fiber web

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IntroductionManufacturing Technolodes

CardedwebsAirlaidwebsNeedle punchingSpunlacingResin bondingSpinbondingStitch bondingFilm to network structures

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11 2 AberWeb and RelatedFabrics

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Woven, Knit Fabric CharacteristicsStrengthFlexibilityShearability,drape, conformabilityFullness, hand, resilienceDimensional stability

Fiber 4 Yarn Fabric(Sheet1Fiber- abric (Sheet)Nonwoven FabricsSheet orweb structures made by bonding and/or interlocking fibers,yams, or filaments by m echanical, thermal, chemical or solvent m eans.

RberWeband Related Fabrics 11-3

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Classes of Nonwoven MaterialsFiber-web structures(Homogeneous)Multiplex structures(Laminates, omposites)

Netlike structures(Fibrilated films, Formed webs)

1 1 4 AberWebandRebtedFabflcs

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ic

RWaRaeFc1-5

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Major Markets ($MM)1974 %na. 1984 %ma* 1990

cov stk (bb diap) 75 215 9 360-(other) 35 65 9surgical packs 33 160 10 285

gowns, acc.wipes, towels 32 145 12 285interlinings 65 115 7coat/lam. substr. 35 150 11geotex./roo ing 100 17 245filter media 13bedd/h.f. acc. 12durable paper 13disp. apparel 13carpet comp. 8

source: S t a ~1984)

11-6 RberWeb and Related Fabrics

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1970 1977

Dry Staple 100 178Spunbonded 21 48W e t Laid 14 32Otherb 5 27Total 140 285

Table 1 1-1 US Consumption of Nonwovens1982 1984 1990a

187 207 23093 118 21445 50 7265 90 159390 465 675

'EstimatedbIncludes air laid pulp, spunlaced, melt blown, composite and porous film.Source: J o h n R Starr, Inc.

RberWeband RelatedFabrlcs 11-7

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E-II HI ---

1-8RWeanRaeFc

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Typical End Use AreasApparel InterfacingsArt CanvasesAuto ComponentsBattery SeparatorsBeddingBlanketsBo o k CoversBuilding MaterialsCarpet ComponentsCoated FabricsDiapersDraperiesElectrical InsulationFiltersFumitureLuggage

MapsMattress CoversPackagingQuiltsRoad and Soil StabilizationSafety GarmentsSanitary NapkinsSheets and PillowcasesShoe ComponentsSurgical Packs and GownsTable CoversTea BagsTowelsUndergarmentsWall CoveringsWipes

AberWeb and Related Fubdcs 11-9

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Other Typical End Use ApplicationsFor NonwovensArtificial LeatherBedspreadsBibsCable WrappingsCapsCasket LinersCheese WrapClean Room ApparelClothing InsulationCoverallsExaminationGownsIncontinent PadsIroning Board PadsKitesLab Coats

LabelsLampshadesParachutesPennantsRobesScouring PadsSignsSleeping Bag LinersSwimwearTailors PatternsTarpaulinsTentsWash ClothsWindow Shades

11-10 FiberwebandRelatedFabrlcs

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Cellulosics (Rayon, Acetate)Wood Pulp

F mCotton

Polyamides (Nylons)PolyestersPolypropyleneAcrylicsGlassetc.

ProcessesDry Formed: Carded, Air-LaidSpunbondedSpunlaced (?)Wet-LaidCompositeFilmExtrusionNeedle Punched (?)

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RberWeband Related Fabrlcs 11-11

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Elements Of Manufacturing Technologies(Using Staple Fibers)PreparationWeb Formation- arding systems-Gamett systems- ir-Laid systemsBonding-Mechanical- hemical- hermal/Sonic

11-12 F W e b nd Related Fabdcs

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a. feed latticeb. squeeze zonec. feed rolld. lickeridtakerine. first or breaker cylinderf. intermediate doffer ortransfer rollg. cleaner roll

h. angle rolleri. maincylinderk. worker1. stripperm. fancyrolln. doffer0. vibrating comb

AberWeband RelatedFa- 11-13

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Figure 11-1 Carded Web Flow

31 . C d 3.Transport lamce2.cardweb ~ ~ o n t i n u o u s ~ p r o n

2.cardweb3.Tlcnsport Lattice

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We

ReaeFc11

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Carded Webs0.1 - 0.3 (oz/yd2) on conventional cards(low mass, bulk and integrity)up to 3 (oz/yd2) on modem NW cardsTo Build a Fleece:

Layering by tandem cardsParallel LappingCrossLappingup to 2.5 lbdin (MIC)/h.r(conventional card).up to 10 Ibdin (WCYhr (modernNW cards).

