Web Material Structuring Belt Nested Layer Design
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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, such as sanitary tissue products, due to inadequate penetration and bonding between the structuring and support layers.
Innovation Solution
The introduction of a web material structuring belt comprising a support layer, a structuring layer, and a modifying material, such as an air perm controlling material, with an optional associating layer that enhances lamination properties by improving penetration, adhesion, and air permeability, allowing for better fiber realignment and structure formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the structuring layer is laminated to the support layer at the interface, then structure formation is achieved, but lamination strength and durability are reduced
Solution Approach 1:
The structuring layer is embedded within the support layer rather than being surface-laminated, creating a nested configuration where the structuring layer is surrounded by support layer material. This nesting provides mechanical interlocking and distribution of stresses, preventing delamination while maintaining structure formation capability.
Solution Approach 2:
The support layer is designed with non-uniform properties, being denser in regions where the structuring layer is embedded and more open in other regions. This local variation in density and porosity allows the structuring layer to be securely held in place where needed while maintaining overall air permeability and drying efficiency.
2Ease of manufacture
If the structuring layer does not penetrate into the support layer, then lamination is simplified, but air permeability and drying efficiency are reduced
Solution Approach 1:
The support layer exhibits spatially varying density and porosity characteristics. Regions adjacent to the embedded structuring layer are denser to provide mechanical support and retention, while other regions maintain higher porosity to ensure adequate air flow through the entire belt structure, enabling efficient drying without requiring full penetration of the structuring layer.
3Manufacturing precision
If the structuring layer extends entirely through the support layer, then fiber realignment is maximized, but air permeability is reduced
Solution Approach 1:
The structuring layer is positioned and embedded within the thickness of the support layer rather than extending through it entirely. This nested arrangement allows the structuring layer to effectively realign fibers in the web material while the surrounding support layer material maintains air flow paths, preventing the air permeability reduction that would occur with full penetration.
4Strength
If bonds are used to laminate the structuring layer to the support layer, then lamination is achieved, but imperfections are created in the structured fibrous structure
Solution Approach 1:
The structuring layer and support layer are combined into a single integrated belt structure through embedding, eliminating the distinct interface between layers. This merging removes the need for separate bonding operations and the associated bond lines that create imperfections, resulting in a more uniform structured fibrous structure without surface defects.
Solution Approach 2:
By nesting the structuring layer within the support layer, the design eliminates the traditional lamination interface where bonds would be applied. The embedded configuration provides inherent mechanical attachment without requiring additional bonding materials or processes, thereby preventing bond-related imperfections from appearing in the final structured product.
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.