1. technical textiles
TRANSCRIPT
Technical TextilesBy: Granch Berhe
2015
Textile product manufactured primarily for its performance and functional properties rather than aesthetic or decorative characteristics
Technical Textiles
What is Technical Textile?
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Some of the common products of technical textiles are:-
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Agro – techAgriculture, horticulture and forestry
BUILD – techBuilding and construction
CLOTH – techTechnical components of shoes and clothing
GEO – techGeotextiles, civil engineering
HOME – techComponents of furniture, household textilesand floor coverings
INDU – techFiltration, cleaning and other industrial usage
SEGMENTS OF TECHNICAL TEXTILES
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MEDI – techHygiene and medical
MOBIL – techAutomobiles, shipping, railways and aerospace
OEKO – techEnvironmental protection
PACK – techPackaging
PRO – techPersonal and property protection
SPORT – techSport and leisure
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MATERIALS FOR TECHNICAL TEXTILES
1. Regular/Generic fibers• Natural fibers: Cotton, silk, wool, jute, hamp, ramie, flax• Regenerated fibers: Viscose, Lyocell.• Synthetic fibers: Nylon, PET, PP, Acrylic.
2. Specialty variants of regular/generic fibers• Flame retardant• Super absorbent • Antimicro bacterial • Ultra fine fibers. etc.
3. High tech/high performance fibers:• High chemical- and combustion-resistant organic fibres: Nomex, Kevlar• High performance inorganic fibres: Glass, Asbestos, Carbon
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Generic Fibers
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Viscose Polyester Other fibresBasic
Characteristics Specialty Variant Basic Characteristic Specialty Variant Fibre Additional
Characteristic
Very good softness
Viscose for nonwovens
High melting point, high heat and chemical resistance
High Tenacity PET
Super-absorbent fibre (acrylic)
High absorbency
Excellent absorbency
Viscose with tri-lobal cross-section
Very low moisture absorbency
trilobal cross-section
High Density Polyethylene (HDPE)
High tensile strength
Added strength and moderate abrasion resistance
Temperature regulating Viscose (Outlast )
High strength, Good abrasion resistance,, Good resiliency
Hollow fiber High Modulus PE (HMPE)
Higher modulus
Relatively poor strength wet
Short cut PET/Viscose
Inert, biocompatible & flexible
Flame retardant
High Tenacity Nylon
High tenacity and low shrinkage
Low resiliency Anti-microbial, Anti-bacterial viscose fibers.
Anti-microbial, Anti-fungal, Anti-bacterial PET fibers.
High Tenacity PP
High strength and stability
Natural and pure Fire Retardant (FR) Viscose/PET
Cationic dyeable
Anti bacterial Acrylic
Prevents & limits the growth of bacteria, fungi and microbes.
Specialty variants of regular/generic fibers
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Fiber Characteristics Applications Key players
Meta Aramid (Nomex)
Heat Resistance, high strength and high impact absorbing capacity
Fire retardant apparel, bullet proof jackets, helmets, gloves etc.
Dupont (USA), Teijin Twaron (Japan), SRO Group (China), Yantai Spandex (China), Kermel (France)
Para Aramid (Kevlar)
High strength to weight ratio, Excellent thermal & chemical stability
Fire retardant apparel, bullet proof jackets, helmets, gloves etc.
Dupont (USA), Teijin Twaron (Japan), Yantai Spandex (China)
Carbon Low weight and high strength
Air craft body, wind mill wings, racing cars.
Toray Industries (Japan), Toho Tenax (Japan), Mitsubishi Rayon (Japan), Zoltek (USA), Hexcelcorp (USA), SGL Carbon AG (Germany) , Kemrock (India)
Polyphenylene sulfide Fibres (PPS)
Highly resistance to heat, acid and alkaline
Electrical products, liquid filters, dryer canvas.
Armoco Fabrics & Fibres Co (USA), Toyobo (Japan), Toray Industries (Japan), etc
Glass fiber Thermal insulation properties with high strength and low elongation.
Automotive bodies, hockey sticks, boats, surfboard etc.
