Relationship between tensile properties of fibres and nonwoven fabrics

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1 Indi an 10rnal of Fibre & Textile Research Vol. 26, December 200 I, pp Relationship between tensile properties of fibres and nonwoven fabrics P C Patel & V K Kothari a Department of Tex ti le Technology, Indian Institte of Technology, New Delhi Indi a Received 21 Jne 2000; revised received and accepted 16 Ocrober 2000 The stress-strain behavior of spn bonded needle-pnched fabri c, spn bonded heat-sealed fabric and staple fi bre needle-pnched fabric has been stdied sing wide-width tensile test method. The stress-strain behavior of constitent fi bres of these fabrics has also been stdied and the strctral parameters of nonwoven fa brics evalated as these are the main two factors which inoence the mechanical properties of nonwoven fabrics. The fibre network theory has been sed to predict the stress-strain behavior of fabric sing the fibre data and strctral parameters of nonwoven fabrics. It is observed that there is good agreement between theoretical and experimental vales in case of heat-sealed spnbonded nonwoven fabric. In case of needle-pnched fabrics, the stress-strain crve of the staple fibre fabric shows major deviation from the ex perimental crve while the stress-strain crves fo r spnbonded needle-pnched fabrics show sbstanti al deviation from the experimental crves. The slippage of fibres is a dominating factor in the deformation of needle-pnched nonwoven fabrics in general and staple fibre fa brics in particlar and hence both the modls and breaking stress are fond to be mch lower than the theoretical vales. The strctre of nonwoven fabrics is the most important fac tor affecting the tensi le behavior of these fa brics. Keywords: Heat-sealed fabric, Needle-pnched fabric, Nonwoven fabri c, Stress-strain behavi or, Tensile properti es 1 Introdction Nonwoven fabrics are extensively sed in different applications de to their excellent properties. These fabrics for applications like geotextiles are manfactred from fibres like polypropylene and polyester sing manfactring processes like heat sealing (thermal bonding) and needle pnching (mechanical bonding). The formation of the strctre of these fabri cs depends on the fibre arrangement in the web, fibre properties and bonding method sed in the prodction of fabric. When this strctre is sbjected to tensile load, the deformation of the fabric, viz. the extension of fabric in the direction of applied load and the contraction of fabric in the transverse direction, takes place. In case of nonwoven fabrics, fibre properties and fabric strctre mainly affect the fabric properties. The extension of the fabric is attribted to the rearrangement of fibre geometry and fibre extension. If tensile properties of fibres and details of fabric strctre are known, it shold be possible to relate them to the tensile properties of the fabric. Backer and Petterson 1 developed the fibre web theory to relate fibre modls and web geometry to the fabric modls of thin nonwoven strctres. "To whom all the correspondence shol d be addressed. Phone: ; Fax: ; ko thari@textile.iitd.ernelin Hearle and Stevenson 2. 3 developed fibre network theory for the prediction of tensile properties of nonwoven fabrics. Hearle and Newton 4 modified thi s theory to accont for the fibre slippage throgh binder and theoretically determined the stress-strain crves of several bonded fibre nonwoven fa brics. They demonstrated the extent of applicability of theory in relation to the amont of binder materi al and the fibre crl. Hearle and SltanS stdied the inflence of fibre type, fibre fin eness and staple length on the tensile behavior of some needle-pnched fabrics. In thi s work, the stress-strai n behavi or of nonwoven fabrics of different strctres and polymer types has been stdied to relate the tensile properties of fibres and fabric strctre. 2 Materials and Methods Polyester and polypropylene fabrics of th e specifications as given in Table I were sed. The stressstrain relationship of the fibres in these fabrics has been stdied on the Instron tensile tester after preparing the specimens of filaments/fibres removed careflly from the respecti ve nonwoven fabrics. A total of 30 fil aments/fibres of 100 mm gage length were tested and average stress-strain crve was obtained in each case. tensile tests were carried ot sing wide-width test method with 200 mm fabric width and 100mm gage length sing special jaws at a strain

