Technical TextilesBy: Granch Berhe

2015

Textile product manufactured primarily for its performance and functional properties rather than aesthetic or decorative characteristics

Technical Textiles

What is Technical Textile?

Granch Berhe 2015

Some of the common products of technical textiles are:-

Granch Berhe 2015

Agro – techAgriculture, horticulture and forestry

BUILD – techBuilding and construction

CLOTH – techTechnical components of shoes and clothing

GEO – techGeotextiles, civil engineering

HOME – techComponents of furniture, household textilesand floor coverings

INDU – techFiltration, cleaning and other industrial usage

SEGMENTS OF TECHNICAL TEXTILES

Granch Berhe 2015

MEDI – techHygiene and medical

MOBIL – techAutomobiles, shipping, railways and aerospace

OEKO – techEnvironmental protection

PACK – techPackaging

PRO – techPersonal and property protection

SPORT – techSport and leisure

Granch Berhe 2015

MATERIALS FOR TECHNICAL TEXTILES

1. Regular/Generic fibers• Natural fibers: Cotton, silk, wool, jute, hamp, ramie, flax• Regenerated fibers: Viscose, Lyocell.• Synthetic fibers: Nylon, PET, PP, Acrylic.

2. Specialty variants of regular/generic fibers• Flame retardant• Super absorbent • Antimicro bacterial • Ultra fine fibers. etc.

3. High tech/high performance fibers:• High chemical- and combustion-resistant organic fibres: Nomex, Kevlar• High performance inorganic fibres: Glass, Asbestos, Carbon

Granch Berhe 2015

Generic Fibers

Granch Berhe 2015

Viscose Polyester Other fibresBasic

Characteristics Specialty Variant Basic Characteristic Specialty Variant Fibre Additional

Characteristic

Very good softness

Viscose for nonwovens

High melting point, high heat and chemical resistance

High Tenacity PET

Super-absorbent fibre (acrylic)

High absorbency

Excellent absorbency

Viscose with tri-lobal cross-section

Very low moisture absorbency

trilobal cross-section

High Density Polyethylene (HDPE)

High tensile strength

Added strength and moderate abrasion resistance

Temperature regulating Viscose (Outlast )

High strength, Good abrasion resistance,, Good resiliency

Hollow fiber High Modulus PE (HMPE)

Higher modulus

Relatively poor strength wet

Short cut PET/Viscose

Inert, biocompatible & flexible

Flame retardant

High Tenacity Nylon

High tenacity and low shrinkage

Low resiliency Anti-microbial, Anti-bacterial viscose fibers.

Anti-microbial, Anti-fungal, Anti-bacterial PET fibers.

High Tenacity PP

High strength and stability

Natural and pure Fire Retardant (FR) Viscose/PET

Cationic dyeable

Anti bacterial Acrylic

Prevents & limits the growth of bacteria, fungi and microbes.

Specialty variants of regular/generic fibers

Granch Berhe 2015

Fiber Characteristics Applications Key players

Meta Aramid (Nomex)

Heat Resistance, high strength and high impact absorbing capacity

Fire retardant apparel, bullet proof jackets, helmets, gloves etc.

Dupont (USA), Teijin Twaron (Japan), SRO Group (China), Yantai Spandex (China), Kermel (France)

Para Aramid (Kevlar)

High strength to weight ratio, Excellent thermal & chemical stability

Fire retardant apparel, bullet proof jackets, helmets, gloves etc.

Dupont (USA), Teijin Twaron (Japan), Yantai Spandex (China)

Carbon Low weight and high strength

Air craft body, wind mill wings, racing cars.

Toray Industries (Japan), Toho Tenax (Japan), Mitsubishi Rayon (Japan), Zoltek (USA), Hexcelcorp (USA), SGL Carbon AG (Germany) , Kemrock (India)

Polyphenylene sulfide Fibres (PPS)

Highly resistance to heat, acid and alkaline

Electrical products, liquid filters, dryer canvas.

Armoco Fabrics & Fibres Co (USA), Toyobo (Japan), Toray Industries (Japan), etc

Glass fiber Thermal insulation properties with high strength and low elongation.

Automotive bodies, hockey sticks, boats, surfboard etc.

Owens-Corning Fibreglas, Nicofiber (USA), Fibreglass (Canada), Asahi Fibre Glass Co (Japan), Chemitex-Anilana (Poland), Owens Corning , Goa glass, Twiga (india)

HIGH-TECH FIBRE

Granch Berhe 2015

Fiber Characteristics Applications Key players

Polytetrafluoroethylene (PTFE)

Excellent dielectric properties, high melting point.

Nonstick coating of pans, laboratory containers, magnetic stirrer.

DuPont (USA), Newton Filaments, Inc (USA), Albany Internation Inc. (USA), Toyobo (Japan)

Phenolic fiber High strength Automotive and electrical components.

Phenco (USA), The Vermont Organic Fiber Company (USA)

Conductive fiber

Electric conductive Military garments, intelligent garments.

