Fibers and Polymers 2013, Vol.14, No.5, 854-859 DOI 10.

1007/s12221-013-0854-4

Studies on Compression Behaviour of Polypropylene Needle Punched Nonwoven

Fabrics Under Wet Condition
Sanjoy Debnath* and M. Madhusoothanan1
Indian Council of Agricultural Research, National Institute of Research on Jute & Allied Fibre Technology,
Kolkata - 700 040, West Bengal, India
1
Department of Textile Technology, Anna University, Chennai - 600 025, Tamil Nadu, India
(Received October 7, 2011; Accepted September 26, 2012)

Abstract: The present study deals with the effect of parallel-laid and cross-laid web of polypropylene needle punched
nonwoven fabrics on compression properties (initial thickness, percentage compression, percentage thickness loss and
percentage compression resilience) under wet condition. These compression properties of polypropylene needle-punched
nonwoven under wet condition have also been compared with its dry condition. With the increase in needling density the
initial thickness, percentage compression and percentage thickness loss of the fabrics under wet condition decrease to higher
extent compared to its dry condition both in case of parallel-laid and cross-laid fabrics. Cross-laid nonwoven fabric presents
lower value of initial thickness percentage compression and thickness loss compared to parallel-laid fabric which is very
prominent at high needling density (350 punches/cm2). The percentage compression resilience shows increasing trend with
the increase in needling density both under dry and wet conditions of parallel-laid web. It also follows similar trend in case of
cross-laid nonwoven under wet condition. The optimum needling density for compression resilience of cross-laid nonwoven
fabric under dry condition is 250 punches/cm2.
Keywords: Compression property, Cross-laid, Dry and wet conditions, Needle-punched nonwoven, Parallel-laid, Polypropylene
fibre

Introduction poypropylene, needling density and fabric weight) under wet

Needle punched nonwoven is one of the oldest and
popular form of mechanical bonded nonwoven [1]. This
needle-punched nonwoven can be produced from parallel
laid, cross-laid or random-laid carded fibrous web [2]. The
fabric properties largely depend on the type of web laying
used in the fabric. A lot of work has been done to study the
effect of web laying on various mechanical properties of
needle punched nonwoven [1-3]. Polypropylene fibre reacts
inertly with acid as well as alkali and this makes its use
popular in the area of geotextile and technical textiles. The
fabric consolidation can be achieved either by increase in
depth of needle penetration or needling density of needle
punched fabrics [4-6]. Literature reveals that compression
properties of polyester, polypropylene, and jute-polypropylene
blended needle-punched nonwoven have been studied
thoroughly and found that compression properties depend
largely on fabric weight, needling density, blend proportion
of jute and polypropylene fibres, fibre cross-sectional shapes
and presence of reinforcing material [7-9]. Artificial Neural
Networks (ANN) have been used to model the compression
properties of needle-punched nonwoven and found that the
models can predict the compression property of needle-
punched nonwoven fabric very accurately [10,11]. Recently
there have been studies on the compression properties and
its influencing parameters (fibre cross-sectional type,
presence of reinforcing material, blend composition of jute-
*Corresponding author: sanjoydebnath@yahoo.com
condition of jute-polypropylene blended and polyester
needle-punched nonwoven fabrics [12,13]. It has been found
in these studies that compression properties under wet
condition significantly changes than under dry state. Also,
the effect of reinforcement material and fibre cross-sectional
shapes of polyester needle-punched nonwoven fabric on
compression properties under dry and wet condition differs
widely. However, there has been dearth of published work,
which encompasses the effect of web laying on compression
properties under wet condition of needle-punched nonwoven.
Hence, it is essential to understand the compression charac-
teristics of the needle-punched fabrics under wet condition
too because of its specific applications like geotextile and
carpets.
In this work, the effects of needling density and web
laying viz. parallel-laid and cross-laid on compression
properties of needle-punched nonwoven have been studied.
Polypropylene fibre is selected in this study not only due to
its inexpensiveness but also because of its wide applications
in geotextile, carpet and other industrial usages compared to
other synthetic fibres. Comparison between compression
properties of polypropylene needle-punched nonwoven under
dry and wet conditions has also been covered. Compression
properties those considered are initial thickness, percentage
compression, percentage thickness loss and percentage
compression resilience. Fabrics with same initial thickness
may have different percentage compression. Whereas fabrics
with same initial thickness as well as percentage compression,
may differ in the percentage thickness loss and compression

