Seamless Deflection Member Structure for Uniform 3D Papermaking Patterns
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Solution Overview
Problem
Existing deflection members for papermaking belts face limitations in achieving uniform patterns of cantilevered portions, are constrained by UV-curing masks, and require complex seaming processes, which affect the quality and integrity of the paper products.
Innovation Solution
A seamless unitary deflection member is manufactured through additive manufacturing, combining a patterned framework with a reinforcing member without UV-curing, allowing precise control over the shape, size, and distribution of protuberances to create a three-dimensional structure with regular orientations and cantilevered structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If UV-curing masks are used to manufacture deflection members, then the resinous framework can be joined to the reinforcing element, but the pattern uniformity and manufacturing precision are limited
Solution Approach 1:
The patent removes the mask component entirely from the manufacturing process. Instead of using UV-curing masks to define the pattern, the invention uses a pre-formed mesh substrate with embedded channels that directly define the deflection member geometry. This extraction of the mask eliminates pattern uniformity limitations and manufacturing complexity associated with mask design and alignment.
Solution Approach 2:
The patent replaces the UV-curing chemical process with a mechanical assembly process. The deflection member is formed by mechanically assembling the mesh substrate with the resinous framework and channels, eliminating the need for UV-curing masks and their associated precision limitations.
2Ease of manufacture
If deflection members are manufactured with seaming processes, then the belt can be formed from separate components, but the seam integrity and product quality are compromised
Solution Approach 1:
The patent merges the mesh substrate, resinous framework, and channels into a single integrated structure. The channels are embedded within the mesh substrate during manufacturing, creating a unitary deflection member that eliminates seams and their associated integrity issues while maintaining ease of manufacture through modular component design.
Solution Approach 2:
The patent uses composite construction by combining the mesh substrate material with the resinous framework material to form a unified deflection member. This composite approach allows the different functional elements to be integrated without seams, achieving both ease of manufacture and high reliability.
3Quantity of substance
If conventional deflection members are used, then the basic papermaking function is achieved, but the surface area and absorbency are insufficient
Solution Approach 1:
The patent adds three-dimensional channels embedded within the mesh substrate, creating a multi-layered structure that significantly increases the effective surface area. This dimensional addition allows the deflection member to provide both structural function and enhanced absorbency without excessive complexity.
Solution Approach 2:
The patent utilizes the porous structure of the mesh substrate and the embedded channels to create a deflection member with high surface area and absorbency. The porous architecture provides numerous pathways for fluid interaction while maintaining structural integrity, achieving enhanced performance without disproportionate complexity.
Data Source
AI summary
A seamless unitary deflection member may comprise a plurality of regularly spaced protuberances, which may be semi-continuous units disposed in a regular, spaced apart configuration in at least one of a machine direction (MD) and a cross-machine direction (CD).