Shakespeare Conductive Fibres LLC and Bekaert , Bakaert India (India)

PBI (Polybenzimidazole)

High strength and does not burn or melt.

Automotive parts, aircraft parts, insulation shield etc.

Celanese Acetate

Alginate fiber Highly absorbent Wound dressing, textile printing etc.

Speciality Fibres and Materials Ltd (UK), FMC Biopolymer (USA), Degussa Texturant Systems (Germany), Danisco Cultor (Denmark), Kimica Corporation (Japan), China Seaweed Industrial Association (China)

PBO fiber- Zylon

Highest strength among fibers.

Protective clothing and equipments. Toyobo Co. Ltd. (Japan)

HIGH-TECH FIBRE

Granch Berhe 2015

SEGMENT WISE CONSUMPTION OF FIBRES

Granch Berhe 2015

Clothing Textiles Technical components of shoes and clothing

e.g. liningsAll the natural, man made and Synthetic Fibers

Granch Berhe 2015

Home Textiles

Technical components of furniture, household textiles & floorcoveringsAcetates, acrylics, polyester, natural fibers…..

Granch Berhe 2015

Geo textiles Geotexiles and civil

engineering materialsJute, coir, Polypropylene, Polyester, Polyethylene, polyvinyl chloride, Polyamide, Aramids

Granch Berhe 2015

Granch Berhe 2015

Industrial textiles

Filtration, conveying, cleaning etcNylon, polyester, polypropylene, glass fibers….

Granch Berhe 2015

Medical TextilesHygiene and medical productsPolyester, Cotton, polypropylene, silk etc…

Granch Berhe 2015

Wound dressingChronic wounds: 6.5 million

people - $25 billionImpaired healing – Inflammation

stage is prolongedResistance to

antibiotics

Silver impregnated dressings

Alternative metals, e.g. zinc as well as non-metal bactericides

Naturally derived compounds?

Granch Berhe 2015

Extracorporeal devices- artificial kidney, liver, heart pacer and lung

Granch Berhe 2015

Implantable materials- sutures, vascular grafts, artificial ligaments, cartilages, artificial joints, heart valves etc

Granch Berhe 2015

Granch Berhe 2015

Resorb

Granch Berhe 2015

Protective TextilesPersonal and property protectionNomex, kevlar fibers…

Granch Berhe 2015

Sport TextilesSport and leisure E.g Yatcht, Hot air balloons…Polyester, nylon, spandex, glass fibers…..

Granch Berhe 2015

Granch Berhe 2015

Packaging Textiles

Packaging materialsPolyethylene, polypropylene, glass fibers…..

Granch Berhe 2015

Transportation Textiles

Automobiles, shipping, railways and aerospacePolyester, nylon, glass, UHMWPE, aramids compsites, carbon fibers…

Granch Berhe 2015

Agro Textiles Agriculture, horticulture,

forestry and aquaculture textilesPolypropylene, polyester, polyethylene etc……

Granch Berhe 2015

Construction Textiles Building and

construction textilesKevlar, nomex, carbon fibers……

Granch Berhe 2015

Eco textile Textiles

Environmental protectionCarbon fibers…..

Granch Berhe 2015

Cotton Jute Viscose PET Nylon PP HDPE

LDPE/LLDPE

Aramid Glass Carbon

Agrotech

Meditech

Mobiltech

Packtech

Sporttech

Buildtech

Clothtech

Hometech

Protech

Geotech

Oekotech

Inditech

Summary of Segment wise consumption of different fibres

Granch Berhe 2015

Fiber stage

Yarn stage

Fabric stage

Wet processing stage

Technology at fibre, yarn, fabric

and end conversion stage

APPLICATION STAGES OF TECHNICAL TEXTILES

Granch Berhe 2015

TECHNICAL FIBERS

Granch Berhe 2015

USE OF NATURAL FIBERS AS TECHNICAL FIBERS

 Egyptians and Chinese used papyrus mats in foundation forreinforcement of buildings

In recent past, synthetic fibers were used in floods in 1953 inNetherlands, it could be seen as start of geotextile

 Cotton bales in foundation for earthquake protection

 

 

Cotton

Granch Berhe 2015

Wool

 Wool, a protein fiber, consumption second to cotton

 High extensible, natural waviness, trap air, low thermalconductivity, high thermal resistance, gives comfort and warmth

 Due to morphology of wool, some technical fibers have beenproduced

 Wool is comparatively fire retardant

 Zirconium-and titanium-treated wool has much higher for exampleZirpro (IWS) wool used for fire proof padding in aero planes

Granch Berhe 2015

Flax, Jute, Hemp, Ramie

 Not very common under use

 Jute is used in geotextile, where biodegradable fibersare required

Granch Berhe 2015

Silk Protein-based fiber produced naturally by

the silkworm,

  Structurally similar to wool

 High tenacity, high luster and gooddimensional stability.

