Spirally Wound Industrial Fabric for In-Process Nonwoven Patterning
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Solution Overview
Problem
Existing nonwoven production processes require separate and costly calendaring steps for patterning, leading to high material content, lower bulk, and dimensionally unstable products with difficult-to-see patterns, and incur high initial investments and processing costs.
Innovation Solution
An improved belt or sleeve with through voids and textured surfaces, made from spirally wound industrial strapping material, integrates patterning and texture into the hydroentangling process, reducing material usage and production costs while maintaining or enhancing bulk and absorbency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate calendaring steps are used for patterning, then desired patterns and marks can be produced, but production costs increase and material content becomes excessive
Solution Approach 1:
The patent combines the patterning function with the support member itself by incorporating raised portions and textured surfaces directly into the belt structure. This eliminates the need for separate calendaring equipment, as the support member performs both support and patterning functions simultaneously during the hydroentangling process.
Solution Approach 2:
The support member is pre-formed with specific topographical features, raised portions, and textured surfaces before the nonwoven production process. These pre-integrated features directly impart the desired patterns and marks to the nonwoven product during processing, eliminating subsequent patterning steps.
2Manufacturing precision
If separate calendaring steps are used for patterning, then desired patterns can be produced, but bulk and absorbency are reduced
Solution Approach 1:
The support member integrates patterning features directly into its structure, allowing patterns to be formed during the primary hydroentangling process rather than through separate compression calendaring. This preserves the three-dimensional structure and bulk of the nonwoven product while still achieving desired surface patterns and marks.
3Manufacturing precision
If separate calendaring steps are used for patterning, then desired patterns can be produced, but dimensional stability is compromised
Solution Approach 1:
The support member performs both support and patterning functions simultaneously during the hydroentangling process. The raised portions and textured surfaces on the support member directly transfer patterns to the nonwoven product without requiring subsequent compression, thereby maintaining dimensional stability and preventing pattern distortion under stress.
4Productivity
If traditional support members are used, then nonwoven production can proceed, but additional equipment is required for patterning
Solution Approach 1:
The support member is designed with multi-functionality, serving both as the conveying support for the fiber web and as the patterning tool. The raised portions, textured surfaces, and void patterns on the support member directly impart design features to the nonwoven product, eliminating the need for separate calendaring or embossing equipment.
Solution Approach 2:
The support member combines the support function and patterning function into a single integrated component. This eliminates the need for additional patterning equipment and separate processing steps, thereby simplifying the overall production system and improving efficiency.
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 allows for lower-cost, high-bulk nonwoven products with desired patterns and textures, reducing capital investment and processing costs, and enabling customization of production runs, while maintaining or improving the physical properties of nonwoven products.
Implementation Method 1
fabric formed from strips of material that are spiral wound around two rolls in a side to side abutting manner
Implementation Method 2
The strips are firmly attached to each other by a suitable method to form an endless loop
Implementation Method 3
a fiber batt or web is treated with water streams or jets to cause the fibers to entangle with each other
Implementation Method 4
interlacing of elementary fibers with one another by means of the action of water jets under pressure, which act on the fibrous structure like needles
Implementation Method 5
brought onto the surface of a perforated rotary cylindrical drum, to the interior of which a partial vacuum is applied
Implementation Method 6
The basic web is compressed mechanically between the porous support and the rotary drum wherein a vacuum source removes the excess water
Implementation Method 7
the elementary fibers are intermingled continuously, still on the rotary cylindrical drum, by the compressed and wetted web being subjected to the action of at least one rack of jets of water under high pressure
Implementation Method 8
interlacing of elementary fibers with one another by means of the action of water jets under pressure
Data Source
AI summary
An industrial fabric such as an endless belt or sleeve for use in the production of nonwovens, and a method of making thereof are disclosed. The industrial fabric is produced by spirally winding strips of polymeric material, such as an industrial strapping or ribbon material, and joining the adjoining sides of the strips of material using ultrasonic welding or laser welding techniques. The fabric may then be perforated using a suitable technique to make it permeable to air and/or water.