Web support, production method therefor, and patterning method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for applying patterns to nonwoven substances using mark-welded wires, resin patterns, or fabric patterning face limitations in patterning freedom and durability, especially when subjected to high-pressure water streams.
Innovation Solution
A web support with a cylindrical metal main body featuring recesses, convexities, and water conduction holes is used, allowing for flexible pattern application and high durability, formed through etching and electropolishing of a metal base material to create a cylindrical shape with freely set patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a mark is welded on a wire in accordance with the pattern, then the pattern can be applied to the nonwoven substance, but the mark is hard to be welded and may remove disadvantageously
Solution Approach 1:
The invention extracts the pattern-forming function from separate weldable marks and integrates it directly into the web support structure itself. The recesses and convexities are formed as integral parts of the web support body through molding or machining, eliminating the need for separate welded marks that are difficult to attach and prone to removal.
Solution Approach 2:
The web support is constructed from a single durable material (such as metal or hard plastic) that provides both structural integrity and pattern formation capability. This composite approach ensures the pattern features are as durable as the support structure itself, preventing the separation and removal issues encountered with welded marks.
2Adaptability or versatility
If a resin is formed into a pattern shape corresponding to the pattern, then the patterning freedom is high, but the resin may remove disadvantageously when a high-pressure water stream is repeatedly jetted
Solution Approach 1:
The invention changes the material parameter from soft resin to hard durable material (metal or hard plastic). This parameter change maintains the ability to form various patterns while dramatically improving resistance to high-pressure water streams, preventing the pattern features from being removed or degraded during repeated jetting operations.
Solution Approach 2:
The web support uses a single robust material that combines structural strength with pattern-forming capability. This material selection ensures that the pattern features maintain their integrity under high-pressure water jetting while still allowing for diverse pattern designs to be implemented.
3Device complexity
If fabric for patterning is used, then the structure is simple, but the pattern is limited to a geometrical pattern such as a grating or a houndstooth check
Solution Approach 1:
The web support is designed with a modular and adaptable structure that allows the pattern features (recesses and convexities) to be configured in various arrangements. While the basic structure remains simple and easy to manufacture, the pattern layout can be dynamically adjusted to create different designs, moving beyond fixed geometrical patterns to accommodate diverse patterning needs.
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 web support provides high patterning freedom and excellent durability, preventing pattern dropout and extending service life, while allowing for various pattern applications on nonwoven substances.
Implementation Method 1
jetting a high-pressure water stream on a web
Implementation Method 2
forming, by etching, a recess and a convexity corresponding to the pattern on a front surface of the base material and a water conduction hole
Data Source
AI summary
A web support with a high degree of patterning freedom and excellent durability, a production method therefor, and a patterning method. The web support is used when applying a pattern to a nonwoven substance by jetting a high-pressure water stream on a web. The web support production method comprises: a step of preparing a flat metal base material; a step for forming, by etching, a first water conduction hole and second water conduction hole that pass through the front surface of the base material to the back surface, and a recess on the front surface of the base material that includes the first water conduction hole and that corresponds to the pattern; and a step for forming the base material into a cylindrical main body section by welding the edges of the base material to each other.