854
Compression of Polypropylene Needle Nonwoven in Wet Condition Fibers and Polymers 2013, Vol.14, No.5 855

resilience. Hence detailed study on compression properties the card was then fed to feed lattice of cross-lapper, and
is essential. Therefore, this study will help the manufacturers cross-laid webs were produced with cross-lapping angle of
dealing with needle-punched nonwoven. 20 o. The web was then fed to the needling zone separately
Publications on compression properties under wet condition for parallel-laid and cross-laid fabrics. The required needling
are scanty. In the present paper the compression properties density was obtained by adjusting the throughput speed.
of polypropylene needle-punched nonwoven fabrics have Combining the different webs as per fabric weight (g/m2)
been investigated under wet condition and also compared requirements, webs were passed through the needling zone
with those properties under standard condition (dry condition). of the machine for a number of times depending upon the
Hence, it is essential to understand the compression punch density required. A punch density of 50 punches/cm2
characteristics of the needle-punched fabrics under wet was given on each passage of the web. The face of the web
condition because of its specific applications as geotextile on which punching was done was reversed in alternate
and in carpets. passage. The parallel-laid and cross-laid fabric samples were
produced as per the fabric weight and needling density
Materials and Methods required shown in Table 2. The depth of needle penetration
was kept constant at 11 mm. For all webs, needles of
Material 15×18×36×R/SP, 3½×9 was used.
The polypropylene fibre with fineness of 0.44 tex, 80 mm Measurement of Compression Properties
length was used for preparation of the needle punched To study the compression behaviour of polypropylene
nonwoven samples. Properties of this fibre are shown in the needle punched non-woven fabric under wet condition,
Table 1. samples were cut into pieces of 25×25 cm [12,13] and
soaked in distilled water for a period of 24 h before
Methods conducting the experiment. Distilled water has been taken as
Fabric Preparation identical laboratory material for wetting the samples [12,13].
A roller and clearer card was used to develop the webs for This is used only during comparative study of compression
the polypropylene nonwoven fabric samples. The fibres properties under dry and wet conditions, though in practical
were fed to the lattice of the roller and clearer card at a situation the water quality varies. Polypropylene fibre is
uniform and predetermined rate so that a web of 50 g/m2 can highly hydrophobic in nature and hence a negligible amount
be achieved. The carded fibre web emerged out from the of water can be absorbed by the fibres. However, 24 h is
card was allowed to wound on a drum to obtain the parallel- allowed for uniform adsorption of water between polypropylene
laid web. The number of such layers are then fed to the fibres in the fabric before testing. After 24 h of soaking in
needling zone based upon the fabric weight required (Table distilled water the polypropylene fabric samples were passed
2). In case of cross-laid web, fibrous web emerging out from through a pair of padding mangle with a uniform pressure
exerted upon them by applying a constant load on either side
Table 1. Properties of polypropylene fibres of the top roller. The pressure of 1 kPa between the padding
Property Polypropylene
mangles and their speed of 5 m/min were kept constant. This
pressure and speed were selected in such a way that uniform
Fibre fineness (tex) 0.44
water pickup was maintained in the samples by removing
Density (g/cm3) 0.91
only the excessive water, without affecting the fibre cross-
Tensile strength (cN/tex) 34.5 sectional shapes. Under this condition, water pickup of about
Breaking elongation (%) 54.13 550 % on dry weight of the sample has been maintained in the
Moisture regain (%) at 65 % RH 0.05 fabrics before testing [13,14]. Then, the sample was tested
Moisture regain (%) at 100 % RH 0.05 immediately in a room, which was under the standard testing
conditions. The initial thickness, compression, thickness loss
Table 2. Constructional details of the fabrics and compression resilience were calculated from the compression
Fabric Fabric weight Needling density Web laying* and decompression curves. For measuring these properties, a
code (g/m2) (punches/cm2) P or C thickness tester was used [9,14]. The pressure foot area of
1 393 150 C thickness gauge used was 5.067 cm2 (pressure foot diameter=
φ2.54 cm). The dial gauge with a least count of 0.01 mm and
2 396 150 P
maximum displacement of 10.5 mm was attached to the
3 410 250 C
thickness tester. The compression properties were studied
4 406 250 P
under a pressure range between 1.55 kPa and 51.89 kPa [7-
5 392 350 C 10,12,13].
6 393 350 P The initial thickness of the needle-punched fabrics was
*
(P) parallel laid and (C) cross laid. observed under the pressure of 1.55 kPa [12,13]. The
856 Fibers and Polymers 2013, Vol.14, No.5 Sanjoy Debnath and M. Madhusoothanan