Productivity

Garnet WebsFleece built by layeringProductivity6 lbdin (MIC)/hr.Rando-WebberAir-Laid fleece0.3 - 75 oz/yd21/64in - 4 in thicknessProductivity1 - 8 lbdin (M/Cyh,

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ondQ)Q32

FPf3

2

WeRae

c11

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Needle

Figure 11-2 Fiberwoven Process

BiBarbed Needle Engageing Fibers OnBeing pushed IntoFiberBatt

C

11-16 FlberWeband Related Fabrlcs

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Factors Influencing PropertiesOf NeedlePunched FabricsStructure of web:- 11, X, Random)- xtent of fiber pickupFiber properties:- iber fineness- oefficient of friction- ength

.- xtensibilityWeb weight (thickness)Web movementNeedle penetrationNeedle punch density

RberWebandRelatedFakics 11-19

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p

IL

12FbWbRaeF

c

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Figure 11-3 Spun Laced Systems

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Rberweband Related Fabrks 11 21

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Resin BondingThermoplastic Fibers(Vinyon, Saran, Cellulose, Acetate, PE, Pet)Thermoplastic and Thermosetting Powders(Acrylic beads, Vinyl beads, Phenolic. . )Liauid Binders

Aqueous Solution- PVA, Amylose,Na Alginate, Casein. . )Organic SolventBinders- N. Rubber & Benzene,PVC & Cyclohex ..)Water Based Emulsions- VC- VC Acetate- olyacrylates- crylic Esters- atural R. Latex- utadiene Acrylonirtile- . . Copolymers-Melamine-Melamine-urea- rea-formaldehyde- henol-formaldehyde

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GI

Figure1 1-4 Impregnation Bath Diagram

Web

Web

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1-2WebaRaeFCS

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t

34ch

Du Pont spunbonding processillustrating air aspirator andelectrostatic repulsion techniques.

The spin-draw route to spunbondedfabrics showing the optional use of aseparate feed of bonding filaments.

RberWebandRektedFaklcs 11-25

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A-B -

A*---ASheamOfHotAir C . c a dALB.pdymetfeed D.conneclorscreen

The ManufactureofMelt-BlownSpunbondedTe-

11-26

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Figure 11-5 Fibrillates

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W e b nd RelatedFabrics 11 27

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Figure 11-6 Arachne Stitch Bonding

11 28 W e b ndRelated Fabrlcs

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Figure 11-7 Arachne Stitch Bonding

AberWebandlFelatedFabrlcs 11-29

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1-30FbWo

ae

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Figure 11-8 Malimo Fabric

RberWebandReIatedFabrkX 11-31

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Figure 11-9 Wetlaid

Fiber Suspension

Qcreen 0 C] c DrivingDe-wateringWetLayedFibrousLayer

11-32 FlberWeband Related Fabrics

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Flocked FabricsDefinitionFlocked fabrics consist of short fibers bonded to substrate to achieve adecorative or functional effectFibersNatural or man-made, mostly cotton, rayon, nylon, random or precisioncut, natural or dyed

- -

Rberweband RelatedFaklcs 11 33

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0

0

Flocking MethodsMechanical or beater barElectrostatic- C or AC- ownward- pwardElectrostatic and mechanicalGiroud processElectrostatic alignment and mechanical insertionSynthetick lockingAir turbulence (ttslushmolding)


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Figure 11-10 Electrostatic Flocking: Flocking Down

II II

I

I

RberWebandRektedFabrlcs 11-35

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1-

bWa

aeFc

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I

WebaaeFc13

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BondingAgentsNeoprene (obsolete)Self-reactive acrylic emulsionsUrethanesEpoxides (for metal substrates)

SubstratesWoven fabrics

0 Non wovensPlasticfilmMetal foilLeatherWoodRubberPaperGlassThree-cimensionh objects

_- . Expanded vinyls

11-38 FiberWebondRelated Fabrlcs

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Application Of AdhesiveCoating and laminating techniques- octor blades (knife coating)- iss or transfer rolls- everse transfer rolls- praying- xtruding- ot MeltRoller printing techniquesScreen printing techniques

Finishing TechniauesDyeing

0 Printing0 Embossing0 Shearing

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ltuo-DimensionalDraperiesCarpetsWall PaperVelvetsBoxesShoe UppersBlanketsAuto TopsPaint RollersTumtablecushionsAcousticalDampening

Three-DimensionalHatsToys

UsesUpholstery FabricsFloor TilesWrapping PaperCrushed VelvetsPocket BooksSynthetic FurAcoustical Wall PanelsAuto Window ChannelsNon-slip BasesMar-proof Bas esVibration Dampening

GlovesYarnS

11 40 W e b nd Related Fabdcs

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Figure 1 1= 1 1 Tufting: Yarn Flow

Iiy B . L

I \.I '1

Aberweb and RelatedFabrlcs 11 41

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Figure 11-12 looperLooper

W

' Ustage3


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- -

Needle

YarrJ

Pile

flberweband RelatedFabrlcs 11-43

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Adhesives& BackcoatingFunction- indingTufts- revent Rlling- ttach 2' BackingImproves- and- ear Strength- imensional Stability

. ype- ynthetic Lattices (SBR)- atural Latex (Rubber)- ot Melts- thylene - Vinyl CIApplication- oller Coater- roth 24 - 35 odyd2

11 44 FlberWeband R e l a t e d Fabrics

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Attached CushionsBResFoam RubberSponge RubberVinyl

fiber web

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