TT 433 Advancement of nonwoven Technology

Raw materials: Natural and Synthetic fibres, Bonding agents, Types of bonding agents,
Basic structure of bonding agent formulation, Characteristic properties of polymer
dispersions, Adhesive fibres, Soluble fibres.
Web formation techniques: Fibre prepration, Dry laying, wet laying, Spunlaying, Melt
blowing, SM, SMS fabrics.
Mechanical Bonding: Developments in needle punching technology, Factors affecting
the tensile and bulk properties of needle punched fabrics, Spunlacing technology,
factors affecting the properties of spunlaced fabric, Stitch bonding techniques.
Chemical Bonding: Adhesive Bonding, Methods of bonding agent application, Cohesive
bonding, Drying by convection, conduction, radiation, infra red drier and high
frequency driers.
Thermal bonding: Thermal bonding techniques, Area bonding, Point bonding & their
properties.
Spunbonding and Meltblowing: Techniques, structure and properties of fabrics.
Finishing of nonwoven fabrics: Shrinkage, Calandering, Pressing, Splitting, Grinding
Washing, Dyeing, Printing, Softening, Coating and Laminating.
Applications: Medical and Hygeine, Apparel, Household & Home Textiles, Geotextiles,
Filtration, automotive textiles, agriculture, leather industry
Testing of Nonwoven fabrics: Standards and methods of testing nonwoven fabrics
TT 433 Advancement of nonwoven Technology

Books Recommended:

1. Lunenschloss J and Albrecht W, “Non-Woven Bonded Fabric”, Ellis and

Horwood Ltd., UK, 1985

2. Albrecht W, Fuchs H & Kittelmann, “Nonwoven Fabrics”, Wiley-VCH

Weinheim, 2003.

3. Mrstina V & Fejgal F, “Needle punching textile technology”, Elsevier, 1990.

4. Krcma Radco, “Manual of nonwovens”, Textile Trade Press, UK,1971

5. Gulrajani M L, “Book of Papers of International Conference on

Nonwovens”, The Textile Institute, UK, 1992.
Production of Fabrics
• From yarn
• Weaving
• Knitting
• Directly from fibres
• Nonwovens
A sheet of fibres, continuous filaments, or chopped yarns of any
nature or origin formed into a web by any means, and bonded
together by any means, with the exception of weaving or knitting.
 NON WOVENS – Introduction & History
• Non Woven fabrics consist of fiber mats held together
because of their inherent properties or by mechanical
or chemical processes involving the use of chemical
bonding agent
 NON WOVENS – Historical development

• Felts made from wool or hair are the oldest fabrics

made by man.
• In early times, felts were made from animal hair
using various chemical aides like water, urine or by
mechanical means of trampling and beating
• Slowly other ways of forming the fabrics were
identified with wool as raw material, which had
much more uses than felt
Why nonwovens
• Cuttings and waste can be used
• Properties displayed by conventional textiles are in
excess of requirement

• Better utilization of individual fibre properties than in

conventional textiles
• Desire to reduce the cost
Rates of production
Technology Machine Relative production rate
Weaving Automatic shuttle loom 1 (= 5m2/hr)
Shuttleless loom 2
Knitting Circular knitting 4
Warp knitting 16
Nonwoven Web formation Carding 120-400
Spunlaying 200-2000
Wet laid 2300
Aerodynamic web formation 600
Nonwoven Bonding Needling 30-500

Calendering 2000
Stitchbonding 40
Hot air bonding 5000
Nonwovens
• Nonwoven products appeared in market during 1900-1950s.

• Nonwovens devloped simultaneously in North America, Western

Europe and Japan.

• Until 1990’s the nonwoven production and application remained

in these industrial sectors.

• Worldwide nonwoven market has tripled in 15 years. (2.2 million

tonnes in 1994 to 4.5 million tonnes in 2004 and has increased to
6.5 million tonees in 2009)
2015 WORLD MARKET OF THE
NONWOVEN
NONWOVEN APPLICATIONS
Potential of nonwovens
• Nonwovens have the potential to replace all flexible
structures
(containing, clothing, decorating, displaying,
supporting, separating and filtering).

