INTRODUCTION

 The term ‘nonwovens’ arises from at least half a century ago, when the materials were
often regarded as low-price substitutes for traditional textiles and generally made from
carded, staple fibers on converted textile processing machinery.
 The yarn spinning stage is omitted in the nonwoven processing of staple fibers, with
bonding of the web by various methods – chemical, mechanical or thermal – replacing
the weaving or knitting together of the yarns in traditional textiles.
 In dividing today’s nonwoven products into three major areas – dry laid, wet laid, air
laid or spun – it can generally be said that dry laid materials have their origins in textiles,
wet laid materials in papermaking, and spun laid products in polymer extrusion and
plastics.
 The conventional fabric production is
FIBER YARN FABRIC
 Non woven fiber production
Fiber Fabric
 It eliminates the yarn production process and makes the fabric
directly from the fibers.
 The greatest advantage in nonwoven fabric is the speed with which
the final fabric is produced.
 To produce 500,000 meters of woven sheeting requires 2 months of
yarn preparation,3 months of weaving on 50 looms and 1 month for
finishing and inspection.
 Non woven fabric can deliver the same quantity
of sheeting within 2 months from order.
 Not only are production rate are higher for
nonwoven but the process is more automated,
requiring less labor than knitting or weaving
systems.
 It makes the fabric directly from fibers. It
eliminates the yarn production process.
 HISTORY OF NONWOVEN
 The process of stitch bonding – which originated in Eastern Europe in the
1950s and is still used for some industrial applications – employs both layered
and consolidating yarns, just to prove this point.
 In 1930 a few textile companies began experimenting with bonded materials as
a way of utilizing cotton waste, which next resulting non woven fabric
manufacturing.
 The first commercial production of non woven fabrics began in 1942 in the
United States. Actually it was the result of effort of manufacturing of fabric
directly from fibers.
 The market of non woven products has experienced tremendous growth and has
potential for more.
 The nonwovens industry is highly profitable and very
sophisticated, with healthy annual growth rates – often in double
digits in certain sectors and parts of the world.
 It is perhaps one of the most intensive in investing in new
technology, and also in research and development.
 In nonwoven manufacturing systems, the fibre material or
extruded thermoplastic is deposited or laid on a forming or
conveying surface, and the physical environment at this phase
can be dry, quenched in air, wet or molten – drylaid, wetlaid or
spun.
 A key trend observed over the past twenty years has been a tremendous shift –
especially for the hygiene and medical markets – away from dry laid techniques to
the spun laid route, to the extent that the latter now account for well over 40% of
nonwovens manufactured worldwide. Another trend currently having a significant
impact is that of incorporating nano fibre nonwoven layers into products – most
notably, to date, in the area of filtration fabrics.
 The next major change is likely to be a shift away from petrochemical-based
polymers and fibres towards biobased alternatives such as polylactic acid (PLA),
for some, if not all, technologies.
 It can safely be said that it has the industry’s attention, and is currently the subject
of expansive research and development (R&D) on the part of both technology
suppliers and nonwovens manufacturers.
WORLD NONWOVEN PRODUCTION BY REGION

Global nonwovens production at over

1,500,000 tons in North America,
over 2,000,000 tons in China
, and around 2,500,000 tons in Europe.
 DEFINITION OF NONWOVENS
 INDA, North America’s Association of the Nonwoven Fabrics Industry, describes
nonwoven fabrics as ‘sheet or web structures bonded together by entangling
fibres or filaments, by various mechanical, thermal and/or chemical processes.
DEFINITION OF NONWOVENS

Nonwoven fabrics are broadly defined as sheet or web structures

bonded together by entangling fiber or filaments (and by
perforating films) mechanically, thermally, or chemically. They are
not made by weaving or knitting and do not require converting the
fibers to yarn. The binding process usually occurs through the
pressing of fibres together with an adhesive, chemical binder, heat,
ultrasonic pattern bonding.