  Used as luxury item,

 Biocompatibility and gradualdisintegration an advantage in in medicaltextiles

Silk used for military clothing, due to light weight and for protection from arrows. Commonly used by Mongolian armies

Silk as wound dressing was very common by Chinese and EgyptianGranch Berhe 2015

REGENERATED FIBERS

  Viscose rayon was regenerated fibers in the early 1920s. Has inferior physical properties to cotton

  Improved shape has better tenacity in wet and dry conditions

  Textured and hollow viscose fibers are comparable to cotton

  Fire-retardant (FR) viscose introduced in the 1960s organophosphorous compounds

Viscose rayon

Granch Berhe 2015

• The fibre has relatively high uniformity, tenacity (16 – 30 cN/tex) and modulus, especially if impregnated with rubber. Its moisture content is about 3 % and 16 – 22 % extension at breake.

• Applications in -automotive industry (timing), production of hygienic and sanitary products via nonwoven technology.

 Latest addition is Lyocell also known as Tencel (Acordis) environmentally friendly production method (non-toxic N-methyl morpholine oxide solvent – recyclable)

Lyocell

Granch Berhe 2015

SYNTHETIC FIBERSMade from coal or oil

 Used in carpets, clothing, curtain,packaging

  Nylon 6.6 first fiber in 1939 byDuPont

 Many nylon fibers known aspolyamides produced by using melt

extrusion, many cross-sectional shapesare possible

 High extensibility, significant recovery,more dimensional stability, low

moisture

Nylon

Granch Berhe 2015

• characterized by high tenacity (35 – 90 cN/tex), elasticity (15 – 60 %), resistance to abrasion and moisture (3 – 5 %).

• Capability of energy resilience is a condition for an application in manufacturing climbing ropes and linen for parachutes and sail fabrics.

• The typical application of polyamide is for reinforcing tires for use at low quality roads and of road vehicles

Granch Berhe 2015

Polyester (PET)  Introduced as Dacron by DuPont in

1951. Now second major fiber

  Made by condensation polymerizationof ethylene glycol and terephthalicacid followed

  Durability and compatibility withcotton in blend, low moistureabsorbency, resilience and gooddimensional stability are additionalqualities.

  Glass transition temperature isapproximately 70 °C, resistance toheat and chemical degradation, goodfor Technical Textile

  Flame-retardant Trevira CS andTrevira high tenacity, developed byTrevira GmbH in Germany

Granch Berhe 2015

AcrylicPolyacrylic fibers produced by thepolymerization of acrylonitrile Orlon14 was produced by DuPont.

 Acrilan15 produced by Monsantoand Courtelle, Wool-likecharacteristics.

 Chemically modified acrylics haslow burning behavior and havinghigh absorbency, applicable inhygiene and medical care

Granch Berhe 2015

Polyolefin fibers

Include both polyethylene and polypropylene made by addition polymerization of

ethylene and propylene

Polyethylene has moderate physical properties with a low melting temperature of

about 110 °C for its low density form and about 140 °C for its high density form which

severely restricts its application in low temperature applications.

Polypropylene has better mechanical properties and can withstand temperatures of up to 140 °C

before melting at about 170°C.

Polyolefine fibres are low price, low specific gravity (0.90 – 0.96 g´cm–3), good abrasion

resistance, and low moisture content (0 %).

Replaced jute in packing equipment, ropes, base fabric for floor coverings, linings for

upholstery, technical nets etc

Granch Berhe 2015

• Low melting temperature of polyolefines is an advantage for

application in manufacturing of nonwoven by thermal bonding.

• Both polymers have a density less than that of water which allows

them to float as ropes, nets and other similar applications.

• The availability, low cost and good resistance to acid and alkaline

environments of polypropylene has greatly influenced its growth and

substantial use in geotextile applications

• High water repellency of PP finds application in manufacturing of

diapers and special thermo-physiological clothing, where two

employed layers are: hydrophobic and hydrophilic, and the wicks

made of PP enable transport of the liquidGranch Berhe 2015

PE and PP

Granch Berhe 2015

Spandex Yarn  Polyurethane structure, can stretch

more than 8 times

  Rubber-like properties,

  Used in combination with otherfibers

  Produced by DuPont in 1959(Lycra).

  Expensive fiber, used in fabric

Formation, during knitting, yarn isalso produced by twisting with spandex yarn

Granch Berhe 2015

Functional and High Performance Fibers Driven by special technical functionsPosses unique properties Some of the most prominent of these properties

High tensile strength and stiffnessHigh temperature resistanceHigh flame retardant ability High chemical resistance

FIBRE PRODUCTIONThe latest technologies for spinning of high performance fibers are

Dry-Jet-Wet SpinningGel-Spinning Processes.Granch Berhe 2015

HIGH PERFORMANCE

ORGANIC FIBERS

Granch Berhe 2015

Dry-jet- wet spinning

Rigid-Rod Polymers are the starting materials Often liquid crystalline polymers

Granch Berhe 2015

Gel spinningSpecial process used to obtain high strength or other special fiber propertiesThe polymer is not in a true liquid state during extrusionUHMW and Super drawing

Granch Berhe 2015

Aramid Fibers Long-chain synthetic polyamide at least 85% amide (-CO-NH-)

linkages are attached directly between two aromatic ring. Molecular structure made of linked Benzene rings and amide bonds Aromatic Polyamides

C

O

H2N R

Amide Aromatic Aromatic polyamide

Granch Berhe 2015

TYPES OF ARAMIDBasically araimd fiber could be classified in two types.