Owens-Corning Fibreglas, Nicofiber (USA), Fibreglass (Canada), Asahi Fibre Glass Co (Japan), Chemitex-Anilana (Poland), Owens Corning , Goa glass, Twiga (india)
HIGH-TECH FIBRE
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Fiber Characteristics Applications Key players
Polytetrafluoroethylene (PTFE)
Excellent dielectric properties, high melting point.
Nonstick coating of pans, laboratory containers, magnetic stirrer.
DuPont (USA), Newton Filaments, Inc (USA), Albany Internation Inc. (USA), Toyobo (Japan)
Phenolic fiber High strength Automotive and electrical components.
Phenco (USA), The Vermont Organic Fiber Company (USA)
Conductive fiber
Electric conductive Military garments, intelligent garments.
Shakespeare Conductive Fibres LLC and Bekaert , Bakaert India (India)
PBI (Polybenzimidazole)
High strength and does not burn or melt.
Automotive parts, aircraft parts, insulation shield etc.
Celanese Acetate
Alginate fiber Highly absorbent Wound dressing, textile printing etc.
Speciality Fibres and Materials Ltd (UK), FMC Biopolymer (USA), Degussa Texturant Systems (Germany), Danisco Cultor (Denmark), Kimica Corporation (Japan), China Seaweed Industrial Association (China)
PBO fiber- Zylon
Highest strength among fibers.
Protective clothing and equipments. Toyobo Co. Ltd. (Japan)
HIGH-TECH FIBRE
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SEGMENT WISE CONSUMPTION OF FIBRES
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Clothing Textiles Technical components of shoes and clothing
e.g. liningsAll the natural, man made and Synthetic Fibers
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Home Textiles
Technical components of furniture, household textiles & floorcoveringsAcetates, acrylics, polyester, natural fibers…..
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Geo textiles Geotexiles and civil
engineering materialsJute, coir, Polypropylene, Polyester, Polyethylene, polyvinyl chloride, Polyamide, Aramids
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Industrial textiles
Filtration, conveying, cleaning etcNylon, polyester, polypropylene, glass fibers….
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Medical TextilesHygiene and medical productsPolyester, Cotton, polypropylene, silk etc…
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Wound dressingChronic wounds: 6.5 million
people - $25 billionImpaired healing – Inflammation
stage is prolongedResistance to
antibiotics
Silver impregnated dressings
Alternative metals, e.g. zinc as well as non-metal bactericides
Naturally derived compounds?
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Extracorporeal devices- artificial kidney, liver, heart pacer and lung
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Implantable materials- sutures, vascular grafts, artificial ligaments, cartilages, artificial joints, heart valves etc
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Resorb
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Protective TextilesPersonal and property protectionNomex, kevlar fibers…
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Sport TextilesSport and leisure E.g Yatcht, Hot air balloons…Polyester, nylon, spandex, glass fibers…..
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Packaging Textiles
Packaging materialsPolyethylene, polypropylene, glass fibers…..
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Transportation Textiles
Automobiles, shipping, railways and aerospacePolyester, nylon, glass, UHMWPE, aramids compsites, carbon fibers…
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Agro Textiles Agriculture, horticulture,
forestry and aquaculture textilesPolypropylene, polyester, polyethylene etc……
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Construction Textiles Building and
construction textilesKevlar, nomex, carbon fibers……
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Eco textile Textiles
Environmental protectionCarbon fibers…..