• They can provide innovative, cost-effective and

sometimes unexpected answers to innumerable
business challenges.
Nonwovens consumption in India

• In the year 2002 the value of nonwovens consumed

in India was $200 million.

• Per capita consumption of nonwoven is 0.001kg in

India as compared to 2.25kg in developed
countries.
 Nonwovens Defined

 INDA’S definition: (International Non Woven and Disposable Association)

‘Nonwovens are a sheet, web, or bat of natural and/or man-made fibers or
filaments, excluding paper, that have not been converted into yarns, and that
are bonded to each other by several means’

 EDANA’S definition: (European Disposables and Non Woven Association)

‘Nonwovens are a manufactured sheet, web or bat of directionally or
randomly orientated fibers, 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’
Production Process

Web
Opening
formation Bonding Finishing
of fibres
Production Process

Web formation  Bonding

1. Dry laying 1. Needlepunching
1.Parallel laying 2. Hydroentanglement
2.Cross laying 3. Stitch bonding
3.Random laying 4. Spunbonding
2. Wet laying 5. Meltblowing
6. Chemical bonding
7. Thermal bonding
CLASSSIFICATION OF NON WOVEN
 CLASSIFICATION OF NON WOVEN
On the basis of Raw Material

Non woven

From fibre Combination of

layered material From yarn

Other textile Non textile material

Fibrous web Yarn/ threads (glass, ceramic,
material carbon)
 CLASSIFICATION OF NON WOVEN
On the basis of method of production
◦ Dry Method
◦ Wet Method
Dry Method
Spunbond fabric
NONWOVEN APPLICATIONS
 NONWOVEN APPLICATIONS
PERSONAL CARE AND HYGIENE CLOTHING
• Baby diaper • Components for shoes belt and bags
• Sanitary napkin • Insulating material for protective wear
• Dry and wet napkin • Outfit for the fire protection
• Cosmetic wipes • High visibility clothing
• Disposable underwears • One day work clothing

MEDICAL USE LEISURE AND TRAVEL

• drapes, gowns and packs, face • Sleeping bags
masks, dressings • Suitcase , hand bags
• Curtains and blanket • Vehicles headrests
• Bed linen • CD slipcase
• Pollution controlled gown • Surfboards
• Mattress filling
HOUSEHOLD APPLICATION AUTOMOTIVE
• Handkerchief, • boot liners
• wipes and dusters • oil and cabin air filters
• tea and coffee bags • molded bonnet liners
• fabric softeners
• Stain removers
• food wraps

CONSTRUCTION GEOTEXTILES
• Reinforcement of roads
• roofing and tile underlay • soil stabilization
• thermal and noise insulation • Drainage
• House wrap • sedimentation and erosion control
• Drainage
 FILTRATION INDUSTRIAL

• air and gas • cable insulation

• HVAC • Abrasives
• HEPA (High efficiency particulate • reinforced plastics
arrestance) • battery separators
• ULPA (ultra low particulate air) filters • satellite dishes
• Odour control
AGRICULTURE SCHOOL AND OFFICES

• Covers for greenhouse and • Book covers

cultivation • Postal envelopes
• Protection for seeds and roots • Blotting paper
• Pots for biodegradable plants • Maps , signals
• Material for capillary irrigation
Preparation
of fibres Web laying Bonding Finishing
Bale opening
Description: The raw fiber flocks are plucked from the pressed bale and partly
opened. It is possible to blend different fibers.

Machines

Fig. 2: Detail UNIfloc A 11 take-

Fig.1: Scheme of bale opener (and mixing machine) off unit
Rieter UNIfloc A 11. The production is up to 1000
kg/hr for synthetic fibers (1200 kg/hr for cotton).
Mixing and storage
Principle:
Main goal is a homogenisation of
fiber blend (different fibers of the
some fibers with different quality).
Usualy are fibers stocked in one
direction and remove in
perpendicular direction (see fig. 8
and 9).