A) Para aramide fiberB) Meta aramide fiber

They are chemically same but difference is in structure.A) Para aramide fiber

KevlarTwaronTechnoraSulfron

B) Meta aramide fiberNomex or Mylar NomexTeijinconexNew starKermel

Granch Berhe 2015

P-aramide

C-aramide

M-aramide

Structurally

Granch Berhe 2015

Dry-jet Wet SpinningSpinning Solution

10-20 wt% polymer

100% H2SO4 (H2O free)

removal ofsulfuric acid

Platinum capillary 65

Liquid crystal inpure sulphuric acidat 850C

air gap 10 mm withelongational stretch (6x)

coagulationbath at 100C

Specific points:Solvent: pure H2SO4

Polymer concentration 20%General orientation n the capillaryExtra orientation inthe air gapCoagulation in cooled diluted sulfuric acid

Granch Berhe 2015

CHARACTERSTICS OF ARAMIDS High strength Low elongation at break No melting point, 500°C Low Electrical Conductivity High Chemical Resistance Low Thermal Shrinkage High Toughness Excellent Dimensional Stability Flame Resistant, Self-Extinguishing

• Sensitive to acids and salts• Sensitive to ultraviolet radiation• Prone to static build-up unless finished

Structure dependentMeta vs. Para linkagesStructure of aromatic backbone

• Absorbency• Weight• Flexibility• Weavablelity

Compared to meta(1) Greater tensile strength (2) Greater chemical resistance and (3) Lower moisture regain.

Compared to para(1) Greater chemical, elongation and abrasion

properties (2) (2) Lower moisture regain.

Copolymer

Granch Berhe 2015

van der Waals forcesThe source of strength: H-Bond

Order

Orientation

Granch Berhe 2015

Heat and fire protection productsCut-protection productsBallistic-protection productsCivil engineering productsElastomer reinforcementsEngineering plasticsFriction productsOptical fiber cablesReinforced pipesBullet and explosion protection productsRopes and cables Adhesives, sealant and coatingsSpecialty paper productsCompositesTires,

APPLICATION OF ARAMIDS

Granch Berhe 2015

Granch Berhe 2015

Strength

Para-AramidBullet Proof

Granch Berhe 2015

SulfronGranch Berhe 2015

Meta Aramid

Heat Resistant, Absorbency and Flexibility

Fire Proof

Granch Berhe 2015

Co Aramid

Low absorbency and Better StrengthGranch Berhe 2015

HPPE and UHMWPE• Gel-spun polyethylene fibres are ultra-strong, high-modulus fibres that are

based on the simple and flexible polyethylene molecule.• In the mid of 1970's reports of producing strong and stiff PE fibres started to

appear (modification)• The extension of polymer chains and high longitudinal orientation is a

precondition for accomplishing high mechanical properties. • The result of this treatment is production of high-performance polyethylene

fibre (HPPE)• Ultra-high molecular weight polyethylene (UHMWPE) fibres - strongest fibres

known, with tensile moduli in excess of 70GNm-2.– 15 times stronger than steel and twice as strong as aromatic polyamides

such as Kevlar.– Low in density, – Chemically inert – Abrasion resistant – Melts at around 150 °C and thermally degrades at 350 °C which restrict its

use to low temperature applicationsGranch Berhe 2015

66

Salient features

Moisture regain Zero

Attacked by water none

Resistance to acids excellent

Resistance to alkalis excellent

Resistance to UV light Very good

Granch Berhe 2015

Some ApplicationsBallistic protection

Cut and puncture resistant: for example cut

resistant gloves, fencing suits and chains-

saw hoses.

Composites: Twines and nets:

HPPE fibre is an ideal material for use in

marine environment.

Its density is slightly less than 1,

It does not rot and

Not affected by UV light and seawater

Granch Berhe 2015

HIGH PERFORMANCE

INORGANIC FIBERS

Granch Berhe 2015

 

Organic fibers can withstand only up to 500°CCarbon, glass, asbestos and ceramic inorganic fibers, can bear high temperature, bitter in nature, under use fromcenturies, best use is in by mixing with other materials, plastic sheets one example made by using glass fiber and polymers

 

 

Granch Berhe 2015

CARBON FIBRES• Also called graphite fiber.• It is in the form of several long strands of a material mainly

composed by carbon atoms. Carbon fibre variants differ in flexibility, electrical conductivity, thermal and

chemical resistance.

The primary factors governing the physical properties are degree of carbonization

(carbon content, usually greater than 92% by weight) and orientation of the layered

carbon planes.