A manufactured sheet, web or batt of directionally or randomly

orientated fibres, bonded by friction, and/or cohesion and/or
adhesion, excluding paper and products which are woven, knitted,
tufted, stitch-bonded incorporating binding yarns or filaments, or
felted by wet-milling, whether or not additionally needled. The
fibres may be of natural or man-made origin.
 PROPERTIES OF NON WOVEN
Nonwovens are in fact products in their own right with their own characteristics and performances, but also
weaknesses.
Nonwovens can be made
 absorbent
 breathable,
 drapeable,
 flame resistant,
 heat sealable,
 light, lint-free,
 mouldable,
 soft, stable,
 stiff, tear resistant,
 water repellent,
Obviously though, not all the properties mentioned can be combined in a single nonwoven, particularly those that are
contradictory.
 APPLICATIONS OF NONWOVEN FABRICS
Applications Examples of Use Technologies Employed

Absorbent Baby diapers, feminine hygiene products, and adult Air-laid, carded nonwovens,
hygiene incontinence products spunmelt (SMS, spunbond)
products
(AHP)
Agriculture Crop covers, plant protection Seed blankets, weed Needle punched, spunbond
and control fabrics, greenhouse shading, root control
horticulture bags, biodegradable plant pots, capillary matting,
landscape fabric
Automotive Headliner, dashboard insulation, carpets and Needle punched, spunlace,
flooring, seats, interior trim, cabin air filters, thermally bonded, spunbond
airbags, wheel housing, dashboard insulation, hood
insulation, filtration, heat shields, parcel shelf, boot
liners, boot floor covering, boot carpets
plications Examples of Use Technologies Employed

uilding Insulation (thermal and noise), house wrap, roofing, Dry-laid, needle punche
covers for acoustic ceilings, air infiltration barrier, vapor spunlace, thermobonded,
barrier, flooring substrates, facings for plaster board, spunmelt
pipe wrap, concrete molding layers, foundations and
ground stabilization, vertical drainage
eotextiles Road and rail building, dam, canal and pond lining, Dry-laid, needle punche
hydraulic works, sewer lines, soil stabilization and spun-laid
reinforcement, soil separation, drainage landfill,
filtration, sedimentation and erosion control, weed
control, root barriers, sport surfaces, asphalt overlay,
impregnation base, drainage channel liners

ersonal care Baby wipes, facial wipes, cleansing wipes, hand and Air-laid, spunlace, wet-lai
ipes body wipes, Wet Wipes, personal hygiene wipes,
feminine hygiene wipes, antibacterial wipes, medicated
wipes.
Filtration Engine air, oil, fuel, cabin air, HVAC—industrial Air-laid, electrospun,
heating, ventilation, and air-conditioning, meltblown, needle punched,
industrial consumer products, clean rooms, food spunbond,
and beverage, pharmaceutical/medical, water, spunlace, thermobonded,
blood, hydraulic, antimicrobial, wet-laid
biopharmaceutical, dust, odor
Household Bed linen, blinds/curtains, carpet/carpet backings, Needle punched, spunbond,
covering and separation material, detergent wet-laid
pouches/fabric softener sheets, flooring, furniture/
upholstery, mops, table linen, tea and coffee bags,
vacuum cleaning bags, wall covering, wipes

Medical Disposable caps, gowns, masks, scrub suits and Dry-laid, spunlace, meltblown,
shoe covers, drapes, wraps and packs, sponges, spunbond
dressings and wipes, bed linen, contamination
control gowns, examination gowns, lab coats,
isolation gowns, transdermal drug delivery,
shrouds, underpads, procedure packs, heat packs,
ostomy bag liners, fixation tapes, incubator
mattress, sterilization wraps, wound care,
cold/heat packs, drug delivery
Flame retardant Protective garments, Fire- Fire protective clothing for
nonwovens blockers for seat and upholster, firefighters consists of at least
four layers: outer and inner
shell, moisture barrier, and
thermal. These layers are
expected to provide adequate
heat, flame, liquid, chemical
and mechanical protection.