Fig. 8: Multimixer Trütschler MPM 6

Fig. 9: Principle of mixing and storage chamber with horizontal
storage and inclined withdrawing (example Rieter UNIMIX).
 Feeding

Fig. 7: Scheme of „Hopper“ (opening and feeding machine with

inclined spiked belt).
CARDING PROCESS
Roller and clearer card

1- feed conveyor
2- feeding arrangement
3- transfer roller/ licker-in
4 - main cylinder
5 – undercasing
6 - stripper
7 – worker r
8 – doffer
9 - fancy roller
10- fancy roller stripper .
11 – doffer comb
 Card machine - Doffers

Single doffer card Double doffer card

for lower productivity (for example for higher productivity (to produce
stitch bonded textile line) webs for example for needling,
thermal and chemical bondig)
 Card machine – Doffer accessories
Web delivery from doffer can be aranged in two ways by doffing comb in case of parallel
web to be processed or by condensing rollers in case condensed web is selected for
nonwoven application

Doffing comb Condensing rollers

 Points of carding machine
The card point means a place where the fibers are under mechanical
action of card machine clothing. Three types of carding points we can
found in card machine.

Direction of worker stripper fancy roller

rollers rotating

Relative moving
between the
rollers surfaces
Card clothing cylinder cylinder cylinder
Fiber
Carding point Stripping point Jack up point
cylinder/worker worker/stripper cylinder/fancy roller
cylinder/doffer stripper/cylinder
Points of carding machine
Stripping point
stripper
worker Carding point

worker

cylinder
Stripping point

stripper

cylinder
 ORIENTATION OF FIBRES AND WEB FORMATION

The orientation in the

carded web or other device
determine the following
properties of finished
product-
Strength and extension in
different direction.
Fullness
Bulkiness

o About 50% of nonwoven fabric

production is based on dry-laid web
forming processes. Fibre orientation in web
Randomising
/scrambling
roller
 LONGITUDINALLY ORIENTATED WEBS
The fibres of the card or comb are longitudinally orientated. There are two
methods of laying,
1. discontinuous laying The layering belt length is 20- 60 m.
2. Continuous laying

Discontinuous laying method

LONGITUDINALLY ORIENTATED WEBS
LONGITUDINALLY ORIENTATED WEBS
Discontinuous method
Advantages
• Using only one card or combing machine, heavy webs can be
produced
• Any gsm of fabric can be produced

Limitations
• Length of the fabric is limited to the length of the belt

Continuous method
Advantages
• Continuous length of the fabric can be produced

Limitations
• Large number of machines (Huge capital) are required for heavy
fabrics
TRANSVERSE ORIENTATED FIBRE WEBS
TRANSVERSE ORIENTED WEBS

Discontinuous method
 TRANSVERSE ORIENTED WEBS
Continuous method

Camel back (steep arm laying machine)

Limitation
The width of the fabric depends upon the height of the steep arm of the
swinging layering mechanism

Height of building required is high

TRANSVERSE ORIENTED WEBS
Continuous method

Cross laying machine

 CROSS- LAYED WEB
In order to obtain similar wet strength both cross and longitudinally in
the web, two or more cross and longitudinally orientated web can be put
in layers on top or in between one another. Cross–laid web can be made
either directly, i.e. with cards arranged vertically to one another using a
laying machine Fig.(a), or by building up layers of differently orientated
webs at a later stage. Depending on the selected longitudinally and cross
fibre mass ratios, the strength ratio of the web in both directions can be
varied.

Fig (a):- Manufacture of Cross- Laid web

 AERODYNAMIC WEB FORMING

Compared with carded webs, air laid webs have a lower density, a greater
softness and an absence of laminar structure. Air laid webs offer great
versatility in terms of the fibers and fiber blends that can be used
AERODYNAMIC WEB FORMATION
 PERPENDICULAR LAYERING OR
VERTICAL LAPPING
1. Carded web

2. Reciprocating comb

3. Conveyor belt

4. Wire grid

5. Reciprocating
compressing bar
 Spacer fabrics using perpendicular laying

Vibration vertical laying

1. Carded Web.
2. Feeding Discs.
3. Forming Disc with teeth.
4. Conveyer belt of thermo bonding oven.
5. Wire Grid.
6. Perpendicular laid fiber layer
 PERPENDICULAR LAYERING OR
VERTICAL LAPPING
1. The web is stablised by using through air bonding, as thermloplastic
fibres or bicomponent fibres are used in web

