1Feed the unbonded fiberweb to the needling zone (bonding zone)
feed rollers (needlepunching)
2Filled with barbed needles and given up and down motion to allow repeated needling of the fiberweb
needle board
3During needle penetration, barbs catch fibers and push them through the fiberweb thickness that provide the entanglement of fibers in the fiberweb
barbed needles
4perforated plate with a hole for each needle; supports the fiberweb during needles’ penetration
bed plate
5perforated plate with a hole for each needle; strip the fiberweb off the needles during needles withdrawal from the fiber web after each penetration
stripper plate
6deliver the needled fabric to the next stage or to take up to form fabric roller
delivery rollers (needlepunching)
7size, gage, number of barbs, barb angle, barb depth, barb spacing, kick-up
needle parameters that affect fabric properties
8needle board arrangements
single board (downward or upward), tandem boards (downwards or upwards), opposed tandem boards
9needlepunched fabric uses
automotive, filtration, roofine, geotextiles, aerospace
10needling density
d, pun/m^2
11fiberweb advance/stroke
a, m/stroke
12needling speed
n, strokes/min
13needled fabric width
w, meters
14number of needles in the needle board
m, pun/stroke
15fiberweb processing speed
v, m/min
16production of needled fabric per unit time
p, m^2/min
17needling density formula
d=punches per unit time/areas of fiberweb per unit time
18fiberweb processing speed formula
v=fiberweb advance x needling speed
19production of needled fabric/ unit time formula
needled fabric width x fiberweb advance x needling speed
20a versatile process for bonding fiberwebs to form nonwoven fabrics with aesthetics properties similar to those of woven or knitted fabrics
hydroentanglement
21jet pressure, forming wire type, fiber type, fiber to fiber friction, fibr cross section, fiber length and crimp, fiber linear density, fiber orientation, basis weight
factors influencing hydroentangled fabric properties
22hydroentangled fabric uses
aseptic barriers, medical sponges and dressings, wiping cloths, working apparel
23produced by an integrated process in which flakes of polymer is the feed material, polymer is melted and extruded onto a conveyor belt, loose web of continuous filaments is then moved to the bonding zone to impart integrity and strength to the fibrous web structure
spunbonding
24binder solution is spray on the top of the unbonded fiberweb and then dryed
spray bonding
25unbonded fiberweb goes under a highly concentrated bonder in a foam feed and then dryed and wound
foam bonding
26unbonded fiberweb goes between two smooth or engraved hot rolls to melt the fibers together
calender bonding
27unbonded web is led by a conveyorbelt or drum through hot air flow to melt the fibers together
thru-air bonding
28types of spunbonding
calendder bonding, hydroentanglement, thru-air
29spunbonded fabrics end uses
carpet backing, house wrap, geotextiles, agriculture sheet, filtration, protective clothing, bags
30high velocity air that blows a molten polymer from an extruder die tip to attenuate the filaments/fibers which causes the fiber size to be much smaller than those produced by spunbonding technology
meltblowing
31meltblowing fabric end uses
filtration, medical products, sanitary products, adult incontinence absorbant, oil adsorbents
32fiber aspect ratio
The ratio of fiber length to fiber diameter (for a cylindrical fibers)
33specific fiber surface area
The surface area of fibers expressed in area per unit weight