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Manufacturing Technolodes Cardedwebs Airlaidwebs Introduction Needle punching Spunlacing Resin bonding Spinbonding Stitch bonding Film to network structures -- 11-2 AberWeb and Related Fabrics
Woven, Knit Fabric Characteristics Strength Flexibility Shearability, drape, conformability Fullness, hand, resilience Dimensional stability - Fiber 4 Yarn Fabric(Sheet1 Fiber Fabric (Sheet) Nonwoven Fabrics Sheet or web structures made by bonding and/or interlocking fibers, yams, or filaments by mechanical, thermal, chemical or solvent means. RberWeb and Related Fabrics 11-3
Fiber-web structures (Homogeneous) Classes of Nonwoven Materials Multiplex structures (Laminates, Composites) Netlike structures (Fibrilated films, Formed webs) 114 AberWebandRebtedFabflcs
i c RberWeb and Related Fabrics 11-5
Major Markets ($MM) - 1974 %na. 1984 %ma* 1990 cov stk (bb diap) 75 215 9 360 (other) 35 65 9 surgical packs 33 160 10 285 gowns, acc. wipes, towels 32 145 12 285 interlinings 65 115 7 coat/lam. substr. 35 150 11 geotex./roo fing 100 17 245 filter media 13 bedd/h.f. acc. 12 --._ durable paper 13 disp. apparel 13 carpet comp. 8 source: Sta~ (1984) 11-6 RberWeb and Related Fabrics
I Table 1 1-1 US Consumption of Nonwovens 1970 1977 Dry Staple 100 178 Spunbonded 21 48 Wet Laid 14 32 Otherb 5 27 Total 140 285 1982 1984 1990a 187 207 230 93 118 214 45 50 72 65 90 159 390 465 675 'Estimated bincludes air laid pulp, spunlaced, melt blown, composite and porous film. Source: John R Starr, Inc. RberWeb and Related Fabrlcs 11-7
I E - H I - I I -- 11-8 RberWeb and Related Fabrfcs
Typical End Use Areas Apparel Interfacings Art Canvases Auto Components Battery Separators Bedding Blankets Book Covers Building Materials Carpet Components Coated Fabrics Diapers Draperies Electrical Insulation Filters Fumiture Luggage Maps Mattress Covers Packaging Quilts Road and Soil Stabilization Safety Garments Sanitary Napkins Sheets and Pillowcases Shoe Components Surgical Packs and Gowns Table Covers Tea Bags Towels Undergarments Wall Coverings Wipes AberWeb and Related Fubdcs 1 1-9
Other Typical End Use Applications For Nonwovens Artificial Leather Bedspreads Bibs Cable Wrappings Caps Casket Liners Cheese Wrap Clean Room Apparel Clothing Insulation Coveralls Examination Gowns Incontinent Pads Ironing Board Pads Kites Lab Coats Labels Lampshades Parachutes Pennants Robes Scouring Pads Signs Sleeping Bag Liners Swimwear Tailors Patterns Tarpaulins Tents Wash Cloths Window Shades 11-10 Fiberweband Related Fabrlcs
I F m Cotton Cellulosics (Rayon, Acetate) Wood Pulp Polyamides (Nylons) Polyesters Polypropylene Acrylics Glass etc. Processes Dry Formed: Carded, Air-Laid Spunbonded Spunlaced (?) Wet-Laid Composite FilmExtrusion Needle Punched (?) -- RberWeband Related Fabrlcs 11-11
Elements Of Manufacturing Technologies (Using Staple Fibers) Preparation Web Formation - Carding systems - Gamett systems - Air-Laid systems Bonding - Mechanical - Chemical - Thermal/Sonic -- It. 11-12 FWeb and Related Fabdcs
a. feed lattice b. squeeze zone c. feed roll d. lickeridtakerin e. first or breaker cylinder f. intermediate doffer or transfer roll g. cleaner roll h. angle roller i. maincylinder k. worker 1. stripper m. fancyroll n. doffer 0. vibrating comb AberWeband Related Fa- 11-13
Figure 1 1-1 Carded Web Flow 3' 1.Cd 2.cardweb 3. Transport lamce ~~ontinuous~pron 2.cardweb 3.Tlcnsport Lattice.-.