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Cotton Jute Viscose PET Nylon PP HDPE
LDPE/LLDPE
Aramid Glass Carbon
Agrotech
Meditech
Mobiltech
Packtech
Sporttech
Buildtech
Clothtech
Hometech
Protech
Geotech
Oekotech
Inditech
Summary of Segment wise consumption of different fibres
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Fiber stage
Yarn stage
Fabric stage
Wet processing stage
Technology at fibre, yarn, fabric
and end conversion stage
APPLICATION STAGES OF TECHNICAL TEXTILES
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TECHNICAL FIBERS
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USE OF NATURAL FIBERS AS TECHNICAL FIBERS
Egyptians and Chinese used papyrus mats in foundation forreinforcement of buildings
In recent past, synthetic fibers were used in floods in 1953 inNetherlands, it could be seen as start of geotextile
Cotton bales in foundation for earthquake protection
Cotton
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Wool
Wool, a protein fiber, consumption second to cotton
High extensible, natural waviness, trap air, low thermalconductivity, high thermal resistance, gives comfort and warmth
Due to morphology of wool, some technical fibers have beenproduced
Wool is comparatively fire retardant
Zirconium-and titanium-treated wool has much higher for exampleZirpro (IWS) wool used for fire proof padding in aero planes
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Flax, Jute, Hemp, Ramie
Not very common under use
Jute is used in geotextile, where biodegradable fibersare required
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Silk Protein-based fiber produced naturally by
the silkworm,
Structurally similar to wool
High tenacity, high luster and gooddimensional stability.
Used as luxury item,
Biocompatibility and gradualdisintegration an advantage in in medicaltextiles
Silk used for military clothing, due to light weight and for protection from arrows. Commonly used by Mongolian armies
Silk as wound dressing was very common by Chinese and EgyptianGranch Berhe 2015
REGENERATED FIBERS
Viscose rayon was regenerated fibers in the early 1920s. Has inferior physical properties to cotton
Improved shape has better tenacity in wet and dry conditions
Textured and hollow viscose fibers are comparable to cotton
Fire-retardant (FR) viscose introduced in the 1960s organophosphorous compounds
Viscose rayon
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• The fibre has relatively high uniformity, tenacity (16 – 30 cN/tex) and modulus, especially if impregnated with rubber. Its moisture content is about 3 % and 16 – 22 % extension at breake.
• Applications in -automotive industry (timing), production of hygienic and sanitary products via nonwoven technology.
Latest addition is Lyocell also known as Tencel (Acordis) environmentally friendly production method (non-toxic N-methyl morpholine oxide solvent – recyclable)
Lyocell
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SYNTHETIC FIBERSMade from coal or oil
Used in carpets, clothing, curtain,packaging
Nylon 6.6 first fiber in 1939 byDuPont
Many nylon fibers known aspolyamides produced by using melt
extrusion, many cross-sectional shapesare possible
High extensibility, significant recovery,more dimensional stability, low
moisture
Nylon
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• characterized by high tenacity (35 – 90 cN/tex), elasticity (15 – 60 %), resistance to abrasion and moisture (3 – 5 %).
• Capability of energy resilience is a condition for an application in manufacturing climbing ropes and linen for parachutes and sail fabrics.
• The typical application of polyamide is for reinforcing tires for use at low quality roads and of road vehicles
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Polyester (PET) Introduced as Dacron by DuPont in
1951. Now second major fiber
Made by condensation polymerizationof ethylene glycol and terephthalicacid followed
Durability and compatibility withcotton in blend, low moistureabsorbency, resilience and gooddimensional stability are additionalqualities.
Glass transition temperature isapproximately 70 °C, resistance toheat and chemical degradation, goodfor Technical Textile
Flame-retardant Trevira CS andTrevira high tenacity, developed byTrevira GmbH in Germany
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AcrylicPolyacrylic fibers produced by thepolymerization of acrylonitrile Orlon14 was produced by DuPont.
Acrilan15 produced by Monsantoand Courtelle, Wool-likecharacteristics.
Chemically modified acrylics haslow burning behavior and havinghigh absorbency, applicable inhygiene and medical care
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Polyolefin fibers
Include both polyethylene and polypropylene made by addition polymerization of
ethylene and propylene
Polyethylene has moderate physical properties with a low melting temperature of
about 110 °C for its low density form and about 140 °C for its high density form which
severely restricts its application in low temperature applications.
Polypropylene has better mechanical properties and can withstand temperatures of up to 140 °C
before melting at about 170°C.
Polyolefine fibres are low price, low specific gravity (0.90 – 0.96 g´cm–3), good abrasion
resistance, and low moisture content (0 %).
Replaced jute in packing equipment, ropes, base fabric for floor coverings, linings for
upholstery, technical nets etc
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• Low melting temperature of polyolefines is an advantage for
application in manufacturing of nonwoven by thermal bonding.