2. In addition to fibre composition, fold frequency and fold orientation

affects the fabric properties

3. Compression properties are affected by proportion of thermoplastic

bicomponent fibres and fibre diameter
 PERPENDICULAR LAYERING OR
VERTICAL LAPPING
1. Working width – 2.5 metres

2. Thickness – 15mm to 40mm

3. Web weight – 200 gm/sq. m

4. Production speed – 700 kilos per hour

Such fabrics are being used as foam replacement in automotive

industry,, sound insulation in automotives, depth filtration , air
filtration , thermal insulation and bedding products
Once the vertical lapped structure is bonded and molded into final
shape, it has ability to maintain loft much more than cross lapped
or air laid nonwovens
Struto process
Automotive Trims – seat and side panel upholstry

1. Textile materials are used in automotives because of functionality in

terms of , besides mechanical behaviour

1. Lightness

2. Acoustic and

3. Thermal effects

2. It is used in three main components

1. Car interior

2. Engine compartment

3. Pneumatics
1. The multilayer sturucture consists of fabric (PET), foam (PU) and
backing fabric (PA)

2. It does not offer ability for recycling or reusing

Automotive complex production

1. Different techniques are

employed

1. Flame lamination

In this process the textile

fabric and the PU foam are
linked together using the PU
foam as an adhasive at a speed
of 25m/min

This process generates toxic

flames
Automotive complex production

Different techniques are employed

2. Dry lamination – In this process, hot melt (web, film or powder) is

used to bind the textile layer and the PU foam at a speed of 16m/min

• It does not generate toxic gases

PU foam
PU foam is obtained by chemical reaction between isocyanate
and polyol. The expansion in the foam occurs due to the
reaction between isocyanate and water.

After the expansion it presents a cellular structure which is

characterised by open and closed cells
PU foam
PU foam has disadvantage that it generates toxic gases during
its manufacturing process, lamination process and also during
recylcing of the automotive complex, besides being
flammable

Although recycling of textile fabrics is done after delamination

(PET, PU and PA) but some PU foam remains on textiles
PU foam - replacement
PU foam replacement solutions include
3D spacer fabrics
• Produced by weaving or knitting
• Nonwoven technology
• Carding and vertical lapping
• Struto®
• Santex® Wavemaker
• V-Lap® technologies
• Stitch bonded nonwovens
• Needlepunched nonwoven
 WET-LAID NONWOVENS

• Wet-laid nonwovens are nonwovens made by a modified

papermaking process. That is, the fibers to be used are
suspended in water.

• A major objective of wet laid nonwoven manufacturing is to

produce structures with textile-fabric characteristics, primarily
flexibility and strength, at speeds approaching those associate
with papermaking.

• In the roll good industry 5-10% of nonwovens are made by

using the wet laid technology
 PRODUCTION MACHINERY
There are three characteristic stages in the manufacture of
nonwoven bonded fabrics by the wet-laid method :

 Swelling and dispersion of the fiber in water; transport of

the suspension on a continuous traveling screen

 Continuous web formation on the screen as a result of

filtration

 Drying and bonding of the web

SCHEMATIC PRESENATION OF THE WETLAID PROCESS
THE WETLAID PROCESS
 Tea Bags
 Produced by wet laying process
 12-17 g/m2 weight should have
 high tensile strength
 dry and wet bursting strength
 High porosity for rapid infusion and good retention of tea
leaves
 Paper of 12-14 g/m2 predominantly contains Abaca fibres.
Abaca meets all standards for food packing materials. Other
fibres are hemp, flax and cotton
 Sisal can also be used to produce low quality tea bags
because of its lower tensile strength or knot forming tendency
 Heavier tea bags of 14-17 g/m2 contain upto 25% man made
thermoplastic fibres, to impart heat sealing on the four sides
for making pillow type bags. These man made fibres are
blended in the pulp or added at the web forming stage
ADVANSA is
made from
PET

PET/PP
bicomponent
fibres are also
used for tea
bags
 Filtration paper
 Produced by wet laying process
 It should have high porosity and dimensional stability for
various uses like
 Vaccum cleaner bag filters
 Cigarette filter wrapping (Plug wrap paper)

 In all these applications, upto 60% apaca is blended in various

proportions with pulps of wood, other natural or synthetic
fibres to achieve required performance characterisitcs
 Sisal is also finding applications in this area
 In some cases flax is used for cigarette filter paper wraps
 Bonding
Techniques
 WEB BONDING
The web must be consolidated in some way to have sufficient strength.