Leisure & Travel Sleeping Bags, Luggage,

Handbags,Shopping Bags
Airline Headrests,Pillowcases
Sandwich Packaging,Tents, Food
Delivery,CD Protection,Surf
Boards
 NONWOVENS FOR APPAREL AND FASHION
APPLICATIONS:
 Woven and knitted fabrics are widely employed in apparel and fashion applications.
Nonwoven fabrics find some application in disposable sector and are mostly employed as
components of durable applications. The key areas of applications include interlinings,
protective clothing, shoe linings, and synthetic leather.
 Going into the history of disposable dresses, Scott Paper Company introduced paper
dresses in 1966 and sold more than half a million in less than a year. The dress was
actually part of an advertising campaign and included yarn reinforcement.
 Following the trend, other companies also launched paper products, including evening
dress, wedding gown, water proof rain coats, bikinis, and paper suits;
 Miratec fabrics by Polymer Group International are textured hydro
entangled fabrics and offer applications in durable apparel.
DuPont introduced the spun bonded olefin, TyvekR, which is a
lightweight protective apparel and has achieved a lot of
commercial success. TyvekR-based jackets are also offered but not
in the mainstream.
 EvolonR by Freudenberg is another notable example.
 EvolonR is made from splittable bicomponent fibers, which are
split during hydroentanglement resulting in microfilament fabric
and the fabric is claimed to be processed like a traditional fabric.
 Though nonwovens have some degree of success in commercialization of limited-use
apparel but, in general, struggle to meet the properties required for the durable applications.
 Fabric drape, handle, elastic recovery, and abrasion resistance are important for applications
of nonwovens in main stream apparel.
 Nonwoven technology has advanced and fabrics with desirable properties for apparel
applications are being developed.
 For example, hydroentangled fabrics provide better drape characteristics than other available
nonwoven fabrics as the entanglement and twisting mechanisms during hydroentangling are
superficially similar to the twist in yarns.
 Furthermore, the use of post processing methods, especially coloration approaches,
functional finishes, and joining techniques, are the key to develop nonwovens for durable
apparel applications.
WHAT IS WOVEN FABRIC?
It has a long history ever since the mankind began to woven cloth with hemp
and silk thousands of years ago. Along with the rapid development of textile
technology, various types of material such as cotton, silk, linen, wool,
chemical fiber and more have been used for weaving cloth. The woven
fabric is textile formed via loom with threads woven on a warp and a weft.
Through different weaving equipment and processing technology, the weft
and warp threads are interlacing together according to different thickness
and density.
WHAT IS NONWOVEN FABRIC?

Comparing with the woven fabric, the history of nonwoven fabric is short
that it has been applied in our life since last century. Nonwoven fabric is
produced with staple fiber and long fibers bonding together through
chemical, mechanical, heat and other manufacturing techniques. It is a
fabric that does not need to be spun and woven.
 FIVE DIFFERENCES BETWEEN WOVEN AND
NONWOVEN FABRIC
1. Material

Woven and nonwoven fabric has great differences in the raw material that the woven fabric is
made with cotton, wool, silk, linen, ramie, hemp, leather and etc. while the nonwoven is made
out of polypropylene (abbreviated to PP), PET, PA, viscose, acrylic fibers, HDPE, PVC and etc.

2. Manufacturing Process

Besides, the manufacturing process between woven and nonwoven fabric is also different. The
woven fabric is weaved with looms by interlacing warp and weft threads, when the nonwoven
fabric is directly bonding fibers together by physical means. The nonwoven has no weft and warp
yarn that doesn't need to be interlaced or knitted.
3. Durability

Another great difference between woven and nonwoven is the durability. Usually, the woven
cloth appears more durable than the nonwoven fabric, and the products made by woven
fabric have longer service life. The fibers of nonwovens are arranged in a certain direction,
which is easily splitted from the right angle.

4. Degradability

It is reported that the chemical structure of polypropylene is not strong and the molecular
chain can be easily broken, which means that the nonwoven fabric can be effectively
degraded to the next cycle in the non-toxic form. As reported, a non-woven shopping bag
can be completely decomposed within 90 days in outdoor conditions and 8 years in indoor
conditions. Different to nonwoven, the woven fabric has more stable features with excellent
durability that it can not be degraded naturally as fast as nonwovens.
5. Usage

Lastly, there are great differences in usage between woven and

nonwoven fabrics.The woven fabrics are strong and structurally
sound, widely used to create various kinds of clothes, bedding sets,
sofa, towels and etc.