Weband Related Fakics 11-15
Carded Webs 0.1-0.3 (oz/yd2) on conventional cards (low mass, bulk and integrity) up to 3 (oz/yd2) on modem NW cards To Build a Fleece: Layering by tandem cards Parallel Lapping Cross Lapping Productivity up to 2.5 lbdin (MIC)/h.r(conventional card). up to 10 Ibdin (WCYhr(modern NW cards). Garnet Webs Fleece built by layering Productivity 6 lbdin (MIC)/hr. Rando- Web ber Air-Laid fleece 0.3-75 oz/yd2 1/64 in - 4 in thickness Productivity 1-8 lbdin (M/Cyh,
on d Q) 3 Q) 2 F P 2 f 3 AberWebandRelatedFabrlcs 11-17
Figure 11-2 Fiberwoven Process Needle B i Barbed Needle Engageing Fibers On Being pushed Into Fiber Batt C 11-16 FlberWeb and Related Fabrlcs
Factors Influencing Properties Of Needle Punched Fabrics Structure of web: - (11, X, Random) - Extent of fiber pickup Fiber properties: - Fiber fineness - Coefficient of friction - Length. - Extensibility Web weight (thickness) Web movement Needle penetration Needle punch density RberWeband RelatedFakics 11-19
pi I Lu 11-20 FlberWebond Related Fabrlcs
Figure 11-3 Spun Laced Systems -- Rberweb and Related Fabrks 11-21
I Resin Bonding Thermoplastic 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 Solvent Binders - (N. Rubber & Benzene, PVC & Cyclohex...) Water Based Emulsions - PVC - PVC Acetate - Polyacrylates - Acrylic Esters - Natural R. Latex - Butadiene Acrylonirtile -... Copolymers - Melamine - Melamine-urea - Urea-formaldehyde - Phenol-formaldehyde
Figure 1 1-4 Impregnation Bath Diagram Web GI Web
11-24 W e b and Related FabrlCS
3 4 I c h t Du Pont spunbonding process illustrating air aspirator and electrostatic repulsion techniques. The spin-draw route to spunbonded fabrics showing the optional use of a separate feed of bonding filaments. RberWebandRektedFaklcs 11-25
A- B- A*--- ASheamOfHotAir C.cadAL B.pdymetfeed D.conneclorscreen The Manufacture of Melt-Blown SpunbondedTe- 1 1-26
Figure 1 1-5 Fibrillates -- W e b and Related Fabrics 11-27
Figure 1 1-6 Arachne Stitch Bonding 11-28 W e b and Related Fabrlcs
Figure 1 1-7 Arachne Stitch Bonding AberWebandlFelatedFabrlcs 11-29
11-30 FiberWeb ond Related
Figure 11-8 Malimo Fabric RberWebandReIatedFabrkX 11-31
Figure 11-9 Wetlaid Fiber Suspension Q Screen Wet Layed Fibrous Layer 0 C] c, De-watering Driving 11-32 FlberWeb and Related Fabrics
Flocked Fabrics Definition Flocked fabrics consist of short fibers bonded to substrate to achieve a decorative or functional effect Fibers Natural or man-made, mostly cotton, rayon, nylon, random or precision cut, natural or dyed -- Rberweb and Related Faklcs 11-33
Flocking Methods 0 Mechanical or beater bar 0 Electrostatic - DC or AC - Downward - Upward Electrostatic and mechanical Giroud process Electrostatic alignment and mechanical insertion Synthetic k flocking Air turbulence (ttslush molding) 11-34 FlberWeb and Related Fabrlcs
Figure 1 1-10 Electrostatic Flocking: Flocking Down I I I I I I RberWebandRektedFabrlcs 11-35
11-36 FlberWeb and Related Fabrlcs
I W e b and Related Fabrics 11-37
Bonding Ag ents Neoprene (obsolete) Self-reactive acrylic emulsions Urethanes Epoxides (for metal substrates) Substrates Woven fabrics 0 Non wovens Plasticfilm -- Metal foil Leather Wood Rubber Paper Glass Three-cimensionh objects _- 0. Expanded vinyls 11-38 FiberWebond Related Fabrlcs
Application Of Adhesive Coating and laminating techniques - Doctor blades (knife coating) - Kiss or transfer rolls - Reverse transfer rolls - Spraying - Extruding - Hot Melt Roller printing techniques Screen printing techniques Finishing Techniaues Dyeing 0 Printing 0 Embossing 0 Shearing Aberweb and Related Fabrlcs 11-39
Uses ltuo-dimensional Draperies Carpets Wall Paper Velvets Boxes Shoe Uppers Blankets Auto Tops Paint Rollers Tumtable cushions Acoustical Dampening Upholstery Fabrics Floor Tiles Wrapping Paper Crushed Velvets Pocket Books Synthetic Fur Acoustical Wall Panels Auto Window Channels Non-slip Bases Mar-proof Bases Vibration Dampening Three-Dimensional Hats Toys Gloves YarnS 11-40 W e b and Related Fabdcs
Figure 1 1 = 1 1 Tufting: Yarn Flow B I iy. L I \. I '1 Aberweb and Related Fabrlcs 11-41
Figure 11-12 looper Looper W 'U stage3 11-42 FlberWeb and Related Fabrlcs
Needle YarrJ Pile -- flberweb and Related Fabrlcs 11-43
Function - Binding Tufts - Prevent Rlling - Attach 2' Backing Improves - Hand - Tear Strength - Dimensional Stability. Type - Synthetic Lattices (SBR) - Natural Latex (Rubber) - Hot Melts - Ethylene - Vinyl CI Application - Roller Coater - Froth 24-35 odyd2 Adhesives & Backcoating 11-44 FlberWeb and Related Fabrics
Attached Cushions BRes Foam Rubber Sponge Rubber Vinyl FIberWebandRelatedFabrlcs 11-45