• Both polymers have a density less than that of water which allows
them to float as ropes, nets and other similar applications.
• The availability, low cost and good resistance to acid and alkaline
environments of polypropylene has greatly influenced its growth and
substantial use in geotextile applications
• High water repellency of PP finds application in manufacturing of
diapers and special thermo-physiological clothing, where two
employed layers are: hydrophobic and hydrophilic, and the wicks
made of PP enable transport of the liquidGranch Berhe 2015
PE and PP
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Spandex Yarn Polyurethane structure, can stretch
more than 8 times
Rubber-like properties,
Used in combination with otherfibers
Produced by DuPont in 1959(Lycra).
Expensive fiber, used in fabric
Formation, during knitting, yarn isalso produced by twisting with spandex yarn
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Functional and High Performance Fibers Driven by special technical functionsPosses unique properties Some of the most prominent of these properties
High tensile strength and stiffnessHigh temperature resistanceHigh flame retardant ability High chemical resistance
FIBRE PRODUCTIONThe latest technologies for spinning of high performance fibers are
Dry-Jet-Wet SpinningGel-Spinning Processes.Granch Berhe 2015
HIGH PERFORMANCE
ORGANIC FIBERS
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Dry-jet- wet spinning
Rigid-Rod Polymers are the starting materials Often liquid crystalline polymers
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Gel spinningSpecial process used to obtain high strength or other special fiber propertiesThe polymer is not in a true liquid state during extrusionUHMW and Super drawing
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Aramid Fibers Long-chain synthetic polyamide at least 85% amide (-CO-NH-)
linkages are attached directly between two aromatic ring. Molecular structure made of linked Benzene rings and amide bonds Aromatic Polyamides
C
O
H2N R
Amide Aromatic Aromatic polyamide
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TYPES OF ARAMIDBasically araimd fiber could be classified in two types.
A) Para aramide fiberB) Meta aramide fiber
They are chemically same but difference is in structure.A) Para aramide fiber
KevlarTwaronTechnoraSulfron
B) Meta aramide fiberNomex or Mylar NomexTeijinconexNew starKermel
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P-aramide
C-aramide
M-aramide
Structurally
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Dry-jet Wet SpinningSpinning Solution
10-20 wt% polymer
100% H2SO4 (H2O free)
removal ofsulfuric acid
Platinum capillary 65
Liquid crystal inpure sulphuric acidat 850C
air gap 10 mm withelongational stretch (6x)
coagulationbath at 100C
Specific points:Solvent: pure H2SO4
Polymer concentration 20%General orientation n the capillaryExtra orientation inthe air gapCoagulation in cooled diluted sulfuric acid
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CHARACTERSTICS OF ARAMIDS High strength Low elongation at break No melting point, 500°C Low Electrical Conductivity High Chemical Resistance Low Thermal Shrinkage High Toughness Excellent Dimensional Stability Flame Resistant, Self-Extinguishing
• Sensitive to acids and salts• Sensitive to ultraviolet radiation• Prone to static build-up unless finished
Structure dependentMeta vs. Para linkagesStructure of aromatic backbone
• Absorbency• Weight• Flexibility• Weavablelity
Compared to meta(1) Greater tensile strength (2) Greater chemical resistance and (3) Lower moisture regain.
Compared to para(1) Greater chemical, elongation and abrasion
properties (2) (2) Lower moisture regain.