The nonwoven fabric are lightweight and eco-friendly, widely used

for manufacturing all sorts of recyclable or disposable items such
as surgical gown, facial masks, diapers, wallpaper, industrial filters,
shopping bags and so on.
 MAJOR FIBERS USED IN NONWOVEN
 Nonwovens are textile fabrics consisting of separated fibres which are arranged properly by means of
enduse-oriented technologies. In order to guarantee serviceability of the finished product, they are
bonded.
 For this reason the choice of fibres and possibly bonding materials is of special importance: This relates
to fibre raw materials.
 Virtually all kinds of fibres can be used to produce nonwoven bonded fabrics.
The choice of fibre depends on
– the required profile of the fabric and
– the cost effectiveness
To produce nonwoven bonded fabrics
– chemical fibres of both cellulosic and synthetic origin as well as
– natural fibres and
– inorganic fibres
 The commonly used fibers include natural fibers (cotton, jute, flax, wool),
synthetic fibers (polyester (PET), polypropylene (PP), polyamide, rayon), special
fibers (glass, carbon, nanofibers,bicomponent, superabsorbent fibers), etc .
 Two or more types of fibers are typically utilized. The fibers are usually
blended or mixed in order to improve performance properties of nonwovens, such
as strength and other properties.
 The fiber blend or mix can be natural/natural, synthetic/synthetic, or
natural/synthetic .
 Man-made fibers are the most widely used in the nonwoven industry.
 Owing to impurities and higher costs, natural fibers are of minor importance
for the production of nonwovens.
 Web cohesion, fiber breakage, and web weight uniformity are the
key quality parameters and are influenced by fiber diameter, fiber
length, fiber tensile properties, fiber finish, and crimp.
 The properties of nonwoven fabrics are largely dependent on fiber
properties and fabric structural geometry.
 All kinds of fibers can be used to produce nonwoven fabrics. The
selection of fibers is based on the following features
• the cost-effectiveness,
• the ease of processability, and
• the desired end-use properties of the web.
 NATURAL FIBRES
Vegetable fibres
 The most important constituent of vegetable fibres is cellulose, which is hydrophilic and
hygroscopic. Apart from cellulose, vegetable fibres also consist of several other substances which
affect their properties.
 Cotton is the most important vegetable fibre used to produce nonwoven bonded fabric
 All varieties of cotton belong to the mallow family. To grow properly, the plants need moisture as
well as dry heat alternately at the right times. Cotton is an annual plant and grows to a height of
approximately 1 m to 2 m.
 It grows fruit the size of walnuts which contain seeds covered with cotton fibre. The ripe fruit
shells burst open and the cotton swells out in thick white flocks.
 The crop is usually harvested by machine, so that the cotton fibres are more likely to become
contaminated than if harvested by hand. After harvesting, the seeds are removed with cotton gins
and the cotton is packed into bales.
 The short fibres (linters) are removed by means of specialized machines
and are used to produce a wide range of products, including the raw
material for the production of cupro and acetate fibres.In fact, linters are
also used in the production of nonwoven bonded fabrics.
Raw cotton contains:
– cellulose (80% to 90%)
– water (6% to 8%)
– waxes and fats (0.5% to 1.0%)
– proteins (0% to 1.5%)
– hemicelluloses and pectins (4% to 6%)
– ash (1% to 1.8%)
The quality of cotton and hence the grading depend on the following qualities:
– fibre length (10 mm to 50 mm)
– linear density (1.0 dtex to 2.8 dtex)
– colour
– purity (trash and dust)
– tensile strength (25 cN/tex to 50 cN/tex)
– elongation (7% to 10%)
Cotton, as a natural cellulosic fiber, has many characteristics, such as:
• comfortable,
• good absorbency,
• good color retention,
• well printable,
• machine-washable,
• dry-cleanable,
• good strength,
• well drapeable and
• easy to handle and sew.
 The cotton fibres have to be scoured in an alkaline solution and/or have to be bleached to
obtain the proper qualities and purity standard required for various purposes. cottons
shape and structure make it suitable for use for the production of nonwoven bonded
fabric:
 Cotton has a ribbon-shaped cross-sectional form, a spiral twist, a hollow structure, a high
wet strength for a high module and it is hygroscopic.
 Thus its use for the production of nonwoven bonded fabrics met with a fair degree of
success in the early years. Its success, however, faded quickly because of the impurities
which affected the production and even the quality of the finished product.
 This problem could not be solved, for it is impossible to remove all impurities during the
production process or counteract their effect. This technical problem caused the noted
decline of cotton usage in the production of nonwoven bonded fabrics.
 JUTE
 After cotton, jute is the natural fiber with the second highest production volume. Chemically, the jute is
a highly lignified fiber, which consists of the following:
• cellulose (60%),
• hemicellulose (26%),
• lignin (11%),
• proteins (1%),
• waxes and fats (1%), and
• ash (1%).
 Producing of a compound with the substances cellulose and bastose is differ from bast fibers.
 Jute is a significant fiber for special applications of nonwoven bonded fabrics. It is mostly used because
of its inexpensiveness and good physical properties:
• floor coverings in basic materials,
• base and intermediate layer of tufted floor coverings, and
• upholstery filling pieces
 FLAX

