Web Material Structuring Belt Lamination via Nested Layer Penetration
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Solution Overview
Problem
Existing web material structuring belts, particularly laminated papermaking belts, face issues with lamination strength, air permeability, and fiber realignment, leading to imperfections and reduced durability in structured fibrous structures due to inadequate bonding and penetration between the structuring and support layers.
Innovation Solution
A web material structuring belt comprising a support layer, a structuring layer, and a bonding material, with an optional associating layer that enhances lamination properties by improving penetration, adhesion, and wrapping of components, allowing for better delamination resistance and air permeability control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the structuring layer is laminated to the support layer at the interface, then the belt structure is formed, but lamination strength is insufficient and delamination occurs
Solution Approach 1:
The structuring layer is embedded into the support layer rather than merely laminated to its surface, creating a nested configuration where the structuring layer penetrates and is surrounded by the support layer matrix. This nesting provides mechanical interlocking that significantly enhances lamination strength and prevents delamination under process conditions.
Solution Approach 2:
The invention uses a composite structure combining the structuring layer and support layer with optimized material properties. The support layer is formulated to provide structural integrity while the structuring layer provides surface functionality, and their composite construction ensures strong bonding through proper material selection and interface design.
2Ease of manufacture
If the structuring layer does not penetrate into the support layer, then lamination is simpler, but air permeability is insufficient for efficient drying
Solution Approach 1:
The support layer is designed with differentiated local properties: regions where the structuring layer penetrates have enhanced porosity and air permeability to facilitate drying, while other regions maintain structural integrity. This local quality variation allows the belt to provide both structural support and efficient air flow paths for moisture removal.
3Manufacturing precision
If the structuring layer extends entirely through the support layer, then fiber realignment is maximized, but air permeability is excessively reduced
Solution Approach 1:
The structuring layer penetrates partially into the support layer rather than extending entirely through it. This partial penetration provides sufficient fiber realignment and structuring action in the critical regions where fibers contact the structuring layer, while avoiding excessive penetration that would completely block air flow paths and overly weaken the support layer structure.
4Strength
If bonds are created at the interface between structuring and support layers, then lamination is achieved, but imperfections are created in the structured fibrous structure
Solution Approach 1:
The bonding function is extracted from the interface region and relocated to discrete bonding zones or anchoring points within the support layer matrix. By removing continuous bonding at the interface and replacing it with strategic bonding locations, the structure avoids creating surface imperfections while maintaining sufficient bonding strength through mechanical interlocking at depth.
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.