2 PATEL & KOTHARI: TENSILE PROPERTIES OF FIBRES & NONWOVEN FABRICS 399 Table I- details Type of fibre Linear density dtex Manfactring/bonding method Mass g/m2 AF Polypropylene filament 23 BF Polypropylene filament II C F Polyester filament 6.1 DF Polyester filament 9.6 EF Polypropylene staple 4.4 Spnbonded heat-sealed 200 Spnbonded needle-pnched (srface 190 calendered) Spn bonded needle-pnched 170 Spn bonded needle-pnched 220 Staple fibre needle-pnched 200 rate of 10% / min. Ten samples were tested to obtain the average stress-strain crve for each type of nonwoven fabric. Dring the tensile test, the width of the specimen at the mid position between the jaws was noted at the fixed time intervals corresponding to 10% fabric strain in the test direction. Average of these vales at varios strain levels was taken to calclate the Poisson's ratio. strctre was stdied on projection microscope sing optical method similar to that sed by Hearle and Stevenson 2. Magnification of xl00 was sed and a tracing paper having 25 mm diameter circle marked in the centre of the paper was fitted on the screen of the projection microscope. Samples of 2 cm x 5 cm size were prepared from the nonwoven fabrics sch that larger dimension being ct in the machine direction of the fabric. Each sample was careflly placed on a clean microscope glass slide and a few drops of n-decane were added to improve the fibre definition. On focsing, the fibre projections were clearly visible on the tracing paper throgh the screen tabl e. A position on the slide was then chosen at random and fibres passing throgh the circle were traced. Different layers of the fabric were progressively focsed to examine fibre layers in trn and every time the fibres projections were traced on the tracing paper (Fig. 1). When a fll traverse of the focs throgh the thickness of the specimen appeared, a second position on the microscope slide was chosen at random and a new sheet of tracing paper was positioned. The same process was repeated again. A total of 50 sch tracings were prepared in case of each nonwoven fabric. The angle of each fibre segment in the circle with rcspect to longitdinal direction (L) was measred. The nmber of fibres in each 10 segment was conted and the orientation distribtion fnction (8 j ), defined (0) L f{ t Fig. I--Measrement of strctral parameters of non woven fabrics (a) tracing of fibres on the projection microscope screen, and (b) anglar orientation of fibres in relation to machine direction [fl-f9 - fibres and L -longitdinal direction] as the ratio of nmber of fibres in a 10 anglar interval to the total nmber of fibres for varios midvales of anglar orientation, was obtained. The fibre crl factor (C), defined as the ratio of length of the fibre segment to the shortest distance between the segment ends, was also measred from the same tracing for each type of fabric. 3 Reslts and Discssion 3.1 Stress-strain Characteristics of Fibres Average stress-strain crves of the fibres taken from the nonwoven fabrics are shown in Fig. 2. Table 2 shows that the polypropylene filaments (A r and Br) removed from spn bonded fabrics have higher extension-at-break and lower initial modls. Polyestcr filaments (Cr and Dr) removed from needlepnched spnbondcd fabrics show relatively higher initial modls and lower extension-at-break. Polypropylene staple fibre (Er) shows the highest tenacity and low elongation as the fibres are flly drawn before the formation of web from the staple fibres. In L (b)

3 400 INDIAN 1. FIBRE TEXT. RES., DECEMBER , l-af 40 "'s 2-8f x / J- C I f 2 4-0f z 30 I /;:;:''''4 i /) s- E f - i., /"," 20. /.11.;? i /./P "V / Strain, 0/0 x.. 6 -z ", SO Fibre Ar Br Cr Dr Er Fig. 2-Stress-strain behavior of fibres Table 2-Tensile properties of fibres Fibre linear density dtex Tensile strength cn Tenacity cn/tex Extensionat-break % 127 Table 3--Tensile properties of fabrics (machine direction) Mass Tensile Tenacity Extensiong/m2 strength cn/ lex at-break kn/m % AF BF CF OF EF particlar, the filaments removed from spnbonded heat-sealed fabric show very high extension. 3.2 Stress-strain Behavior of Nonwoven s Table 3 gives the main tensile test reslts for different fabrics based on wide-width tensile test in the machine direction (along the length) of the fabrics. A verage stress-strain crves of varios nonwoven fabrics have been compared and the reslts are shown in Fig Fig. 3--Slress-strain behavior of fabrics Spnbonded heat-sealed fabric (AF) shows mch higher initial modls bt offers very little resistance after 20% extension, eventally leading to the failre of the specimen. However, the need le-pnched spnbonded polypropylene fabric (BF) shows lower initial modls and higher extension-at-break. The above reslts show distinct differences between the stress-strain behavior of nonwovens of different strctres. The stress-strain crves show the striking similarity between the heat-sealed spn bonded fabric AF and the fibre A r. However, needlepnched fabrics show lower initial modls even when the initial modls of fibres is high. This may be owing to the high degree of reorientation and slippage of individal fibres dring the tensile load application on these fabrics. This effect is very prominent in case of staple fibre needle-pnched fabric if one compares the shapes of stress-strain crves of fibre Er (Fig. 2) and fabric EF(Fig. 3). The high modls of the heat-sealed fabrics can be attribted to the rigid bonds formed as a reslt of fsion of fibres at the crossing points in the fabric. There is a gradal decrease in the slope of the crve right pto rptre and the stress vale drops sharply at the rptre. The case of fabric failre is fibre breakage with few fibres slipping in the rptre zone of broken specimen. In case of needle-pnched spnbonded fabric (B F), the observations dring the test show that the fibres are free to move after the initial breakage of weak bonds formed de to the srface calendering and the fabric behaves like a simple needle-pnched strctre for all practical prposes. Polyester spn bonded needle-pnched fabrics (CF and DF) give higher strength with lower extension-atbreak compared to polypropylene spnbonded fabrics (AF and BF). The reslts also indicate that the fabric

