In-line shear resistant nonwoven textiles comprised of selectively slit and embossed film
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Solution Overview
Problem
Industrial textiles with selectively slit and embossed film layers face premature delamination due to internal stresses caused by differential travel distances of film layers around small diameter rolls, leading to repetitive strain and shear forces that compromise bond strength.
Innovation Solution
The film layers are designed with protrusions where one end is integral and the other end is either detached or weakened, allowing for relative movement between layers while maintaining a strong bond, thereby reducing internal stresses and preventing delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the film layers are joined with protrusions mated to land areas, then the bond strength between layers is improved, but the fabric is subjected to repetitive stress and strain causing premature delamination
Solution Approach 1:
The protrusions are segmented into integral portions (attached to land areas) and detached portions (free-standing tabs). This segmentation allows the bonded integral portions to provide strong attachment while the detached portions accommodate differential movement between layers, preventing stress concentration at the bond line and eliminating premature delamination.
2Ease of operation
If the fabric wraps around small diameter rolls, then the conveying function is improved, but internal stresses and shear forces increase causing layer separation
Solution Approach 1:
The fabric structure is made dynamic by incorporating detached protrusions that can move relative to the film layers. As the fabric wraps around rolls of varying diameters, these detached portions flex and adjust their position, allowing the fabric to adapt to different curvature radii without generating excessive internal stresses or shear forces that would cause layer separation.
3Stability of the object's composition
If the protrusions are fully integral to the film, then the structural integrity is improved, but the flexibility to accommodate differential movement is reduced
Solution Approach 1:
Different portions of the protrusions have different structural qualities: the base portions are integral with land areas to maintain structural integrity and provide stable bonding, while the distal portions are detached to provide flexibility and adaptability. This local differentiation of structural properties allows the fabric to simultaneously maintain integrity and accommodate differential movement between layers.
Data Source
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AI summary
A nonwoven industrial textile for conveying in an industrial process, seaming elements and methods of manufacture. The textile comprises at least first and second layers of film. Each layer comprises protrusions separated by land areas and each defining an aperture for a flow path through the layer. For at least one of the layers, the protrusions comprise a first set having first and second ends integral with contiguous land areas, and at least a second set of protrusions each comprising a first end integral with a contiguous land area and an opposing second end having a configuration selected from a detached free end; and a weakened end portion integral with but detachable from a contiguous land area in response to strain. The construction allows for relative movement of the layers during travel over machine components such as rolls, reducing internal strain and risk of delamination.