Single Structured-Fabric Papermaking for High-Bulk Tissue
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing tissue manufacturing processes face challenges in achieving high quality tissue products with superior softness, absorbency, and bulk while maintaining low capital and operating costs, particularly due to the complexity and inefficiencies in fabric usage and drying methods.
Innovation Solution
A papermaking process utilizing a structured fabric without additional belts or fabrics, employing 3-D printing techniques to create a woven fabric with monofilaments and optional overlaid resin, and using vacuum-assisted dewatering and drying methods to form a nascent web directly on the structured fabric, eliminating the need for fabric creping or pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional dry crepe process is used, then production rate is high, but tissue softness and absorbency are limited
Solution Approach 1:
The patent changes the physical and chemical parameters of the forming fabric, using a structured fabric with specific mesh sizes, pore distributions, and surface properties that enable deep fiber penetration while maintaining high production rates. The fabric structure parameters are optimized to achieve both productivity and quality
Solution Approach 2:
The patent employs a composite forming fabric structure combining different materials and layers with distinct functions - some layers provide mechanical strength while others optimize drainage and fiber retention, enabling simultaneous achievement of high production rate and superior tissue quality
2Manufacturing precision
If multiple fabrics and belts are used in forming section, then web formation control is improved, but device complexity and capital cost increase
Solution Approach 1:
The structured forming fabric is designed to perform multiple functions simultaneously - web formation, water drainage, fiber retention, and surface imprinting - all in a single component, eliminating the need for multiple separate fabrics and belts while maintaining precise web formation control
Solution Approach 2:
The patent extracts and consolidates the essential functions previously distributed across multiple fabrics and belts into a single integrated structured fabric, removing unnecessary complexity while preserving the critical web formation control capabilities
3Strength
If fabric creping and pressing are used, then web strength is improved, but bulk and absorbency are reduced
Solution Approach 1:
The structured fabric performs preliminary web consolidation and strength development during the forming stage itself, through controlled fiber maturation and bonding, eliminating the need for subsequent aggressive creping and pressing operations that would compromise bulk and absorbency
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 method achieves high-quality tissue products with enhanced bulk and absorbency at reduced capital and operating costs by ensuring deep fiber penetration and minimal web compaction, surpassing the performance of conventional and hybrid processes.
Implementation Method 1
draining the nascent web through the structured fabric
Implementation Method 2
depositing a dilute fiber slurry out of a headbox to a forming area so as to form a nascent web
Implementation Method 3
drying the nascent web
Data Source
AI summary
A method of forming a fibrous web on a papermaking machine including the steps of depositing a dilute fiber slurry out of a headbox to a forming area comprising a forming surface made up of a structured fabric, wherein the structured fabric is supported by a breast roll and a forming roll, and the forming area is devoid of any additional fabrics or belts other than the structured fabric, draining the dilute fiber slurry through the structured fabric, and drying the fiber slurry.