longer operational cycles while maintaining effective drying and structure formation, reducing discontinuities and fiber build-up.
Implementation Method 1
at least a portion of the seam is associated with the support layer such that the seam extends into, but less than entirely through, the support layer
Data Source
AI summary
Web material structuring belts that impart texture to a web material during a web material structuring operation/process and/or during a structured web material operation/process wherein the web material structuring belts include one or more seams (“seam-containing web material structuring belts”), method for making same and methods for using same to make structured web materials, such as structured sanitary tissue products such as structured toilet tissue, structured paper towels, structured facial tissue, structured wipes and/or structured components of absorbent products, such as structured top sheets for diapers and/or feminine hygiene products and/or adult incontinence products are provided.