NONWOVEN FABRIC

CONSTRUCTION

by Jérôme Verhille

06/04/2011
 Summary
• Introduction
• Definition
• Global production of nonwovens
• The raw materials
• The different processes
• For the web formation
• For the consolidation
• The applications
Definition

This is a sheet fabricated,
consisting of veil or sheet
of fibers oriented in a
particular direction or at
random, linked by friction
and / or cohesion and / or
adhesion, excluding paper
and products obtained by
weaving, knitting, tufting,
seaming or filaments
incorporating son bonding
or felted by wet milling or
not they are needled.
Global production of nonwovens
 The raw materials

 The three categories of raw materials

used to produce a nonwoven fabric are:
- Fibers
- Binders
- Additives
 vegetable fibers

cotton flax jute cannabis

Examples of non woven

 animal fibers

Wool silk
 man-made fibers
artificial fibers synthetic fibers

viscose cellulose polyamide polyester

 mineral fibers

 fiberglass asbestos
 Web formation : Drylaid
drylaid carded

Carding is a mechanical process, which starts with the opening of bales of
fibres which are blended and conveyed to the next stage by air transport.
The fibres are then combed into a web by carding machine, which is a
rotating drum or series of drums covered in fine wires or teeth.
Web formation : Drylaid
drylaid carded
 Web formation : Drylaid
airlaid
 The fibres, which can be very short, are fed into an air stream and from
there to a moving belt or perforated drum, where they can form a
randomly oriented web.
Web formation : Drylaid
airlaid
Web formation : Spunlaid
spunbond
 Polymer granules
are melted and
molten polymer is
extruded through
spinnerets. The
continuous filaments
are cooled and
deposited on to a
conveyer to form a
uniform web. Some
remaining
temperature can
cause filaments to
adhere to one
another, but this
cannot be regarded
as the principal
method of bonding.
 Web formation : Spunlaid
meltblown
 Low viscosity polymers are extruded into a high velocity air stream on
leaving the spinneret. This scatters the melt, solidifies it and breaks it
up into a fibrous web.
 Web formation : Wetlaid
 Dilute slurry of water and fibres is deposited on a moving wire screen
and drained to form a web. The web is further de-watered,
consolidated, by pressing between rollers and dried. Impregnation with
binder is often included in a later stage of the process.
 Consolidation :
Chemical Bonding
 It is the most common methods of bonding. The chemical binder is applied
to the web and is cured. It is also named Latex Bonding because the latex
is the most commonly used binder : it is economical, easy to apply and
very effective. Several methods are used to apply the binder and include
saturation bonding, spray bonding, print bonding and foam bonding.
 Consolidation :
Thermal Bonding
 It is used for thermoplastic fiber. The fiber web is passed between heated
calender rollers, where the web is bonded. In most cases point bonding by
the use of embossed rolls is the most desired method, adding softness and
flexibility to the fabric. Use of smooth rolls bonds the entire surface of the
fabric increasing the strength, but reduces drape and softness.
 Consolidation :
needlepunching
 It mechanically interlocks the fibers through the web. Barbed needles,
mounted on a board, punch fibers into the web and then are withdrawn
leaving the fibers entangled. The needles are spaced in a non-aligned
arrangement and are designed to release the fiber as the needle
board is withdrawn.
 Consolidation :
Spunlace