Different precursors and carbonization processes are used

1. Rayon: high thermal resistance but relatively low strength, application in

aerospace.

2. Acrylic fibre : have higher strength than rayon precursors, used as reinforcement

for a wide variety of plastic composites.Granch Berhe 2015

Creation• Spinning: A polyacrylonitrile plastic is spun into fibers

which are then washed and stretched to the desired diameter.

• Stabilizing: fibers are heated with O2 to make their bonding more thermally stable.

• Carbonizing: fibers then are heated without oxygen, they lose non carbon atoms and bonded carbon crystals are made.

• Treating surface: the surface is slightly oxidized.• Sizing: fibers are coated and wounded into bobbins.

Granch Berhe 2015

Advantages• It has the greatest compressive strength

of all reinforcing materials.• High strength to weight ratio.• Low coefficient of thermal expansion.• Its density is much lower than the density of steel.

Granch Berhe 2015

Some applications of carbon fibres:

• Used to reinforce composite materials• Used structurally in high-temperature

applications.• As an electrode with high surface area and

impeccable corrosion resistance.• Anti-static component. Composites for military aircraft, commercial aircraft Sporting goods, Medical devices, Industrial applications and infrastructure, Tennis rackets, golf club shafts, fishing rods, skis Aerospace

Granch Berhe 2015

Granch Berhe 2015

Granch Berhe 2015

GLASS FIBERS

The first "synthetic" fibre product of the human intelligence.

They are brittle, basically used in composites.High-performance composite materials,

including protective materials, various filters, protective clothing and packing.

Biggest application is the automotive industry for large-scale production of fibre reinforced car parts because of great weight savings.

Granch Berhe 2015

• Eglass fibre 90 % of reinforcement. • R glass fibre is used for special applications, such as,

aviation, space program, and defense due to its special performances regarding fatigue, temperature and moisture.

• AR type is used for cement reinforcement, with high content of zirconium oxide, which gives excellent resistance to alkaline compounds generated during drying. The cement reinforced with AR glass fibre has improved modulus and good durability.

• S type has high stiffness and finds its application where high mechanical properties are required

Granch Berhe 2015

ASBESTOS

crystalline silicates that occur naturally. – The fibres that are extracted have all the textile-

like properties of fineness, strength, flexibility and more importantly, unlike conventional fibres, good resistance to heat with high decomposition temperatures of around 550°C.

– They have carcinogenic problem

Granch Berhe 2015

CERAMIC FIBERS– Aluminosilicate compounds are mixtures of

aluminium oxide (Al2O) and silicon oxide (SiO2); their resistance to temperature depends on the mixing ratio of the two oxides.

– High aluminium oxide content increases their temperature tolerance from a low of 1250 °C to a maximum of 1400°C

• Used for insulation of furnaces and replacement of asbestos fibres in friction materials, gaskets and packing

Granch Berhe 2015

ULTRA FINE AND NOVELTY FIBERS

  Ultra fine fibers have 1.0 dtex or less

  Linear density of extra-fine and microfine is less than 0.1 dtex

  Commonly PET and Nylon are used

  First made in Japan e.g. Mitrelle,Setila, Micrell, Tactel

  Once in woven fabric form their finediameter and tight weave allows

  Up to 30000 filaments cm-2, highlydense, water proof but air andmoisture vapor can pass

Granch Berhe 2015

Specialty Materials has made boron prepreg tape with various cyanate ester and cyanate siloxane resins for space structure stabilization applications.

Pure boron fibres are too brittle to handle but they can be coated on tungsten or carbon coresGranch Berhe 2015

Technical yarns

Granch Berhe 2015

Introduction

• These are yarns for making technical textiles• They are made through special yarn production

techniques or through the election of special fibre blends or a combination of both

• Machines for yarn making– Ring frame– Rotor – Friction– Airjets

Granch Berhe 2015

Staple fiber yarns

• Ring spinning – most versatile– wide ranges of linear

density and twist from a great variety of fibre materials

– Prior material preparation is important

Granch Berhe 2015

Ring spinning

• Ring-spun yarns have a regular twist structure and, because of the good fibre control during roller drafting, the fibres in the yarn are well straightened and aligned. – excellent tensile properties, which are often

important for technical applications.

Granch Berhe 2015

• The ring spinning system can be used for spinning cover yarns - combination of technical properties.– high strength yarn with good comfort

characteristics may be spun from a high strength filament core with natural fibre covering.

– technical yarns, such as flame-retardant and antistatic yarns can also be made by incorporating flame-retardant and electricity conductive fibres.

Granch Berhe 2015

• Limitations – low production, high drafting and spinning tension (problem for low tension fibers)

Granch Berhe 2015

Rotor spinning

Advantage of speed, cost reduction

Yarns are of lower strength than ring spurn Better evenness

Granch Berhe 2015

Friction spinning

• The main application -industrial yarns and for spinning from recycled fibres.

• It can be used to produce yarns from aramid and glass fibres and with various core components including wires.

• Application - tents, protective fabrics, backing material, belts, insulation and filter materials.

