Web Material Structuring Belt With Penetrative Lamination
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Solution Overview
Problem
Existing web material structuring belts, particularly laminated papermaking belts, suffer from issues such as delamination, insufficient lamination strength, poor lamination quality, inadequate drying efficiency, and impaired fibrous structure formation due to insufficient penetration and bonding of the structuring layer into the support layer, leading to structural imperfections and reduced durability.
Innovation Solution
The introduction of an associating layer that extends into but does not entirely through the support and/or structuring layer, enhancing penetration, adhesion, and wrapping of components, along with improved bonding and air permeability, to create a web material structuring belt capable of imparting texture and structure to fibrous structures at higher speeds and temperatures.
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 simple, but the lamination strength is insufficient and delamination occurs
Solution Approach 1:
The structuring layer penetrates into and wraps around the support layer yarns, creating a nested configuration where the structuring layer is embedded within the support layer structure. This nesting increases lamination strength by creating mechanical interlocking rather than just surface bonding, while the penetrative association provides the structural complexity needed to prevent delamination during high-speed operation.
2Reliability
If the structuring layer does not penetrate into the support layer, then the manufacturing process is simple, but the lamination quality is poor and durability is reduced
Solution Approach 1:
The structuring layer is formed with a predetermined penetrative structure before lamination, allowing it to automatically wrap around and associate with the support layer yarns during the belt formation process. This preliminary structuring ensures reliable penetration and wrapping action without requiring complex post-manufacturing processes, thereby improving durability while maintaining manufacturing simplicity.
3Productivity
If the belt operates at higher speeds and temperatures, then productivity increases, but the lamination quality deteriorates and delamination occurs
Solution Approach 1:
The belt structure incorporates a dynamic associating layer that can flex and conform to the support layer during high-speed operation. The penetrative structure allows the layers to maintain their association through the dynamic forces generated at higher speeds, while the wrapping configuration provides thermal stability during high-temperature drying, thereby maintaining lamination quality under increased productivity conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables effective structuring and drying of fibrous structures while improving lamination strength and durability, allowing for faster production speeds and efficient fibrous element realignment.
Implementation Method 1
an associating layer that associates with the support layer and the structuring layer, wherein at least a portion of the associating layer extends into, but does not extend entirely through, a z-direction thickness of the support layer and/or the structuring layer
Implementation Method 2
impart structure to a web material during a web material structuring operation and/or structured web material forming operation
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.