 Flax is the one of the oldest cultivated plants with a cultural importance
dating to prehistorical periods. Linseed was first found in the former
Mesopotamia. Fragments, linseed, and capsules are estimated to be from the
eighth millennium.
 Flax was discovered during the excavation of Ali Kosh in Iran. In old
Egyptian graves and seaside settlements in Switzerland, linen fabrics and
mummification bandages were found. They originated around 5000-3000
B.C. The oldest fabric fragment found to date is from a settlement in ancient
Egypt
 There are wild-growing, small herbaceous perennials and cultivated annual flax plants.
Flax is cultivated worldwide in tropical and cold climate zones.
 Fiber flax grows in humid,moderate climates, whereas oil flax grows in dry, warm
areas. The harvest reaps approximately 4000 kg/ha. The fibers are embedded in the
parenchyma of the stem in a high concentration and are freed by retting.
 Then the flax is washed, dried, and broken to loosen the brittle wood from the bast and
to separate the fibers from each other. The wooden parts are removed by means of
scotches . Finally, the fibers are combed by means of hackles. The properties of
technical fibers and single fibers have to be distinguished. The technical fiber is 200-
800 mm in length and composed of a fiber bundle.
 It has a fineness of about 10-40 dtex. The single fiber has a length of 7-42
mm depending on its location in the stem, its diameter is about 15-37
μm,and the density lies between 1.43 (raw) and 1.52 g/cm3 (bleached). The
maturity of the fiber is determined by harvesting time.
 Good fiber profit with good fiber quality may be obtained at the time of
yellow maturity. The relative strength fluctuates between 30 and 55 cN/tex.
For all these properties, flax fiber is used for nonwoven bonded fabrics,
mostly for the fabrication of filling pieces.
 WOOL
 Wool is the most important animal fiber used in
manufacturing nonwoven bonded fabrics. It is used
mainly as reclaimed wool or cuttings because of its high
price.
 The variation in quality and the impurities in reclaimed
wool as well as the chemical and physical properties
determined by its provenance impose restrictions on its
use .
 Wool is a suitably stiff and permanently crimped bi-component fiber. The
distinct variations in thickness are in most cases favorable to produce
nonwovens .
 Wool fiber is initially used to make felt. The wool fibers are then pressed
into a flat sheet and subjected to moisture, heat, and agitation.
 The scaly structure of the wool fiber causes the fibers to interlock and mat.
 Animal felts have been used since ancient times. Traditional felting method
is still used for producing clothing item such as hats, slippers, interlinings
and handbags. In addition to traditional felting method, modern pressed
felting techniques are used in a wide range of industrial applications.
 These products are used for polishing metals, optical surfaces plastics, and
jewelry, and in manufacturing seals, gaskets, washers, felt nibs and markers,
air and liquid filters, oil wicks, piano cushion felts, shoes, toys, pennants,
table covers, notice boards, bookbinding, furniture components and
orthopedic appliances.
 Wool is not only used for producing felts but also used for producing
needle-punched, hydroentangled, thermally and chemically bonded fabrics.
In recent years, the production of serviceable, lightweight wool fabrics of
70-150 g/m2 for apparel applications using a process known as
hydroentanglement has been commercialized.
 Man-made fibers such as polyester, polypropylene, viscose rayon, and
blends containing cotton, wood pulp, and other fibers can be used for
producing hydroentangled bonded fabrics in the medical and hygiene
industries.

