Structuring Fabric With Sublayer Beads for Stronger Pattern Bonding
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Solution Overview
Problem
Existing structuring fabrics face issues with insufficient bonding of extruded beads to the woven base fabric, especially under high-speed circulation and force, due to limited contact area, which affects the dimensional stability and visibility of the pattern in the fiber web.
Innovation Solution
The use of sublayer-beads of polymeric material provides a foundation for structuring-beads, increasing the contact area and bonding strength without compromising the dimensional stability, by protruding deeper into the woven base fabric and forming a form-fit connection with yarns, while maintaining the permeability and visibility of the pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If extruded structuring-beads are used on the web facing side of the woven base fabric, then a visible structure can be provided to the fiber web, but the bonding of the structuring-beads to the woven base fabric is insufficient and they may peel away under high-speed circulation and force
Solution Approach 1:
The invention divides the bonding function into two separate components: structuring-beads that provide the visible pattern and sublayer-beads that provide the bonding function. The structuring-beads rest on the sublayer-beads rather than directly contacting the woven base fabric, allowing each component to be optimized for its specific function without compromise.
Solution Approach 2:
The sublayer-beads act as an intermediary between the structuring-beads and the woven base fabric. They penetrate deeper into the fabric to provide strong anchoring while supporting the structuring-beads, thereby mediating the bonding function that the structuring-beads alone cannot achieve.
2Strength
If the viscosity of the resinous material is reduced to increase contact area, then bonding may improve, but the dimensional stability of the structuring-beads is adversely affected
Solution Approach 1:
The invention separates the bonding function (handled by sublayer-beads with lower viscosity that penetrate the fabric) from the structuring function (handled by structuring-beads with higher viscosity that maintain dimensional stability). This segmentation allows each bead type to have optimized viscosity for its specific purpose.
Solution Approach 2:
Different regions of the polymeric material have different viscosity characteristics. The sublayer-beads use lower viscosity material for deep penetration and bonding, while the structuring-beads use higher viscosity material for dimensional stability and pattern definition.
3Strength
If structuring-beads are forced into the woven base fabric by a calendaring device, then contact area increases, but the cross-sectional shape of the structuring-beads cannot be maintained
Solution Approach 1:
The invention separates the anchoring function (sublayer-beads penetrating the fabric) from the pattern-defining function (structuring-beads maintaining their shape on top). This eliminates the need to deform structuring-beads to increase contact area, as the sublayer-beads provide the anchoring independently.
Solution Approach 2:
Instead of forcing structuring-beads into the fabric to increase contact area, the invention inverts the approach by placing sublayer-beads underneath the structuring-beads. The sublayer-beads are the ones forced into the fabric, while the structuring-beads remain undisturbed on top to maintain their cross-sectional shape.
Data Source
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Figure 3~4
AI summary
The invention concerns a structuring fabric for use in a machine to produce a structured fiber web, preferably a structured tissue fiber web, the structuring fabric having a machine direction, a cross machine direction and a thickness direction, wherein the structuring fabric comprises a woven base fabric, the woven base fabric having a web facing side and a machine side, wherein the structuring fabric further comprises a plurality of structuring-beads of polymeric material on the web facing side of the woven base fabric, the structuring-beads being suitable to provide a visible structure to the fiber web that is produced on the structuring fabric, and wherein the structuring-beads are resting on an upper foundation surface of corresponding sublayer-beads of polymeric material, the sublayer-beads thereby providing a foundation for the structuring-beads. The invention furthermore refers to a manufacturing process for such a structuring fabric.