work done during compression, and Wc', the work done

during recovery process. Wc and Wc' were calculated
separately from the area under the curves using a computer
programme [7,12].
The average of ten readings from different places for each
sample was considered. The coefficient of variation was less
than 6 % in all the cases.
Compression properties under dry condition were carried
out in the standard atmospheric condition maintained at
65 % ±2 % RH and 20 o ±2 oC [15] as fibre properties
changes with varying temperature and relative humidity. The
fabrics were conditioned for 72 h in the above mentioned
atmospheric conditions before testing.
Figure 1. General nature of compression recovery curve of needle
punched polypropylene fabric under wet condition.
Results and Discussion

corresponding thickness values were observed from the dial
gauge for each corresponding load of 1.962 N. A delay of 30 s
was given between the previous and next load applied.
Similarly, 30 s delay was also allowed during decompression
cycle at every individual load of 1.962 N. This compression
and recovery thickness values for corresponding pressure
values were used to plot the compression-recovery curves.
Figure 1 shows the general nature of compression-recovery
curves of polypropylene needle-punched nonwoven fabric
under dry and wet conditions.
The percentage compression, percentage thickness loss
and percentage compression resilience under dry and wet
conditions were estimated separately using the following
relationships [7-10,12,13]:
T0 – T 1
- × 100
Compression (%) = --------------
T0
T0 – T2
- × 100
Thickness loss (%) = --------------
T0
Wc ′ – Wc
- × 100
Compression resilience (%) = -------------------
T0
Where, T0 is the initial thickness, T1, the thickness at
maximum pressure, T2, the recovered thickness, Wc , the
The Table 3 presents the effect needling density and types
of web laying on compression properties. The compression
properties studied are initial thickness, percentage compression,
percentage thickness loss and percentage compression resilience.
This table also represents the percentage difference between
dry and wet conditions of each compression properties
separately. Figures 1-4 represent the effect of needling
density, web laying types (cross-laid and parallel-laid)
polypropylene needle-punched nonwoven under dry and wet
conditions.
Effect of Dry-Wet Conditions, Web Laying (Parallel
Laid and Cross-Laid) and Needling Density on Initial
Thickness
Table 3 presents the effect of web laying (parallel-laid and
(1) cross-laid) and needling density on initial thickness of
polypropylene needle-punched nonwoven under dry and wet
conditions of the fabric. Under wet condition the initial
(2) thickness of the fabrics are lower compared to its dry
condition irrespective to web laying types (Figure 2). This is
due to formation of consolidated structure under wet
(3) condition. Around 30 % of reduction in initial thickness of
the fabric has been observed in case of cross-laid web
nonwoven under dry condition compared to parallel-laid
fabric with the increase in needling density from 150 to 350

