Spirally Woven Industrial Fabric 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 material content, lower bulk, and dimensionally unstable patterns, which are difficult to maintain, especially when subjected to stress.
Innovation Solution
An improved endless belt or sleeve with through voids and textured surfaces, made from spirally wound plastic strapping material, integrates patterning and texture directly into the hydroentangling process, eliminating the need for separate calendaring and enhancing fiber support and release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate calendaring steps are used for patterning nonwoven products, then patterns can be created, but production costs increase and material content becomes higher
Solution Approach 1:
The patent combines the patterning function with the hydroentangling support member itself. The support member incorporates raised portions and recesses that directly impart the desired pattern to the nonwoven product during the hydroentangling process, eliminating the need for separate calendaring steps and reducing material content.
Solution Approach 2:
The pattern is pre-formed into the support member before the nonwoven production process begins. The raised portions and recesses are integrated into the support member structure in advance, so the patterning action occurs automatically during hydroentangling without requiring subsequent calendaring operations.
2Ease of manufacture
If separate calendaring steps are used for patterning, then patterns can be created, but bulk and absorbency are reduced
Solution Approach 1:
The patterning function is merged with the support member structure, allowing patterns to be created during hydroentangling without the high-pressure compression of calendaring. This preserves the bulk and absorbency of the nonwoven product while still achieving the desired pattern.
3Ease of manufacture
If separate calendaring steps are used for patterning, then patterns can be created, but dimensional stability of patterns deteriorates when subjected to stress
Solution Approach 1:
The support member itself becomes the patterning tool, with raised portions and recesses that are structurally integrated. This eliminates the need for separate calendaring that compromises dimensional stability, as the pattern is imparted through the support member's inherent structure rather than through compressive force.
4Productivity
If conventional support members are used, then nonwoven production can proceed, but fiber support and release are insufficient
Solution Approach 1:
The support member features localized raised portions and recesses that provide enhanced fiber support in specific areas. The textured surface with varying topography improves fiber holding during hydroentangling while facilitating release of the finished product, addressing both support and release requirements.
Data Source
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Figure 3(a)~3(c)
Figure 3(d)~3(f)
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.