 VISCOSE AND LYOCELL

 Regenerated cellulosic fibers such as viscose and lyocell also have nonwoven hygiene, wipes
and incontinence applications, for virtually the same reasons that make cotton suitable for those
uses, but also because their production conditions are not conducive for microbial growth -- an
advantage as well for many other applications.
 Technical applications include electrical insulation, automotive and filtration; as well as medical
drapes, swabs and wound dressings. Nonwoven processes used include spunlace, needlepunch and
chemical bonding.
 In the filtration arena, Lenzing Viscose has long been used in food and beverage applications;
while Tencel, with its tendency to fibrillate, is being promoted for automotive fuel and oil filters,
cigarette filters, and industrial air and liquid process filters.
 Lenzing reports Tencel's properties include significantly increased wet strength and low linting in
addition to the absorbency, softness and breathability that are inherent in both Lenzing Viscose and
Tencel.
 Viscose, Tencel and lyocell are spunlaced for hygiene, wipes and other personal care
products, as well as for gauzes and face masks. They may be blended with polyamide
or polyester into spunlaced coating substrates, such as for artificial leather.
 Low-linting lyocell and Tencel also can be used for clean room wipes.
Needlepunched viscose, Tencel and lyocell, alone or in blends, have applications in
hygiene and medical products, wipes, coating substrates and artificial leather.
Chemical bonding applications include medical drape, food contact, interlining and
household wipes.
 MAN-MADE FIBERS
Polyester
As its name indicates, this type of fiber consists of macromolecules of esters
which are chemicals made of acids and alcohol . If many of these basic
molecules are combined, they will form polyesters .The earliest study on
polyester was conducted by W.H. Carothers at DuPont in the early 1930s,which
is comparable to the present-day studies on condensation polymers.
They are inexpensive, easily produced from petrochemical sources, and have a
desirable range of physical properties. They are strong, lightweight, easily
dyeable and wrinkle resistant, and have very good wash wear properties.
Therefore, it is mostly used in nonwoven production. Cross-sectional polyester
fibers are used in the following three major areas
• Apparel: Every form of clothing;
Home Furnishings: Carpets, curtains, draperies, sheets and pillowcases, wall coverings, and
upholstery; and
 Other Uses: Hoses, power belting, ropes and nets, threads, tire cords, auto upholstery, sails,
floppy disk liners, and fiberfill for various products including pillows and furniture.
 Surgeons’ gowns, for example, were once woven from linen but are now for the most part
made from repellant-treated entangled polyester fiber pulp composites on spun-bond melt-
blown laminates.
 These new gowns are far superior to the older material in providing a breathable barrier
between the surgeon and the patient, which serves to significantly reduce hospital infections.
 Spun-lace mattress pad facing (100% polyester) continues to be the replacement for spun-
bonded material because of the textile-like character of entangled fiber fabrics.
 Polyethylene terephthalate (PET) has become the most important polymer type of fibrous
prostheses.
 It is reasonably inert, biocompatible, flexible, and resilient and has an appropriate level
of tissue acceptance.
 However, polymerization initiators, antioxidants, titanium dioxide, and other
impurities should be minimized to improve its biocompatibility .
 Polyester is less flammable than cellulosic fibers because it melts while coming in contact
with the flame.
 Crystar, a DuPont trade name, is used to produce as a polyester spunbonded
fabrics .
 Among the bi-component fibers, polyester is the most used fiber. Because of its
increasing strength and soft hand of the nonwoven fabric, polyester is used in
continuous bi-omponent filaments having a sheath component made of linear low-
density polyethylene (PE) and a core component made of polyester.
 The tensile strength of the fabrics is improved remarkably by the bi-component
filaments and depends on the linear low-density polyethylene /polyester ratio. The
ultrasonically bonded polyester/polypropylene blend like Matarh’s Ultraskin, the
protective clothing, is said to protect wearers from rain while offering the
breathability needed to provide comfort .
 Most of the insulation and industrial products are manufactured from synthetic and inorganic
fibers by dry- and wet-laid methods.
 Nonwoven polyester fiber mats are used to produce electrical insulation laminates and electrical
tape backing appliances.
 Polyester and hightemperature-resistant m-aramid nonwoven mats are used as a cost-efficient
interchange for aramid paper for insulation composites .
 Polyester fiber composites are widely used as filtration media.
 The layers of composite structure give excellent tear strength, a smooth, fiber-free surface, and
edge stability. These products supply higher filtration efficiencies than calendared spun-bonded
media .
 Polyester fibers are used inside seat cushions, back pillows, mattresses and
waterbeds,decorative and throw pillows, outdoors furniture, and even hand-stuffed custom
upholstery in fiberfill applications
 POLYPROPYLENE
 The fibers from polypropylene were introduced to the textile arena in the 1970’s and
have become an important member of the rapidly growing family of synthetic fibers.
 Polypropylene is generally available as chips or granules which are white in color
and are semi crystalline. Polypropylene fibers are produced by a larger variety of
processes than any other melt-spun fibers.
 Polypropylene has established itself as a very useful industrial and household fiber.
 However,it has not made a very significant impact in the apparel sector mainly due
to its hydrophobicity lock of dyeability and slightly waxy handle.
 Polypropylene nonwovens are increasingly being used as filter fabrics for wet
filtration in the chemical and pharmaceutical industries. Industrial applications also
include medical and surgical disposables.
 Polypropylene is also used extensively in sheath-core configuration to take advantage of the lower
melting point of the former in thermally bonded spunbonds; the polypropylene core fiber retains its
fibrous character and excellent physical properties.
 Even though there is only a very small window of temperature at which polypropylene will melt for
bonding purposes,the fabrics made in this manner do not suffer any appreciable loss of fiber
properties .
 Bicomponent fibers also may be used in nonwoven applications. FiberVisions' sister company ES
FiberVisions manufactures bicomponent fibers for hygiene, cosmetics, filtration, medical, industrial
and agricultural applications.
 These might be biodegradable, or have a PP or polyester core and a PP or polyethylene sheath; or
they may be based on specialized polymers. They often are used in low-level blends to bind other
fibers. Processes include thermal bond, carded through air, airlaid, wetlaid, carded needlepunch and
carded spunlace.
 Teabags and wipes are two wetlaid applications using short cut fibers. Airlaid nonwovens using
bicomponent fibers are used primarily for baby wet wipes, industrial oil.
 POLYAMIDE