This strength is provided by bonding, a vital step in the production of nonwovens.

The choice of method is at least as important to ultimate functional properties as

the type of fiber in the web.

There are three basic types of bonding:

a) Mechanical
b) Thermal
c) Chemical
 MECHANICAL NEEDLE PUNCHING TECHNIQUE
BONDING
STITCH BONDING
HYDRO ENTANGLEMENT

SATURATION ADHESIVE BONDING

CHEMICAL SPRAY ADHESIVE BONDING
BONDING OR FOAM BONDING
ADHESIVE BONDING APPLICATION OF POWDER
NON WOVEN
PRINT BONDING
FABRIC
BONDING DISCONTINUOUS BONDING
TECHNIQUES THERMAL BONDING HOT CALENDARING
BELT CALENDARING
THROUGH AIR THERMAL BONDING
ULTRASONIC BONDING
RADIANT HEAT BONDING

BONDING OF -
SPUNLAID WEBS
Calculations For Carding & Lapping
For correct setting up of web forming machines it is
necessary to be acquainted with calculations specified by
their manufactures.
For web forming machines, in most of cases machines are
technologically directly connected with needle punching
machines.
So it is first necessary to compare the production of web
forming and needle punching machines.
 Scheme of technological
calculation of web forming
 Following case may occur
∆ 6b3 𝑚3 𝑣3 𝑚𝑎𝑥
Q max (1-100)< 100

∆ 6b3 𝑚3 𝑣3 𝑚𝑎𝑥
Q max (1-100)= 100

∆ 6b3 𝑚3 𝑣3 𝑚𝑎𝑥
Q max (1-100)> 100

Where Q max is the minimum possible production of carding machine((kg h-1)

∆- waste from carding (%)

b3 - width of web before entering the needle punching machine(gm m-1)

𝑣3 max- maximum speed on the entry into the needle punching machine (m min-1)
According to which case occurs, the line production will be limited either by the
maximum possible production of the carding machine Q max, by the speed on the
entry into the needle punching machine v3, or by both. The required width b3 of the
web and the areal weight m3 before the needle punching machine depends on the
product design and they cannot be changed. If therefore inequality (1) is valid then:

Q = 6b3 𝑚3 𝑣3 𝑚𝑎𝑥
100;∆
(kg h-1)

If equality (3) is valid, then:

∆
100 𝑄𝑚𝑎𝑥(1;100)
𝑣3 = (m min-1)
6𝑏3 𝑚3

Where Q is the real production of the carding machine (kg h-1) and v3 is the real
speed on the entry into the needle punching machine (m min-1).
If therefore, the production Q of the carding machine is geared to the speed 𝑣3 at
entry into the needle punching machine. It is the possible to continue the
calculation.
On the basis of the necessary draft 𝑝3 , it is possible to calculate the value 𝑚2 of the
areal weight of the web after lapping, the width b2 after lapping and the delivery 𝑣2
of the web. Then it holds true that:
𝑏3 𝑚3 𝑣3=𝑏2 𝑚2 𝑣2
With regards to a low draft p3. we put in the further calculation b2=b3, then:
𝑣3
𝑣2 = 𝑝3 (m min-1)
𝑚2 = 𝑚3 𝑝3 (g m-1)
When calculating the speed 𝑣1 of laying the fleece and the areal weight 𝑚1 of the
fleece, we must take into consideration the construction limitation of the carding
machine as to the maximum and minimum possible circumferential speed 𝑣1 of the
doffer. The width 𝑏1 of the fleece is constant and is determined by the working width
of the carding machine.
We can therefore calculate the marginal possible combination of 𝑚1 and 𝑣1 :

𝑚2 𝑏2 𝑣2
𝑚1 min= (gm m-1)
𝑏1 𝑣1 𝑚𝑎𝑥
𝑚2 𝑏2 𝑣2
𝑚1 max= (gm m-1)
𝑏1 𝑣1 𝑚𝑖𝑛
𝑚2 𝑏2 𝑣2
𝑣1 min= (m min -1)
𝑏1 𝑚1 𝑚𝑎𝑥
𝑚2 𝑏2 𝑣2
𝑣1 max= (m min -1)
𝑏1 𝑚1 𝑚𝑖𝑛