Granch Berhe 2015

Wrap spinning• Wrap spinning is a yarn formation

process in which a twistless staple fibre strand is wrapped by a continuous binder

• Core yarns,mostly filaments, can be added to the feed.This can be used to provide extra yarn strength or other special yarn features

• carbon-coated nylon filament yarn can be used to produce yarns for antistatic fabrics.

• Soluble binders can be used for making yarns for medical applications.

Granch Berhe 2015

Ply yarns

• For high strength and modulus yarns for technical and industrial applications, ply yarns are often needed.

• These are co-twisted yarns

Granch Berhe 2015

Filament yarns• Aramide filament yarns

– Kevlar and nomex– Aramid yarns are more flexible and easier to use in subsequent

fabric making processes, be it weaving, knitting, or braiding• Glass filament yarns– widely used in the manufacture of reinforcement for

composites.– E-glass has very high resistance to attack by moisture and has

high electrical and heat resistance. It is commonly used in glass-reinforced plastics in the form of woven fabrics.

– C-glass is known for its chemical resistance to both acids and alkalis. - chemical filtration.

– S-glass is a high strength glass fibre and is used in composite manufacturing.

Granch Berhe 2015

• Carbon filament yarns – From rayon and arcylic– Oxidative (200-300oC) – carbonization (1000oC) –

graphitization (3000oC)– Brittle and conductive

• HDPE filament yarns– Produced by gel spinning process from

polyethylene with an extra high molecular weight.– Characterized by high paralyzing and crystalline

Granch Berhe 2015

Technical Fabrics

Fabrics manufactured primarily for their technical performance and functional properties rather than their aesthetic or decorative characteristics

Granch Berhe 2015

Methods for producing fabrics

• Weaving • Knitting• Lace making• Net making• Felting• Tufting• Non-woven processes

A 3-D Fabric

Granch Berhe 2015

WOVEN FABRICS

Granch Berhe 2015

Warp (Ends) & Weft (Picks)

Granch Berhe 2015

Woven Fabric Specifications

• Fabric construction– Warp count x weft count/ ends per inch x picks per

inch• Fabric area density / GSM• Cover factor• Type of weave• Crimp• Fabric width• Thickness

Granch Berhe 2015

Fabric area density• The loom state cloth area density depends on the

weaving specification, that is, yarns, thread spacing and weave, and on any additives, such as size, which are used to improve the weaving process.

• Finished cloth area density is frequently altered by chemical treatments .

• The area density of the fabric can be varied by changing the linear density or count of the yarns used and by altering the thread spacing, which affects the area covered by the yarns in relation to the total area.

Granch Berhe 2015

Cloth cover factor• Cloth cover factor = warp cover factor + weft cover factor• Cover factor in SI units =

• Cover factor formula by Pierce =

Granch Berhe 2015

Area density and cover factor• Low area density fabrics of open construction

include bandages

• Light area density fabrics high cover factor fabrics include medical filter fabrics

• Heavy open cloths include Geotextiles fabrics

• Heavy closely woven fabrics include cotton awnings.

Granch Berhe 2015

Plain weave

• 90% technical fabrics have plain weave

Granch Berhe 2015

Other types of weave

Twill weave

Satins and sateen

Granch Berhe 2015

Triaxial weave

•Triaxial fabrics are defined as cloths where the three sets of threads form a multitude of equilateral triangles•Two sets of warp yarns are generally inserted at 60° to the weft, •Tetra-axial fabrics where four sets of yarns are inclined at 45° to each other

Granch Berhe 2015

Triaxial weaves• The tear resistance, bursting resistance of

Triaxial fabrics is greatly superior to that of standard fabrics

• They have a wide range of technical applications including sailcloths, tyre fabrics, balloon fabrics.

Granch Berhe 2015

Classification of Weaving Machines

• Single-phase weaving machines– Machines with shuttles (looms):

• Hand operated (hand looms)• Non-automatic power looms (weft supply in shuttle changed

by hand)• Automatic weaving machines

– Shuttle less weaving machines:• Projectile• Rapier• Jet machines– air (with or without relay nozzles)– liquid (generally water)

• Multiphase weaving machines

In single phase machines, one weft thread is laid across the full width of the warp sheet followed by the beat-up and the formation of the next shed in preparation for the insertion of the next pick.

In multiphase machines, several phases of the working cycle take place at any instant so that several picks are being inserted simultaneously.Granch Berhe 2015

Projectile looms…• They are used not only for weaving a vast range

of standard fabrics but also for heavy industrial fabrics of up to 8m wide, for – sailcloth, – conveyor belts,– tyre cord fabrics,– awnings, – Geotextiles, – airbags and – a wide range of filter fabrics of varying area density

and porosity.