Spunlace (or hydroentanglement) is a process of using fluid forces to lock
the fibers together. This is achieved by fine water jets directed through
the web, which is supported by a conveyor belt. Entanglement occurs
when the water strikes the web and the fibers are deflected. The vigorous
agitation within the web causes the fibers to become entangled.
 The applications
Examples Quality Sought
Hygiene and cleanliness table linen, towels, tea towels, rags, filters strength, gentle, absorbent
Sanitary products disposable personal care, baby diapers, strength, gentle, absorbent
sanitary napkins, incontinence
Medical products drapes, clothing, masks, bandages, gauze barrier effect bacteriological,
anticontamination,
safety, disposable
Stand alone product headliner, doors, carpets, sound insulation for strength, flexibility, ease of
or incorporated the automotive industry, floors or walls for the forming, fire, waterproof,
into composite building materials for binding, synthetic leather mildew resistance
Products for clothing apparel interlining flexibility, lightness,
and fashion shape retention, quality
Filtration products separation by ion exchange and catalytic strength, homogeneous
separation, food processing, air conditioning, tea structure, resistance
bags, tea bags herbal tea bags, vacuum cleaner to chemical attack
Sealants and building roofing felts, geotextiles strength, flexibility,
for landscaping, drainage stability, rot
Products for agriculture tablecloth crop protection, capillary, strength, flexibility,
and gardening greenhouses, protects seedlings and roots stability, rot
Products for cable sheathing membranes, speakers, strength, flexibility,
industrial uses satellite dishes, coating materials, compressibility, porosity,
core materials, abrasive resistance to aging,
temperature changes
Packaging & protection pouches, envelopes, packing bags, food, tents strength, flexibility, stability,
protection, seal
Print media products reproduction painting, decorative strength, flexibility, stability,
products for walls or ceiling, art books, record printing,
children's books, wet strength resistance to wet
 Bibliography
 http://cerig.efpg.inpg.fr/tutoriel/non-tisse/sommaire.htm


http://www.engr.utk.edu/mse/Textiles/Dry%20Laid%20Nonwovens.htm


http://www.pgi-industrial-europe.com/en/web-formation

 http://tappi.micronexx.com/JOURNALS/PDFS/95JUN185.pdf

 http://www.lenzing.com/sites/nh08/english/html/1_7.htm


Definition :
http://en.wikipedia.org/wiki/Nonwoven_fabric


Cotton :
http://collant.wordpress.com/2009/02/12/problemes-de-transpiration-la-solution-se-trouve-dans-vos-chaussettes/
http://textiles.indiabizclub.com/products/fabric_products

 Flax :
http://desfleursetc.blog.pacajob.com/index.php/post/2007/10/03/Une-plante-une-fleur-un-blogueur
http://arteforkoroseal.com/product.php?pno=30112


Jute :
http://jutekorea.webs.com/
http://french.alibaba.com/product-gs/jute-non-woven-bag-328299787.html

 Cannabis :
http://tgwke.blogspot.com/2006_10_01_archive.html
http://forum.agriavis.com/viewtopic.php?id=7729

 Wool :
http://www.asia-futon.ch/Deutch/pagesD/laineD.htm
http://www.hellopro.fr/chausson-glerups-montante-2001282-1360848-produit.html
 Bibliography
 Silk :
http://fr.wikipedia.org/wiki/Cocon
http://french.alibaba.com/product-gs/100-silk-nonwoven-facial-mask-ns-m10--318810352.html

 Viscose :
http://www.bhimbros.com/wool.htm
http://www.best-b2b.com/Sub-cat/808/810/adhesive-bonded-fabric_17.html

 Cellulose :
http://www.isolation-ecologique.com/-/p/262/c/3.html
http://www.velincart.it/nappes_papier.htm


Polyamide :
http://www.fibre-maxmodel.com/fibre-polyamide.html
http://www.best-b2b.com/Sub-cat/808/830/industrial-textile_24.html


Polyester :
http://www.diytrade.com/china/4/leads/1484108/Regenerated_Polyester_Fiber.html
http://www.espacerevetements.com/fr/mur_Revetement-mural_Voile-Polyester_600810

 Fiberglas :
http://fr.academic.ru/dic.nsf/frwiki/628026
http://www.espacerevetements.com/fr/mur_Revetement-mural_Voile-de-Verre_600808

 Asbestos :
http://www.blog-economie-energie.fr/2010/05/comment-se-debarasser-de-lamiante/
http://www.expert-paca.com/diagnostics_vente.php

 Wallpaper :
http://french.alibaba.com/product-gs/painted-non-woven-wallpaper-343315725.html