Copolymer
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van der Waals forcesThe source of strength: H-Bond
Order
Orientation
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Heat and fire protection productsCut-protection productsBallistic-protection productsCivil engineering productsElastomer reinforcementsEngineering plasticsFriction productsOptical fiber cablesReinforced pipesBullet and explosion protection productsRopes and cables Adhesives, sealant and coatingsSpecialty paper productsCompositesTires,
APPLICATION OF ARAMIDS
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Strength
Para-AramidBullet Proof
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SulfronGranch Berhe 2015
Meta Aramid
Heat Resistant, Absorbency and Flexibility
Fire Proof
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Co Aramid
Low absorbency and Better StrengthGranch Berhe 2015
HPPE and UHMWPE• Gel-spun polyethylene fibres are ultra-strong, high-modulus fibres that are
based on the simple and flexible polyethylene molecule.• In the mid of 1970's reports of producing strong and stiff PE fibres started to
appear (modification)• The extension of polymer chains and high longitudinal orientation is a
precondition for accomplishing high mechanical properties. • The result of this treatment is production of high-performance polyethylene
fibre (HPPE)• Ultra-high molecular weight polyethylene (UHMWPE) fibres - strongest fibres
known, with tensile moduli in excess of 70GNm-2.– 15 times stronger than steel and twice as strong as aromatic polyamides
such as Kevlar.– Low in density, – Chemically inert – Abrasion resistant – Melts at around 150 °C and thermally degrades at 350 °C which restrict its
use to low temperature applicationsGranch Berhe 2015
66
Salient features
Moisture regain Zero
Attacked by water none
Resistance to acids excellent
Resistance to alkalis excellent
Resistance to UV light Very good
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Some ApplicationsBallistic protection
Cut and puncture resistant: for example cut
resistant gloves, fencing suits and chains-
saw hoses.
Composites: Twines and nets:
HPPE fibre is an ideal material for use in
marine environment.
Its density is slightly less than 1,
It does not rot and
Not affected by UV light and seawater
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HIGH PERFORMANCE
INORGANIC FIBERS
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Organic fibers can withstand only up to 500°CCarbon, glass, asbestos and ceramic inorganic fibers, can bear high temperature, bitter in nature, under use fromcenturies, best use is in by mixing with other materials, plastic sheets one example made by using glass fiber and polymers
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CARBON FIBRES• Also called graphite fiber.• It is in the form of several long strands of a material mainly
composed by carbon atoms. Carbon fibre variants differ in flexibility, electrical conductivity, thermal and
chemical resistance.
The primary factors governing the physical properties are degree of carbonization
(carbon content, usually greater than 92% by weight) and orientation of the layered
carbon planes.
Different precursors and carbonization processes are used
1. Rayon: high thermal resistance but relatively low strength, application in
aerospace.
2. Acrylic fibre : have higher strength than rayon precursors, used as reinforcement
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Creation• Spinning: A polyacrylonitrile plastic is spun into fibers
which are then washed and stretched to the desired diameter.
• Stabilizing: fibers are heated with O2 to make their bonding more thermally stable.
• Carbonizing: fibers then are heated without oxygen, they lose non carbon atoms and bonded carbon crystals are made.
• Treating surface: the surface is slightly oxidized.• Sizing: fibers are coated and wounded into bobbins.
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Advantages• It has the greatest compressive strength
of all reinforcing materials.• High strength to weight ratio.• Low coefficient of thermal expansion.• Its density is much lower than the density of steel.
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Some applications of carbon fibres:
• Used to reinforce composite materials• Used structurally in high-temperature
applications.• As an electrode with high surface area and
impeccable corrosion resistance.• Anti-static component. Composites for military aircraft, commercial aircraft Sporting goods, Medical devices, Industrial applications and infrastructure, Tennis rackets, golf club shafts, fishing rods, skis Aerospace
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GLASS FIBERS
The first "synthetic" fibre product of the human intelligence.
They are brittle, basically used in composites.High-performance composite materials,
including protective materials, various filters, protective clothing and packing.
Biggest application is the automotive industry for large-scale production of fibre reinforced car parts because of great weight savings.
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• Eglass fibre 90 % of reinforcement. • R glass fibre is used for special applications, such as,
aviation, space program, and defense due to its special performances regarding fatigue, temperature and moisture.
• AR type is used for cement reinforcement, with high content of zirconium oxide, which gives excellent resistance to alkaline compounds generated during drying. The cement reinforced with AR glass fibre has improved modulus and good durability.
• S type has high stiffness and finds its application where high mechanical properties are required
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ASBESTOS
crystalline silicates that occur naturally. – The fibres that are extracted have all the textile-
like properties of fineness, strength, flexibility and more importantly, unlike conventional fibres, good resistance to heat with high decomposition temperatures of around 550°C.
