Three-Layer Papermaking Felt Structure for High-Speed Stability
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Solution Overview
Problem
High-speed tissue paper machines require a felt structure that maintains paper smoothness and stability over time without crushing, as existing felts with two batt layers fail to ensure compatibility and durability due to premature crushing of the intermediate layer.
Innovation Solution
A felt structure with at least three batt fiber layers of varying fineness (0.5 to 6 dtex, 1.5 to 15 dtex, and 6 to 30 dtex) and molecular weight, where the second and third layers penetrate the substrate for entanglement and resistance to collapse, while the first layer does not penetrate to maintain surface smoothness and prevent fabric pattern transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a two-layer batt structure is used with thin fibers in the upper layer and coarse fibers in the intermediate layer, then surface smoothness is improved and water permeability is maintained, but the intermediate layer crushes prematurely causing fabric pattern transfer and weight unevenness
Solution Approach 1:
The patent divides the batt structure into three distinct layers with different fiber fineness characteristics. The first layer (0.5-6 dtex) provides surface smoothness, the second layer (1.5-15 dtex) acts as a transition zone, and the third layer (6-30 dtex) provides structural support and prevents crush. This segmentation allows each layer to perform its specific function optimally without the intermediate layer crushing as in two-layer structures.
Solution Approach 2:
Each layer of the batt is assigned different local qualities in terms of fiber fineness to match its specific functional requirements. The uppermost layer uses the finest fibers for surface smoothness, the intermediate layers use progressively coarser fibers for structural support, and the lowest layer uses the coarsest fibers for durability. This local quality differentiation resolves the contradiction by optimizing each region for its specific purpose.
2Productivity
If high-speed operation is implemented in tissue paper machines, then productivity increases, but the felt structure becomes insufficient to maintain stability and smoothness over time
Solution Approach 1:
The patent creates a composite batt structure combining three different fiber types with varying fineness (0.5-6 dtex, 1.5-15 dtex, and 6-30 dtex) in a layered configuration. This composite structure leverages the advantages of each fiber type: fine fibers for smoothness, medium fibers for transition, and coarse fibers for structural integrity. The composite nature allows the felt to withstand high-speed operation while maintaining composition stability and papermaking performance.
Data Source
AI summary
A felt for papermaking which is less prone to be crushed during operation of high speed paper machine, promptly begins stable papermaking after starting the machine, assures durability, and maintains surface smoothness.