Segmented Tile Deflection Member for Durable Papermaking Belts

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Solution Overview

Problem

Existing deflection members used in papermaking and nonwoven production processes face challenges in terms of size, durability, and endurance under extreme processing conditions, limiting their commercial viability and the quality of fibrous webs produced.

Innovation Solution

A deflection member with a three-dimensional topography created via additive manufacturing, comprising patterned framework tiles fastened to a reinforcing member using stitching or other fastening elements, allowing for customizable air or liquid flow and enhanced structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If additive manufacturing is used to create deflection members with three-dimensional topography, then manufacturing flexibility and structural customization are improved, but size and durability under extreme processing conditions deteriorate

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoiddurability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The deflection member is divided into multiple individual tiles that can be separately manufactured through additive manufacturing and then assembled into a complete belt. Each tile can be optimized independently for manufacturing flexibility while the collective assembly provides the required durability and size for commercial papermaking machines.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The deflection member combines additively manufactured tiles with a reinforcing member (such as a woven fabric or mesh) to create a composite structure. This composite construction enhances the durability and mechanical strength of the otherwise fragile additively manufactured tiles, enabling them to withstand extreme processing conditions.

Inventive Principle:

Principle #40Composite materials

2Productivity

If deflection members are made larger to fit commercial papermaking machines, then productivity is improved, but durability and endurance under extreme conditions worsen

Engineering Contradiction:

Improvebelt sizeVSAvoidendurance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Instead of manufacturing one large deflection member that would be difficult to produce and prone to failure, the system segments the belt into multiple smaller tiles. These tiles are assembled to form a large-area belt suitable for commercial papermaking machines while maintaining the durability of individual manageable components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The large-scale deflection member is constructed as a composite system where additively manufactured tiles are mounted on a reinforcing substrate. This composite structure enables the belt to span large areas required for high-productivity papermaking while the reinforcing member provides the mechanical strength and endurance needed under extreme processing conditions.

Inventive Principle:

Principle #40Composite materials

3Reliability

If traditional manufacturing methods are used for deflection members, then durability is improved, but manufacturing precision and customization capability worsen

Engineering Contradiction:

ImprovedurabilityVSAvoidstructural precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Additive manufacturing enables local quality variations in the deflection member tiles, allowing different regions of each tile to have customized topographies and structures optimized for specific functional requirements. This level of manufacturing precision and customization is not achievable with traditional manufacturing methods.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system combines additively manufactured tiles (providing manufacturing precision and customization) with a traditional reinforcing member (providing durability). This composite approach allows each component to contribute its strengths, resolving the contradiction between manufacturing precision and durability.

Inventive Principle:

Principle #40Composite materials

4Strength

If deflection members are designed for high strength, then structural integrity is improved, but softness and absorbency of the produced fibrous webs worsen

Engineering Contradiction:

Improvestructural integrityVSAvoidproduct quality

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The additively manufactured tiles are designed with localized three-dimensional topographies that create specific flow patterns for the fibrous web. By varying the topography locally across different regions of the tiles, the system can control air or liquid flow to produce webs with desired softness and absorbency while the overall tile structure maintains structural integrity.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The composite construction separates the structural function (provided by the reinforcing member and tile framework) from the web-forming function (provided by the controlled void spaces and topography). This allows the deflection member to have high structural integrity while simultaneously enabling the production of soft and absorbent fibrous webs through optimized flow channels.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20250290252A1Deflecting member for making fibrous structures

Publication Date: 2025.09.18 PROCTER & GAMBLE CO

AI summary

A deflection member that includes a reinforcing member that includes a resin coating, and at least one tile fastened to the resin coating.