– They have carcinogenic problem
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CERAMIC FIBERS– Aluminosilicate compounds are mixtures of
aluminium oxide (Al2O) and silicon oxide (SiO2); their resistance to temperature depends on the mixing ratio of the two oxides.
– High aluminium oxide content increases their temperature tolerance from a low of 1250 °C to a maximum of 1400°C
• Used for insulation of furnaces and replacement of asbestos fibres in friction materials, gaskets and packing
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ULTRA FINE AND NOVELTY FIBERS
Ultra fine fibers have 1.0 dtex or less
Linear density of extra-fine and microfine is less than 0.1 dtex
Commonly PET and Nylon are used
First made in Japan e.g. Mitrelle,Setila, Micrell, Tactel
Once in woven fabric form their finediameter and tight weave allows
Up to 30000 filaments cm-2, highlydense, water proof but air andmoisture vapor can pass
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Specialty Materials has made boron prepreg tape with various cyanate ester and cyanate siloxane resins for space structure stabilization applications.
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Technical yarns
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Introduction
• These are yarns for making technical textiles• They are made through special yarn production
techniques or through the election of special fibre blends or a combination of both
• Machines for yarn making– Ring frame– Rotor – Friction– Airjets
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Staple fiber yarns
• Ring spinning – most versatile– wide ranges of linear
density and twist from a great variety of fibre materials
– Prior material preparation is important
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Ring spinning
• Ring-spun yarns have a regular twist structure and, because of the good fibre control during roller drafting, the fibres in the yarn are well straightened and aligned. – excellent tensile properties, which are often
important for technical applications.
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• The ring spinning system can be used for spinning cover yarns - combination of technical properties.– high strength yarn with good comfort
characteristics may be spun from a high strength filament core with natural fibre covering.
– technical yarns, such as flame-retardant and antistatic yarns can also be made by incorporating flame-retardant and electricity conductive fibres.
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• Limitations – low production, high drafting and spinning tension (problem for low tension fibers)
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Rotor spinning
Advantage of speed, cost reduction
Yarns are of lower strength than ring spurn Better evenness
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Friction spinning
• The main application -industrial yarns and for spinning from recycled fibres.
• It can be used to produce yarns from aramid and glass fibres and with various core components including wires.
• Application - tents, protective fabrics, backing material, belts, insulation and filter materials.
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Wrap spinning• Wrap spinning is a yarn formation
process in which a twistless staple fibre strand is wrapped by a continuous binder
• Core yarns,mostly filaments, can be added to the feed.This can be used to provide extra yarn strength or other special yarn features
• carbon-coated nylon filament yarn can be used to produce yarns for antistatic fabrics.
• Soluble binders can be used for making yarns for medical applications.
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Ply yarns
• For high strength and modulus yarns for technical and industrial applications, ply yarns are often needed.
• These are co-twisted yarns
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Filament yarns• Aramide filament yarns
– Kevlar and nomex– Aramid yarns are more flexible and easier to use in subsequent
fabric making processes, be it weaving, knitting, or braiding• Glass filament yarns– widely used in the manufacture of reinforcement for
composites.– E-glass has very high resistance to attack by moisture and has
high electrical and heat resistance. It is commonly used in glass-reinforced plastics in the form of woven fabrics.
– C-glass is known for its chemical resistance to both acids and alkalis. - chemical filtration.
– S-glass is a high strength glass fibre and is used in composite manufacturing.
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• Carbon filament yarns – From rayon and arcylic– Oxidative (200-300oC) – carbonization (1000oC) –
graphitization (3000oC)– Brittle and conductive
• HDPE filament yarns– Produced by gel spinning process from
polyethylene with an extra high molecular weight.– Characterized by high paralyzing and crystalline
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Technical Fabrics
Fabrics manufactured primarily for their technical performance and functional properties rather than their aesthetic or decorative characteristics
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Methods for producing fabrics
• Weaving • Knitting• Lace making• Net making• Felting• Tufting• Non-woven processes
A 3-D Fabric
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WOVEN FABRICS
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Warp (Ends) & Weft (Picks)
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Woven Fabric Specifications
• Fabric construction– Warp count x weft count/ ends per inch x picks per
inch• Fabric area density / GSM• Cover factor• Type of weave• Crimp• Fabric width• Thickness
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Fabric area density• The loom state cloth area density depends on the
weaving specification, that is, yarns, thread spacing and weave, and on any additives, such as size, which are used to improve the weaving process.