Where 𝑣1 max is the maximum possible circumferential speed of the doffer (m min -1)

𝑣1 max is the minimum possible circumferential speed of the doffer (m min -1)
The circumferential speed of the doffer is then:
𝑚2 𝑏2 𝑣2
𝑣1 = (m min-1 )
𝑚1 𝑏1

Subsequently the control of the justification of the equality 𝑏2 = 𝑏3 :

𝑏2 𝑣1 2 :𝑣2 2 ;𝑣3 2
𝑏3 = (m)
𝑣1

The angle between the fleece is calculated:

𝑣2
tan ∝ =
𝑣1
Determination of the weight of the fed lot and the time interval of feeding is made accordingly to the
formula:
∆
60 𝑚𝑣 (1; )
100
𝑡𝑣 = (s)
𝑚3 𝑏3 𝑣3

where 𝑡𝑣 is the time interval of one feed load(s)

m, is the weight of one feed load (g)
The range of the weight of the feed load and its time interval is determine by the construction of the
carding machine.
The revolution of the doffer are calculated from the formula:
𝑣1
𝑛𝑠 = (𝑚𝑖𝑛;1)
𝜋𝐷𝑥
Where ns are the revolutions of the doffer (𝑚𝑖𝑛;1 )
𝐷𝑠 is the diameter of the doffer (m)
For a better understanding here is an example of the entire calculation
The needle punching machine should be supplied by a fibrous web with areal
weight m3 = 325 gm-2 and width b3 = 2.5 m; the maximum possible production of
the carding machine Q max for the processed fibrous mixture is 120 kg h-1 and the
waste ⩟ = 3%; then construction of the carding machine determines the following
data;

Circumferential speed of the doffer v1 = 15 to 40 m min-1

Width of the carding machine b1 = 2m

Areal weight of the fleece m1 = 10 to 30 g m-2

Weight of feed load mv = 100 to 600 g

Time interval of the feed load t v = 10 to 40 s

Necessary technological draft on the feeding conveyor of the needle punching

machine p3 = 1.05

Diameter of the doffer Ds = 1.05 m

Solution
∆
100 𝑄𝑚𝑎𝑥(1;100) 100∙120∙ 1;0.03
𝑣3 = = = 2.39 m min-1
6𝑏3 𝑚3 6∙2.5∙325

Since the needle punching machine makes it possible to reach

an even higher speed, the calculation is correct.
𝑣3 2.39
𝑣2 = = = 2.28(m min-1)
𝑝3 1.05

𝑚2 = 𝑚3 𝑝3 = 325∙1.05 = 341(g m-2)

𝑚2 𝑏2 𝑣2 341∙2.5∙2.28
𝑚1 min = = = 24.3 g m-2
𝑏1 𝑣1 𝑚𝑎𝑥 2.40

𝑚2 𝑏2 𝑣2 341∙2.5∙2.28
𝑚1 max = = = 64.8 g m-2
𝑏1 𝑣1 𝑚𝑖𝑛 2.15
 𝑚2 𝑏2 𝑣2 341∙2.5∙2.28
𝑣1 min = = = 32.4 m min-1
𝑏1 𝑚1 𝑚𝑎𝑥 2.30

𝑚2 𝑏2 𝑣2 341∙2.5∙2.28
𝑣1 max = = = 97.2 m min-1
𝑏1 𝑚1 𝑚𝑖𝑛 2.10

When we compare these values it follows that:

𝑚1 can vary with in the interval 24.3 to 30 g m-2
𝑣1 can vary with in the interval 32.4 to 40 m min-1
If n =12 then :
𝑚2 341
𝑚1 = = = 28.4 g m−2
𝑛 12
𝑚2 𝑏2 𝑣2 341∙2.5∙2.28
𝑣1 = = = 34.2 m min-1
𝑚1 𝑏1 28.4 ∙ 2