4 PATEL & KOTHARI : TENSILE PROPERTIES OF FIBRES & NONWOVEN FABRICS 401 strctre can alter the stress-strain behavior significantly. Fibres C r and Dr have nearly the same tenacity bt the extension of Dr is nearly two times that of the Cr. The needle pnching process prodces fabric OF which has higher breaking stress and lower breaking elongation. The needle-pnched nonwoven made from staple fibres (E F ) shows the lowest initial modls and higher strength than other fabrics. As the load increases initially, the reorientation and slippage of fibres occr withot offering mch resistance to extension. The strctre develops a tension becase of the presence of vertical pegs formed by the needling process, and jamming of the strctre occrs after the initial phase, giving rise to a distinct increase in fabric modls. The slippage of the fibres dominates dring the test, giving higher extension-at-break. 3.3 Prediction of Properties The theoretical stress-strain relationship of fabric was obtained sing the following eqations based on the fibre network theory3 : er= (l/c) {(l+e)2.cos 2 8t +(l-v.e)2.sin 2 8. } (1) qr= J(er) (2) QL = qr cos 8.. ( 8.) cos 8. (3) where e is the fabric strain; er, the fibre strain; C, the crl factor; 8., the fibre angle to the stress direction; v, the fabric Poisson's ratio; qr, the fibre stress; ( 8.), the fibre orientation distribtion fnction; and QL, the fabric stress. 15, , Sample AF 12 The relationship between stress and strain of fibres removed from different fabrics was obtained from the average stress-strain crve of fibre. The theoretical and experimental stress-strain crves of different fab-.. L 35r , Samp le BF Strain, % Fibre Fa br ic ( Experime ntal) Fig. 5--Comparison of theoretical and experimental stress-strain behavior of sample BF , Sample (F Fi bre ;Fibrt.. " z (Theoretical) Fa bric (Experimental) )( 18 -z! 12 (Theoretical J It.O Strain, Fig. 4--Comparison of theoretical and experimental stress-strain behavior of sample AF Fig. 6---Comparison of theoretical and experimental stress-strain behavior of sample C F

5 402 INDIAN J. FIBRE TEXT. RES., DECEMBER , Sample OF f ibre 50, Sample EF I Theoretical J )( z.:: fabric I Theore ticoll (Experimental J Stroin, % Fig. 7--Comparison of theoretical and ex perimental stress-strain behavior of sample DF rics (A F, B F, C F, O F and E F ) based on above eqations have been plotted along with stress-strain crves of fibres for comparison (Figs. 4-8). The theoretical stress-strain crve of spn bonded heat-sealed fabric (A F ) shows good agreement with the experimental crve (Fig. 4). This is becase the fabric is thin with rigid bonds and hence the network of web remains intact dring the tensile test of the specimen. The orientation of the fibres in the network, measred in two dimensions, holds good dring the test for this type of strctre. Theoretical stress-strain crves of spnbonded needle-pnched fabrics (Figs 5-7) and staple fibre needle-pnched fabric (Fig. 8) show large deviations from the experimental crves. The thick web of the fabric and loose frictional bonds in the strctre of the needle-pnched fabrics allow slippage of fibres on application of external load which changes the fabric strctre sbstantially dring the corse of testing, reslting in lower initial modls than predicted by the theory. In case of needle-pnched fabric made from carded web of staple fibres (EF)' there is even larger difference between the theoretical and the experimental Fig. &-Comparison of theoretical and experimental stress-strain behavior of sample EF stress-strain crves (Fig. 8) de to the higher slippage at fibre ends. 4 Conclsions Deformation in varios nonwoven fabrics depends on the type of strctre formed by the bonding method. In case of heat-sealed nonwoven fabrics, initial modls is high bt it decreases gradally with the increase in stress while in case of needle-pnched fabrics, initial modls is low bt it increases with the frther increase in load as the strctre gets locked. The prediction of stress-strain behavior sing the fibre network theory gives close approximation in case of heat-sealed fabrics. However, in case of needle-pnched fabrics, the predicted stress-strain characteristics differ sbstantially with the experimental reslts. References 1 Backer S & Petterson DR, Text Res J, 30( 1960) Hearle J W S & Stevenson P J, Text Res J, 33( 1963) Hearle J W S & Stevenson P J, Text Res J, 34(1964) l. 4 Hear1e J W S & Newton A, Text Res J, 38( 1968) Hearle J W S & Sltan M A I, J Textlnsf, 59(1968)

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