Structuring Belt Lamination for Strength and Drying Balance
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Solution Overview
Problem
Existing web material structuring belts, particularly laminated papermaking belts, suffer from issues such as insufficient lamination strength, poor lamination quality, inadequate drying efficiency, and structural imperfections due to inadequate penetration and bonding of the structuring layer into the support layer, leading to delamination, reduced durability, and inefficient fiber realignment.
Innovation Solution
The web material structuring belt design involves a structuring layer that extends into the support layer, providing improved penetration, adhesion, and wrapping of support layer components, enhancing lamination strength, air permeability, and fiber realignment while maintaining effective drying capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the structuring layer is laminated to the support layer at the interface without penetration, then the lamination process is simple, but the lamination strength is insufficient and delamination occurs
Solution Approach 1:
The structuring layer is designed to penetrate into the support layer, with the support layer wrapping around the structuring layer components. This nested configuration creates interlocking bonds that significantly enhance lamination strength and prevent delamination during high-speed papermaking operations.
2Strength
If the structuring layer penetrates deeply into the support layer, then the lamination strength improves, but the air permeability decreases and drying efficiency is reduced
Solution Approach 1:
The penetration depth of the structuring layer into the support layer is precisely controlled to optimize both lamination strength and air permeability. This local quality adjustment ensures sufficient bonding strength while maintaining adequate air flow channels for efficient drying of the structured fibrous structure.
3Ease of manufacture
If the structuring layer does not extend into the support layer, then the manufacturing process is easier, but the durability and functional life of the belt are reduced
Solution Approach 1:
The structuring layer is pre-configured to extend into the support layer during the lamination process, creating preliminary bonds that enhance durability. This preliminary action ensures the belt can withstand the demanding conditions of high-speed papermaking operations throughout its functional life.
4Productivity
If the structuring layer is laminated without penetration, then the production speed can be maintained, but the fiber realignment and structure formation are insufficient
Solution Approach 1:
The structuring layer is designed with dynamic penetration into the support layer, allowing optimal fiber realignment and structure formation. This dynamic configuration enables the belt to maintain high production speeds while achieving superior fiber orientation and structured fibrous structure quality.
Data Source
AI summary
Web material structuring belts that impart structure to a web material during a web material structuring operation and/or structured web material forming operation, method for making same and methods for using same to make structured web materials, for example structured fibrous structures, such as structured sanitary tissue products such as structured toilet tissue, structured paper towels and structured facial tissue are provided.