Table 3. Effect of web laying types (parallel laid and cross laid) on compression properties under dry and wet state
Fabric Initial thickness (mm) Compression (%) Thickness loss (%) Compression resilience (%)
code D W %∆ D W %∆ D W %∆ D W %∆
1 5.87 5.85 0.34 54.92 52.80 3.86 25.05 24.46 2.36 28.56 29.58 -3.57
2 6.64 6.57 1.05 55.57 53.45 3.82 27.20 27.08 0.44 28.76 28.02 2.57
3 5.07 4.98 1.78 38.07 37.54 1.39 17.87 17.60 1.51 34.12 33.94 0.53
4 6.64 6.49 -2.26 57.49 56.61 1.53 28.29 27.52 2.72 29.31 28.30 3.45
5 4.08 4.25 -4.17 37.51 36.02 3.97 17.40 16.57 4.77 25.05 35.02 -39.80
6 5.72 5.67 0.87 52.38 51.21 2.23 24.85 24.62 0.93 29.82 28.56 4.23
(D) dry condition, (W) wet condition, and (%∆) percentage difference.
Compression of Polypropylene Needle Nonwoven in Wet Condition
Figure 2. Effect of dry-wet conditions, web laying types and
needling density on initial thickness of polypropylene needle-
punched nonwoven.
punched/cm2. During needling, the degree of fabric consolidation
depends on the amount of fibres plucked by the needle barbs
[4]. In case of cross-laid web, the amount of fibres plucked
by the needle barbs during each needling process is higher
than parallel-laid web. This forms higher amount of fibre-to-
fibre entanglements. As a result, with the increase in
needling density decrease in fabric thickness in case of
cross-laid web is much higher compared to parallel-laid
web.
Effect of Dry-Wet Conditions, Web Laying (Parallel
Laid and Cross-Laid) and Needling Density on Percent-
age Compression
The decrease in percentage compression under wet
condition is much higher in the case of cross-laid fabric
samples (Figure 3) compared to parallel-laid fabric sample
with the increase in needling density. This effect is very
prominent at high needling density (350 punches/cm2). In
general, the percentage compression decreases with the
increase in needling density from 150-350 punches/cm2.
With the increase in needling density, there is better
entanglement in case of cross-laid web compared to parallel
laid web and as a result fabric consolidation is high [4,9].
During compression pressure, because of consolidated structure
in cross-laid fabric, the fabric compressibility is less.
However, for the same pressure in case of parallel-laid
fabric, the compression is high. Irrespective to fabric laying
Figure 3. Effect of dry-wet conditions, web laying types and
needling density on percentage compression of polypropylene
needle-punched nonwoven.
Fibers and Polymers 2013, Vol.14, No.5 857
type, under wet condition percentage compression is low
than its dry state. Under wet condition, percentage compression
of polyester needle-punched nonwoven fabrics of different
fibre cross-sections are also less compared to its dry state as
found from the literature [12]. Due to capillary action the
water component enters in the fabric structure under wet
condition. Hence, during compression cycle, the water
components present in the fabric structure act as lubricant
and reduce the fibre-to-fibre friction as a result compression
deformation increases [12]. Thus, more amount of deformation
can be obtained under wet condition compared to its dry
condition keeping other parameters constant. Hence, the
percentage compression is found lower under wet condition
both in parallel and cross-laid structure at all levels of
needling density.
Effect of Dry-Wet Conditions, Web Laying (Parallel
Laid and Cross-Laid) and Needling Density on Percent-
age Thickness Loss
Table 3 depicts the effect of web-laying (parallel-laid and
cross-laid) and needling density on percentage thickness loss
of polypropylene needle-punched nonwoven under dry and
wet conditions of the fabrics. Figure 4 shows that the
percentage thickness loss values are lower under wet condition
irrespective to fibre laying types. Under wet condition, the
water pickup by the fabric is mostly due to capillary action
[12] as the fibre component (polypropylene) is hydrophobic
in nature (Table 1). The water component acts as lubricant
and reduces fibre-to-fibre friction in the fabric structure.
Thus, during compression phase more amount of deformation
takes place. Similarly, in decompression phase, due to
removal of compression load from the fabric surface, many
of the fibers return back to their original position because of
presence of residual energy in the fibers [7,13]. Under wet
condition, the water acts as lubricant which reduces friction
among the fibre compared to its dry condition. Hence, the
percentage thickness loss is less under wet condition than its
dry state. Cross-laid web presents lesser percentage thickness
loss compared to parallel-laid web fabric samples as
depicted from the Figure 4. In case of cross-laid webs, fibres
orientation is in bi-directional in the fabric. This causes