 Polypropylene (PP) is used in diaper, baby wipe, filtration, automotive,

geosynthetics, furniture backing, construction, insulation and acoustics applications,
among others.
 Synthetic man-made fibers account for the largest part of the raw material used in
manufacturing nonwoven bonded fabrics. Polyamide fibers are the oldest ones that
are used in production, and they also increase the serviceability of the product.
 Because of its low specific gravity, it may replace other fibers to reduce basis weight
and system cost; but modifying the fiber's surface may also provide alternatives to
replace other PP fibers in certain applications.
 Only a few of the many known polyamides have reached large-scale significance for
production. Only polyamide 6 (PA6) and polyamide 6.6 (PA66) came to large-scale
production. Polyamide 6 is known as perlon and polyamide 6.6, which is generally
called nylon.
 The term “normal” is of great importance for nonwoven bonded fabrics, because:
 co-polyamide fibers can also be used;
 The filaments used in spun-laid methods are produced under different conditions than
the textile or technical man-made methods with regard to their production conditions;
 Very strong and excellent tear strength fibers are not used in nonwoven bonded
fabrics, whereas they are used in tarpaulins, conveyor belts, and tires, • fibers which
react differently when dyed can be used together, for example, in needle floor
coverings;
 Nylon fibers are used as nonwovens separators in Ni/H and Ni/Cd batteries;
 These fibers find application in high-performance wipes, synthetic suede, heat
insulators, battery separators and specialty papers ;
 Fibers have excellent physical properties like polyester fiber, and it has a high
melting point, which conveys good high-temperature performance .
 OTHER FIBERS