Granch Berhe 2015

L680W series high-efficiency fibre glass rapier cross weaving machine

Suitable for the weaving of various gridding cloth used in civil engineering, hydraulic construction, building materials, chemical engineering and transportation areas

Granch Berhe 2015

OMNI plus 800 air jet weaving machine

• Gauze– Gauze is a lightweight, open-texture fabric produced in

plain weave, used for bandages, food wrapping etc.• Parachute

– Parachute is industrial, heavy-filament, rib stop cloths made of fine nylon fibre

• Tyre cord– Tire cord is a fabric used to reinforce the tires of

vehicles

Granch Berhe 2015

OMNI plus 800 air jet weaving machine

• Umbrella cloth– Umbrella cloth is usually made with a cotton warp

and rayon or nylon filling, which is then treated to make it water repellent.

• Camping tent cloth – Camping tent cloth is a fabric used for the outer

covering of tents for recreational camping.

Granch Berhe 2015

OptiMax rapier weaving machine

• Conveyer belt– Conveyor belt is a continuously moving strip or

surface for transporting a load of objects from one place to another.

• Filter cloth– Filter cloths are mainly made up of monofilaments

and/or multifilament's.

Granch Berhe 2015

Woven either on rapier or air-jet technology

• Sail cloth– Sail cloth is any heavy, plain-weave canvas fabric,

usually made of cotton, linen, polyester, jute, nylon etc. that is used for sails and apparel.

• Seat fabrics– Seat fabrics are used to cover seats in the transport

industry (automotive, aviation, etc.)• Air bags

– Airbag is a heavy denier nylon fabric for personal protection in various forms of transportation.

– Most airbag fabrics are woven with rapier weaving technology.

Granch Berhe 2015

OMNIplus 800 TCThe most advanced tire cord weaving machine

Granch Berhe 2015

Knitted technical textiles

Granch Berhe 2015

Definition • Warp knitting is a method of making a fabric by normal

knitting means, in which the loops made from each warp are formed substantially along the length of the fabric

• Weft knitting is a method of making a fabric by normal knitting means, in which the loops made by each weft thread are formed substantially across the width of the fabric.

• Single-jersey fabric is a weft-knitted fabric made on one set of needles.

• Double-jersey fabric is a weft-knitted fabric made on two sets of needles,

Granch Berhe 2015

Needles

• Basically latch and beard needles used, others are compound

Bearded needles -expensive to manufacture, can be producedin finer gauges and supposedly knit tighter and more uniform stitches comparedwith latch needles, but have limitations with regard to the types of material thatcan be processed as well as the range of structures that can be knitted on them.

Granch Berhe 2015

End use products

• Flat bar machines: Cleaning clothes, three-dimensional and fashioned products for technical applications, multiaxial machines are under development

• Circular machines: Hose machines: seam free hose, tights, industrial use dye bags, knit-de-knit yarns, industrial fabrics

Granch Berhe 2015

Warp knitting• Higher machine speeds, (up to 3500cpm)• Finer gauges (up to 40 needles per inch)• Wider machines (up to 260 inches)• Some speciality raschel machines such as Co-we-nit and Jacquard

machines• More recently, redesigned full-width weft insertion raschel and

tricot machines• Stable constructions, such as sharkskins, queenscord, etc.• Various net constructions utilising synthetic yarns• Mono-, bi-, tri- and multiaxial structures for technical applications• Three-dimensional and shaped (fashioned) structures for medical

and other high technology products.

Granch Berhe 2015

6

• Tricot machines: car seats, technical fabrics• Raschel machines:nets, fishing nets, sports

nets, technical fabrics, curtain lace, power nets, tablecloths, bed covers, elastic bandages, cleaning cloths, upholstery, drapes, velvets, carpets, fruit and vegetable bags, geotextiles, medical textiles.

End use

Granch Berhe 2015

NONWOVEN and their APPLICATION

Granch Berhe 2015

Defination of nonwoven• Structure produced by bonding or interlacement of fiber or

both accomplished by mechanical , chemical ,thermal or solvent mean and the combination of techniques .

Term does not include paper or fabric that are woven, knitted or tufted or those made by other felting process.

or we can say that nonwoven is direct conversion of fiber

to fabric.

Granch Berhe 2015

Why to go for nonwoven????• Due to high production a versality of use of

different fibres to produce final product having required properties according to final product and also elimination of spinning and weaving process

Granch Berhe 2015

Manufacturing ProcessManufacturing Process

Various techniques are used for manufacturing of nonwovens but some of the techniques that are used specially for the Medical applications point of view are as follows:

Spun bonding Spunlacing Meltblowing Needle punching Wet laid Dry laid

Granch Berhe 2015

Spun bondingSpun bonding

Spun bonding is used when more strong webs are needed.

Webs produced are soft, porous and dimensionally stable.

Spun bonding is mostly used for products like :- Face masks Head wears Shoe covers Bed linens and Disposable clothing .