better entanglement of fibres during the process of needling
Figure 4. Effect of dry-wet conditions, web laying types and
needling density on percentage thickness loss of polypropylene
needle-punched nonwoven.
858 Fibers and Polymers 2013, Vol.14, No.5
compared to parallel-laid web consisting fibres of unidirectional
orientation [9]. Better-entangled fibres have less probability
of slippage during compression deformation. During decom-
pression phase when compression load is removed, the
recovery from the deformation is better due to higher fibre-
to-fibre entanglement in case of cross-laid web compared to
parallel-laid web structure.
Effect of Dry-Wet Conditions, Web Laying (Parallel
Laid and Cross-Laid) and Needling Density on Percent-
age Compression Resilience
The percentage compression resilience shows increase in
trend with the increase in needling density both under dry
and wet conditions of parallel-laid web (Figure 5). In case of
parallel-laid nonwoven, fibres are stacked one above another
mostly in parallel fashion. This occupies more space for
same number of fibres per unit area of fabric compared to
cross-laid needle punched nonwoven. Hence, to achieve
consolidation by needling, parallel-laid web nonwoven
requires higher amount of needling compared to cross-laid
needle-punched nonwoven. The percentage compression
resilience depends on the residual repulsion energy generated
during compression of the fibres in the fabric structure [16].
Due of insufficient entanglement of fibres obtained with the
increase in needling density from 150-350 punched/cm2,
there is mild increase in percentage compression resilience
observed in case of parallel-laid fabrics. However, in case of
cross-laid needle punched nonwoven under dry condition,
the optimum needling density is 250 punched/cm2 and
beyond which the fibre damage occurs [9]. This causes drop
in compression resilience under dry condition. With the
increase in needling density, cross-laid fabric under wet
condition shows increase in trend of percentage compression
resilience. At high needling density (350 punches/cm2),
there is wide difference in percentage compression resilience
compared to its dry state as found from Figure 5. As the
needling process was done under dry condition, beyond the
optimum needing density (250 punches/cm2) the fibres are
under stretched condition in the form of entanglement in the
fabric structure. However, under wet condition due to
presence of water and residual energy in the fibres because
Figure 5. Effect of dry-wet conditions, web laying types and
needling density on percentage compression resilience of
polypropylene needle-punched nonwoven.
Sanjoy Debnath and M. Madhusoothanan
of excessive needling, fibre-to-fibre slippage occurs as the
surface friction of fibres reduces. Since, the fibres are in
relaxed phase even at high needled fabric under wet
condition, a portion of energy spent by the fibres during
compression are utilized to its maximum extent during
decompression phase. Because of this reason, the cross-laid
polypropylene needle-punched nonwoven behaves differently
under dry and wet conditions.
Conclusion
Following conclusions can be drawn from the discussions
made on the results obtained in the studies on compression
properties under dry and wet condition of polypropylene
needle-punched non-woven fabrics.
Under wet condition with the increase in needling density
from 150 to 350 punches/cm2 decrease in initial thickness,
percentage compression and percentage thickness loss of the
fabrics are high compared to its dry condition irrespective to
web-laying types. Cross-laid nonwoven fabric presents
lower value of initial thickness percentage compression and
thickness loss compared to parallel-laid fabric. However,
this effect is very prominent at high needling density (350
punches/cm2). Around 30 % of reduction in initial thickness
of the fabric has been observed in case of cross-laid web
nonwoven under dry condition compared to parallel-laid
fabric with the increase in needling density from 150 to 350
punched/cm2. The percentage compression resilience shows
increasing trend with the increase in needling density both
under dry and wet conditions of parallel-laid web. It also
follows similar trend in case of cross-laid nonwoven under
wet condition. Percentage compression resilience of cross-
laid fabric under dry condition initially increases up to
needling density of 250 punched/cm2 and it dropped down
with further increase in needling density.
Acknowledgement
One of the authors (S D) is grateful to the Director of
NIRJAFT, for encouragement and valuable support and is
also thankful to CSIR, New Delhi, India for awarding Senior
Research Fellowship during this project work.
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