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NONWOVEN
A nonwoven is a sheet of fibres, continuous filaments, of any nature or origin, that have been formed into a web and bonded together by mechanical, chemical or thermal means
NONWOVEN
Nonwovens have specific characteristics that allow them to deliver highperformance across a wide range of applications. Specific functions include:
- absorbency,
- resilience, - softness, - flame retardancy, - cushioning, - bacterial barrier and sterility
The versatility of nonwovens means that they can provide innovative, cost-effective and sometimes unexpected answers to innumerable business challenges.
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NONWOVEN
Specific properties can be achieved by selecting raw materials and methods or by applying finishing treatments to nonwovens, such as printing, embossing, molding,
METHODOLOGY
The development of STANDARDS is on going and long term process. The process will begin and proceed further with following steps:
PROPERTIES IDENTIFIED
Absorption Nonwoven Absorption - Absorbency, Absorptive Capacity, Wicking Rate Nonwoven Absorption - Centrifuge Retention Capacity Nonwoven Absorption - Absorption Under Pressure
Abrasion Resistance Abrasion Resistance of Textile Fabrics - Taber Abrasion Abrasion Resistance of Textile Fabrics - Martindale Abrasion (View test) Bursting Strength Diaphragm Method (Mullen) Ball Burst (Constant-Rate-of-Traverse) Ball Burst (Constant-Rate-of-Extension) Chemical Analysis Component Analysis Moisture Ash Image Analysis Fiber diameter distribution Porosity, apertures and hole analysis Formation Analysis Permeability Air Permeability Water Vapor Transmission Nonwoven Coverstock Liquid Strike-Through Rate; 6 Simulated Urine
AREAS TARGETED
Fabric
Development of Standards for Nonwoven
Products
Products Specifications
DRAFT FORMULATION
A committee comprising of 15 members with five experts from each of the following categories
Academicians, TRAs and COEs Nonwovens fabric manufacturing Industry and User / Converting industry
Based on laboratory experimentations, test results, statistical evaluations, data collected; initial draft will be formulated and opened to industry, users and research organisation for feed back The nonwoven is basic technology used as intermediate product for various applications. Therefore, we expect the involvement of other COEs to achieve the targets. In due course of time with involvement and consultation / recommendation of BIS representative draft will be finalized for publication.
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Non-woven
Introduction Web formation methods Bonding Systems Discussion
Introduction
Fabrics can be made from fibres as well as from yarns. Conventional fabric production:
Fibre Yarn Fabric (knitting or weaving)
Non-woven production
Fibre Fabric
It eliminates the yarn production process and makes the fabric directly from fibres.
Introduction (2)
The great advantages in non-woven fabrics is the speed with which the final fabric is produced. All yarn preparation steps are eliminated, and the fabric production itself is faster than conventional methods. To produce 500,000 meters of woven sheeting requires 2 months of yarn preparation, 3 months of weaving on 50 looms and 1 month for finishing and inspection. Non-woven fabric can deliver the same quantity of sheeting within 2 months from order.
Introduction (3)
Not only are production rate are higher for nonwovens, but the process is more automated, requiring less labour than even most modern knitting or weaving systems. The nonwoven process is also efficient in its use of energy.
Production Rate
Fabric production method Weaving Knitting Nonwoven Rate of fabric production 1 m/min 2 m/min 100 m/min
Applications
Nonwoven fabrics can be engineered to give a wide variety of properties. Nevertheless, their aesthetic properties (handle, drape, appearance) are such that they are not in direct competition with conventional fabrics in the outerwear market. Woven and knitted fabrics will not be replaced by nonwovens in the near futrue. Currently, the main areas of growth in nonwovens are in geotextiles, medical and hospital uses, disposable products and filters.
Web formation
A nonwoven fabric is basically a web of fibres held together in some way. The web may be made of staple fibres or filaments, or from portions of polymer film.
The properties of cross-laid webs do not vary with direction as much as do those of straight-laid web
The Rando-Webber gives a randomly orientated web, with no Directionality in its properties
Spraying method
Short thermoplastic fibres can be SPRAYED onto a belt to produce a random web. The are subsequently fused by the application of heat and pressure.
Non-woven
Bonding systems in non-woven
Needled felts Adhesives Heat bonding Stitch bonding
Discussion
Introduction
In last section, we introduced what is non-woven fabrics, its advantages and application. Non-woven production
Fibre Fabric
To make non-woven fabric, the first step is web formation, to make a strong and parallel web. The second step called bonding is to combine different webs together to make a stronger layers (with different thickness and fabric weight) for particular end uses.
Needle punching. The barbed needle tangles together some fibres from each layer of the web to make a stronger web.
Photo Adhesive
Bodning 2) Adhesive
The adhesive can be applied to the web as a printed pattern or as a sprinkling of powder. The properties of an adhesive-bonded nonwoven depend to quite a large extent on the properties of the adhesive polymer used. Commonly used adhesives are polyvinyl acetate (PVA glue) polyacrylonitrile, PVC.
Adhesive bonding: a cellulosic wiper, with the adhesive applied in colour stripes and resin-impregnated fibreglass used to reinforce pipes
Heat Bonding
When a web of thermoplastic fibres (polyester, nylon) or filament is heated, the fibres cross over each other at many points, there are many rigid welding spots in nonwoven fabric. This makes heat-bonded fabrics rather stiff and inextensible. In order to produce a softer fabric without the use of adhesives, thermoplastics fibres with lower melting point are blended in the web with fibers with higher melting point. On heating, only the low melting point fibers melt. This way, fewer weld points are formed and the resultant fabric has more desirable textile properties. Such melt-welded fabrics are called Melded fabrics.
Melt-bonding at selected points to give extra stability to a spun bonded polypropylene geotextile
Stitch Bonding
Webs may also be given extra strength by stitching them through with yarns. Such structures are usually more flexible and less paper-like than heat-bonded or adhesive bonded nonwovens. Stitch bonding is based on principle of warp knitting but with needles designed to stitch through webs of various thickness. A web of fibres or web of yarns or a cheap fabric forms the base. Sharp-pointed needles pierce the base and loop binding yarns through it. In this way, relatively cheap but stable fibres, with or without pile, can be produced.
Carpet underfelts are often stitch-bonded, and may incorporat a layer of loosely woven hessian for extra length