Spiral-Wound Support Member for Nonwoven Patterning

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Solution Overview

Problem

Existing nonwoven production processes require separate and costly calendaring steps for patterning, leading to high initial investments, increased processing costs, and reduced bulk and stability of the final product due to high pressure compression, which limits the production run length and results in products with unclear, dimensionally unstable patterns.

Innovation Solution

A spiral-wound support member, such as a belt or sleeve, with a topographical pattern and through voids, is used in the spunlacing or hydroentangling process, allowing for in-line patterning and improved fiber support, reducing material content, and maintaining product bulk and absorbency, while avoiding the need for separate calendaring equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a separate calendaring process is used for patterning nonwoven products, then the initial investment for equipment is high, but the production cost increases and productivity decreases

Engineering Contradiction:

Improvepatterning capabilityVSAvoidequipment requirements

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines the patterning function with the hydroentangling support member itself. The support member includes integrated topographical features (raised portions and recesses) that directly imprint patterns onto the nonwoven product during the hydroentangling process, eliminating the need for separate calendaring equipment and operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The support member serves multiple functions simultaneously: it supports the fibrous web during processing, provides the topographical pattern for product design, and facilitates water jet penetration for hydroentangling. This multi-functionality reduces the number of separate equipment pieces needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If high pressure compression is applied during calendaring to create patterns, then the pattern definition is improved, but the bulk and dimensional stability of the product deteriorates

Engineering Contradiction:

Improvepattern definitionVSAvoiddimensional stability

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

Instead of compressing the nonwoven product to create patterns (traditional calendaring), the patent uses the support member's topographical features to positively form raised portions on the product surface. The recesses in the support member allow water jets to penetrate and entangle fibers in those areas, creating pattern definition without compression-induced damage to bulk or dimensional stability.

Inventive Principle:

Principle #13The other way round (Inversion)

3Length of stationary object

If material content is increased to maintain product caliper after calendaring compression, then the caliper is maintained, but the absorbency and bulk of the product decreases

Engineering Contradiction:

Improveproduct caliperVSAvoidmaterial content

Core Design Contradiction:

Length of stationary objectVSQuantity of substance

Solution Approach 1:

The support member's topographical features are pre-configured with raised portions and recesses that directly transfer the desired pattern and bulk characteristics to the nonwoven product during formation. This preliminary structuring eliminates the need for subsequent compression that would otherwise require additional material to maintain caliper, thereby preserving absorbency and bulk properties.

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If a separate patterning process is added to the production line, then the pattern quality is improved, but the processing time and production cost increase

Engineering Contradiction:

Improvepattern qualityVSAvoidproduction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patterning function is merged into the hydroentangling support member, allowing pattern formation to occur simultaneously with the web support and water jet entangling processes. This integration eliminates separate patterning steps and maintains continuous production speed while achieving high pattern quality through the support member's precise topographical features.

Inventive Principle:

Principle #5Merging (Combining)

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 enables lower-cost, high-bulk nonwoven products with desired patterns and textures, allowing for longer production runs and improved performance characteristics like higher absorbency, without the need for expensive calendaring equipment and with reduced material usage.

Implementation Method 1

a fibrous web is positioned on the topographical support member. The support member with the entangled fibers thereon is passed under jets of high pressure fluid, typically water. The jets of water cause the fiber to intertwine and entangle with each other

Methodology Applied

Scientific EffectHydroentanglement:

Implementation Method 2

The jets of water cause the fiber to intertwine and entangle with each other in a particular pattern, based on the topographical configuration of the support member

Methodology Applied

Scientific EffectHigh pressure fluid jet action: Jet

Data Source

PatentEP2847379B2Industrial fabric including spirally wound material strips with reinforcement

Publication Date: 2022.03.02 ALBANY INT CORP

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Figure 3A~3C
Figure 3D~3F

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 (16) of polymeric material, such as an industrial strapping or ribbon material, and joining the adjoining sides of the strips (16) 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.