Granch Berhe 2015

Flow chart of Spun bonding Processes

Granch Berhe 2015

Manufacturing Processes

Granch Berhe 2015

Wet laid – principle of technologyThere are three characteristic stages in the manufacture of nonwoven bonded fabrics by the wet-laid method .•Swelling and dispersion of the fiber in water; transport of the suspension on a continuous traveling screen•Continuous web formation on the screen as a result of filtration•Drying and bonding of the web

Fiber swelling and dispersion

Suspension transport

Web formation

Water recyclingGranch Berhe 2015

Wet laid

Wet-laid nonwovens are nonwoven fabrics made by a modified papermaking process, that is, the fibers to be used are suspended in water, and specialized paper machines separate the water from the fibers to form a uniform sheet of material which is then bonded and dried to produce rolls of product.

Granch Berhe 2015

Air laid - principle

The fiber material is at first opened by rotating cylinder named lickerin. Then single fibers are dispersed into the air stream and condensed on the perforated cylinder or belt.

Air laid fabric compared with carding technology has these features:

• The fibers are oriented randomly on the fabric surface – isotropic structure.

• Voluminious webs can be produced

• Wide variety of processable fibers

Granch Berhe 2015

The Bonding Process is the essence of Nonwoven Technology. Mechanical Bonding

Needle Punching

Stitch Bonding

Hydro-entanglement (Spun-lace)

Chemical Bonding Binder Application – Wet

Powder Application – Dry

Thermal Bonding Calendar

Hot Air

Spun Bonding / Melt Blown

Bonding technologies

Granch Berhe 2015

Granch Berhe 2015

Thermal bonding Wet-laid webs may be thermally bonded by

the application of heat providing the web contains a fiber or an additive that will fuse at the selected bonding temperature and will flow between the fiber junctions. On cooling, the binder material locks the fiber network together.

Granch Berhe 2015

Granch Berhe 2015

Granch Berhe 2015

Melt blown

Granch Berhe 2015

Application Area 1)Sanitary and Medical uses

1.Feminine Hygiene

2.Diapers3.Patient Apparel4.Surgical gown/ mask

2) House hold textiles 1.Floor & wall covering2.Blankets 3.Pillow covers, Bed sheets4.Towels5.Luggage & Table cloth6.House hold wipes

3)Civil Engg. Application 1.Geotextiles water proofing2.Roofing material

Granch Berhe 2015

4)FOOTWEAR APPLICATIONS

1.Shoe cover 2.Lining 3.Sole

5) APPARELS 1.Interlinings 2.Protective clothing 3.Laboratory aprons

6)OTHER UTILITY MATERIAL

1.Decorative textiles 2.Book covers 3.Tea bags 4.Tents

Granch Berhe 2015

Applications of nonwovens in medical Applications of nonwovens in medical textilestextiles

Bandages Simple bandages Light support bandages Orthopedic bandages

Cotton pads, wound dressings and adhesive tapes

Granch Berhe 2015

Contd.Contd.

Disposable surgical clothing:

Gowns Caps Masks

Granch Berhe 2015

Contd.Contd.

Disposable surgical coverings:• Blankets• Floor coverings of hospitals (anti-bacterial)• Cloths/ wipes

Drapes Bed coverings

Granch Berhe 2015

Contd.Contd.

Nonwovens are used to replace or repair different organs, bones like artificial kidney, liver, heart, mechanical lung, ligaments, vascular grafts, heart valves, blood vessels, artificial skins, nasal strips etc.

Granch Berhe 2015

Properties of the medical nonwoven

The main criteria for determining the suitability of textile products are :-

• – barrier efficiency toward bacteria, viruses, liquids and dust particles

• – capacity to absorb and store body fluids• – resistance to mechanical influences

Granch Berhe 2015

• Nonwoven fabrics can be used in the following household textile applications:

• – floor coverings• – sub-upholstery materials• – webbings Materials for use in the contract sector have to

meet legal specifications regarding their flammability.

Granch Berhe 2015

NONWOVEN HOUSEHOLD PRODUCT

Nonwoven wall hanging China nonwoven carpet

Granch Berhe 2015

NONWOVEN IN PROTECTIVE CLOTHING

FLAME RESISTANCE NONWOVEN GLOVES

NONWOVEN USED RESIST TO CHEMICAL

Granch Berhe 2015

Filter fabrics

• Pulsejet fabric filters are widely used in many industries like solid, fuel, Fired power generation.

• e.g. for industrial dust removal or for cleaning atmospheric air.

• Conveyor belts, seal gasket, other industrial equipment.

• nonwoven fabrics are to be used as filter media for both wet and dry filtration.

• The end-use-specific textile physical and general physical parameters should also be determined:-

Granch Berhe 2015

Geo Textiles

• Nonwoven geotextiles:- nonwoven geotextiles are thicker and made either from short

and continuous filaments, carded or laid in even patterns and then mechanically (needle punched) or thermally bonded.

Woven geotextiles Nonwoven geotextiles

Granch Berhe 2015

Benefits of nonwoven geotextiles

• Cheap and easy to manufacture.• Superior chemical resistance in even the

aggressive environment application.• Highly porous structure• Staple fibres needle punched together to form

fabric capable of withstanding construction installation stresses.

Granch Berhe 2015

GEO NONWOVEN

7Granch Berhe 2015