Glass
 Glass fiber is an inorganic nonmetallic man-made fiber.
 Glass fiber mats are excellent heat and noise insulation materials. They are capable
of withstanding temperatures above 150°C.
 Textile glass as a mineral material is naturally inflammable and does not release
steam or poisonous gases when subjected to heat.
 Glass fabrics are highly efficacious for filtering various liquids; filters of glass fibers
used for filtering corrosive chemical reagents have a life 10 or 15 times longer than
those made of usual materials (cotton, metal web etc).
 Glass staple fibers are used for the reinforcement of plastics and building materials
for insulation and so forth .
 CARBON
 Although first produced for electric lamp filaments from cupro-cellulose by Pauly, Fremery, Bromert
and Urban at Oberbruch near Aachen, Germany, in 1898, carbon fibers only gained significance after
1963. In recent years, carbon fibers have found much attention.
 They are made by means of thermal degradation of viscose fibers or polyacrylonitrile fibers at
temperatures up to 1000°C or even 1500°C. The fibers contain between 95 and 98 % carbon.
 Carbon fiber is not used on its own, but mixed with resin as fiber reinforced materials. This is called a
composite material and is now one of the most important structural and heat-resistant materials.
 The composite material made of glass fiber and plastic is distinguished as glass fiber-reinforced
plastics (G-FRP) from that made of carbon fiber and plastic (carbon fiber-reinforced plastic, C-FRB).
 Such composites are mainly used in:
• aircraft cabin structural materials, such as floor, other internal sections and operations systems;
• ski-poles; • natural gas storage tank; • fishing rod; • golf shafts; and • tennis racket
 BICOMPONENT
 There has been a trend in the polymer industry since the midsixties to apply polymer
blends and mixtures for the modification of material properties. In the man-made
fiber industry, this trend is realized in the manufacture of fibers consisting of two or
more components .
 Bicomponent fibers can be defined as “extruding two polymers from the same
spinneret with both polymers contained within the same filament.” A close relative is
“co-spun fiber,” which is a group of filaments of different polymers, but a single
component per filament, spun from the same spinneret.
 Bicomponent filaments can be used to produce a bonded fabric, with one of the
components being thermoplastic to facilitate heat bonding and the other component
having properties that will enhance the quality of the final fabric. Bicomponent fibers
are also used for spunlaced nonwoven products like medical disposable textiles,
filtration products and air-laid nonwoven structures as absorbent cores in wet wipes
 SUPERABSORBENT FIBERS
 Superabsorbent (also known as superabsorbent polymers or SAP) consists of a material which can
absorb many times its own weight in aqueous fluids. Superabsorbent fibers absorb 50-150 times their
own weight while the diameter increases. The small diameter of the fiber, which is about 30 µm,
gives a very high surface area for contact with the liquid.
 Viscose rayon or cotton without load only absorbs about 30 times, wool 17 times, and polyester 3
times their own weight . The advantage that fibers offer compared to powders is due their physical
form, or dimensions, rather than their chemical nature . Also, the fiber surface is not smooth. It has a
crenulated structure with longitudinal grooves.
 These are beneficial in transporting moisture to the surface. The lubricant has also been selected to
enhance this wetting effect and results in a very high rate of moisture absorption. Typically, the fiber
will absorb 95% of its ultimate capacity in 15 seconds .They are therefore an ideal material for use in
products which are designed to contain fluids such as baby diapers/nappies, incontinence products,
and feminine hygiene pads and liners
CLASSIFICATION OF NONWOVEN FABRICS
Nonwovens may be classified as either disposal or durable goods.
 Disposable/non durable
Disposable or nondurable non wovens include such one-time use products as diapers,
medical dressings, household wipes, and disposable protective clothing.
 Durable Goods
Durable goods are used for apparel interfacing, automobile headliners, road
underlayments, and carpets.
According to the production process, it can be divided into:
 Spunlaced non-woven fabrics: Spunlaced process is to spray high-pressure micro-water into
one or more layers of fiber network, so that the fibers are intertwined, so that the fiber
network can be strengthened and have a certain strength.
 Thermal bonded non-woven fabric: Thermal bonded non-woven fabric refers to adding
fibrous or powdery hot-melt bonded reinforcing materials into the fabric, which is then
strengthened by heating, melting and cooling.
 Pulp air-laid non-woven fabrics: air-laid non-woven fabrics can also be called dust-free
paper, dry paper-making non-woven fabrics. It uses air-flow netting technology to loosen the
wood pulp fiberboard into a single fiber state, and then uses air-flow method to agglutinate
the fibers on the screen curtain, and then reinforce the fibernet into cloth.
 Wet non-woven fabrics: Wet non-woven fabrics are made by loosening the fibre raw
materials placed in the water medium into single fibers and mixing different fibre raw
materials into fibre suspension slurry. The suspension slurry is transported to the netting
mechanism, and the fibers are netted and consolidated into fabrics in the wet state.
 Spunbonded non-woven fabrics: Spunbonded non-woven fabrics are made of continuous
filaments after the polymer has been extruded and stretched. The filaments are laid into nets,
which are then self-bonded, heat-bonded, chemically bonded or mechanically strengthened to
turn the nets into non-woven fabrics.
 Melt-blown nonwovens: Melt-blown nonwovens process: polymer feeding – – melt extrusion
– – fiber formation – – fiber cooling – – Netting – – reinforced fabric.
 Needle-punched nonwovens: Needle-punched nonwovens are a kind of dry nonwovens.
Needle-punched nonwovens use the puncture effect of needles to reinforce the fluffy fibre
web into cloth.
 Sewing nonwovens: Sewing nonwovens is a kind of dry nonwovens. Sewing is to use warp-
knitted coil structure to reinforce fibre web, yarn layer, non-textile materials (such as plastic
sheet, plastic thin metal foil, etc.) or their combination to make nonwovens.
 Hydrophilic non-woven fabrics: mainly used in the production of medical and health
materials, in order to achieve better hand feel and non-scratching skin. For example, sanitary
napkins and sanitary gaskets make use of hydrophilic function of hydrophilic nonwovens.
 BONDING AGENTS
 Bonding agents are the glue as it binds the web firmly to give the nonwoven
fabric.
 These agents largely determine the wear properties of the woven fabric.
 The bonding agents have such a greater influence on the properties of the fabric
 That the requirements of the finished product determine the choice of the
bonding agent.
 WHY NEED CHEMICAL BINDER?
 To improved characteristics such as strength, softness, adhesion, firmness,
durability, stiffness, fire retardance , hydrophilicity, hydrophobicity, anti-
microbial properties, organic compatibility, reduced surface tension, improved
dimensional stability and solvent, wash and acid resistance.
 The required properties can be varied depending on the end-uses.
CLASSIFICATIONS OF BINDERS
There are three main kinds of binders: butadiene copolymers, acrylates, and vinyl
copolymers.
 The chemical compositions influence Tg, hardness and softness, hydrophobicity and
hydrophilicity, elasticity, aging, and dry tensile strength of binders.
 The higher the Tg, the higher will be the dry tensile strength of binderschemical
structure attached to polymer chains, which influences wet and solvent properties.
 To modify binder properties, copolymerization with a small amount of monomers
with special functionality is performed.
 The main functionalities in binders are carboxyl and amide side chains.