The control of the narrowing due to the draft on the feeding

conveyor to the needle punching machine:
𝑏2 𝑣1 2 :𝑣2 2 ;𝑣3 2 2.5 34.22 :2.282 ;2.392
𝑏3 = = = 2.499 m
𝑣1 34.2
 Contd..
The laying angle:
𝑣2
tan ∝ = = 0.066, and from this ∝ = 3.8◦
𝑣1

The time interval of the feed load at its weight of 500 g :

∆
60 𝑚𝑣 (1;100) 60 ∙ 500 ∙ 0.97
tv = = = 12 s
𝑚3 𝑏3 𝑣3 325 ∙ 2.5 ∙ 2.39

Revolution of the doffer

𝑣1 34.2
Ns= = = 10.4 𝑚𝑖𝑛;1
𝜋𝐷𝑥 3.14 ∙ 1.05
 MECHANICAL BONDING
 In mechanical bonding the
strengthening of the web is
achieved by inter-fiber friction
as a result of the physical
entanglement of the fibers

The webs are joined by means

of needles and jets of air and
water

The webs can also be

reinforced by working in thread
or fabric e.g. layer of thread,
woven or knitted fabrics
NEEDLE PUNCHING MECHANISM
 NEEDLE PUNCHING TECHNOLOGY

A needle punched nonwoven is

a fabric made from webs or batts
of fibers in which some of the
fibers have been driven upward
or downward by barbed needles .
This needling action interlocks
fibers and holds the structure
together by friction forces.
Barbed needle in action
 NEEDLE PUNCHING TECHNOLOGY
Parameters of needles:
 Proportions (length, diameter, density
of barbs, size of barbs)
 Shape of needle parts (shape of
working blade, shape of barbs)
 Type of needle (felting, structuring)
 Location on the needle board
 Single board system
 Tandem board system
 Double board system

Penetration depth
It changes number of working barbes
It increases textile strength (until some
value) and decreases textile thickness.
When the penetration depth is too
high fibers are pulled through the
textile – non uniform textile
Double needle board
Applications of needlepunched fabrics
Methods of needlepunching
 According to elements used
Needled Felt (N.F) – is the needlepunching only of the staple
fibres or endless filament web, lapped at once or gradually
Batt on Base (B.o.B) – is the needlepunching of staple fibre
or endless filament web combined with another element,
mostly a supporting base, which gives the product the
required qualities or facilitates the needlepunching process.
Such an element can be woven or knitted fabric, nonwoven
fabric, yarn, roving, paper, foil, plastic foam and other
elements placed under one web, between the webs or
several layers of web
Needled Reinforced (N. R) – is the needlepunching of the
raised pile of a woven or knitted fabric or other reinforced
material
Other elements used in B.o.B
Threads – used as backing material for carpets, geotextiles,
lapping felts for tannery, ironing materials, filter fabrics
Paper – crepe paper has been in used for improving dimensional
stability. Sometimes smooth paper with polyethylene foil on other
side is also used
Foils – thermoplastic foils (PVC, PET) is inserted into web, which
when exposed to heat, bonds the neighbouring fibres .
Sometimes, Aluminium foil is also used to improve useful
properties of floor covering and are supposed to reflect heat
PU foam – for producing textile interlinings for clothings,
combination of PU foam and needlepunched nonwoven is ideal.
Foam adds to voluminosity and lightness and web improves the
feel
Woven or knitted fabrics – woven are commonly used, called as
scrim. Open weave to avoid damage to the yarns and also to the
barbs of needles. Knitted fabrics are used only, where dimensional
change is required after finishing like shrinking or shaping
COMMON NEEDLE PUNCHING
MACHINE SEQUENCES
 Pre needling
Before main needling process, with a small unit that has less
punching density and higher stroke, it is applied to the mass of
fibers to reduce thickness and provide strength.
Advantages:
1. The thickness of web is reduced, thus more compact structure can be better
needled by needle loom.
2. Uniform web structure can be fed to needle loom without undesired folds.
3. The risk of delamination and amount of waste from web sticking to the
conveyor is reduced.
4. Resistance to abrasion and pilling of the needlepunched fabrics increase.
5. It is possible to produce individually different layered fabrics.
6. Web elongation is kept in minimum level.
7. Better stabilized and strong fabrics can be produced by preneedling.
Cylindric pre-needle loom of Asselin
Appearance and degree of compression of a
needle felt are influenced by”