• Finished cloth area density is frequently altered by chemical treatments .
• The area density of the fabric can be varied by changing the linear density or count of the yarns used and by altering the thread spacing, which affects the area covered by the yarns in relation to the total area.
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Cloth cover factor• Cloth cover factor = warp cover factor + weft cover factor• Cover factor in SI units =
• Cover factor formula by Pierce =
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Area density and cover factor• Low area density fabrics of open construction
include bandages
• Light area density fabrics high cover factor fabrics include medical filter fabrics
• Heavy open cloths include Geotextiles fabrics
• Heavy closely woven fabrics include cotton awnings.
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Plain weave
• 90% technical fabrics have plain weave
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Other types of weave
Twill weave
Satins and sateen
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Triaxial weave
•Triaxial fabrics are defined as cloths where the three sets of threads form a multitude of equilateral triangles•Two sets of warp yarns are generally inserted at 60° to the weft, •Tetra-axial fabrics where four sets of yarns are inclined at 45° to each other
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Triaxial weaves• The tear resistance, bursting resistance of
Triaxial fabrics is greatly superior to that of standard fabrics
• They have a wide range of technical applications including sailcloths, tyre fabrics, balloon fabrics.
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Classification of Weaving Machines
• Single-phase weaving machines– Machines with shuttles (looms):
• Hand operated (hand looms)• Non-automatic power looms (weft supply in shuttle changed
by hand)• Automatic weaving machines
– Shuttle less weaving machines:• Projectile• Rapier• Jet machines– air (with or without relay nozzles)– liquid (generally water)
• Multiphase weaving machines
In single phase machines, one weft thread is laid across the full width of the warp sheet followed by the beat-up and the formation of the next shed in preparation for the insertion of the next pick.
In multiphase machines, several phases of the working cycle take place at any instant so that several picks are being inserted simultaneously.Granch Berhe 2015
Projectile looms…• They are used not only for weaving a vast range
of standard fabrics but also for heavy industrial fabrics of up to 8m wide, for – sailcloth, – conveyor belts,– tyre cord fabrics,– awnings, – Geotextiles, – airbags and – a wide range of filter fabrics of varying area density
and porosity.
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L680W series high-efficiency fibre glass rapier cross weaving machine
Suitable for the weaving of various gridding cloth used in civil engineering, hydraulic construction, building materials, chemical engineering and transportation areas
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OMNI plus 800 air jet weaving machine
• Gauze– Gauze is a lightweight, open-texture fabric produced in
plain weave, used for bandages, food wrapping etc.• Parachute
– Parachute is industrial, heavy-filament, rib stop cloths made of fine nylon fibre
• Tyre cord– Tire cord is a fabric used to reinforce the tires of
vehicles
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OMNI plus 800 air jet weaving machine
• Umbrella cloth– Umbrella cloth is usually made with a cotton warp
and rayon or nylon filling, which is then treated to make it water repellent.
• Camping tent cloth – Camping tent cloth is a fabric used for the outer
covering of tents for recreational camping.
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OptiMax rapier weaving machine
• Conveyer belt– Conveyor belt is a continuously moving strip or
surface for transporting a load of objects from one place to another.
• Filter cloth– Filter cloths are mainly made up of monofilaments
and/or multifilament's.
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Woven either on rapier or air-jet technology
• Sail cloth– Sail cloth is any heavy, plain-weave canvas fabric,
usually made of cotton, linen, polyester, jute, nylon etc. that is used for sails and apparel.
• Seat fabrics– Seat fabrics are used to cover seats in the transport
industry (automotive, aviation, etc.)• Air bags
– Airbag is a heavy denier nylon fabric for personal protection in various forms of transportation.
– Most airbag fabrics are woven with rapier weaving technology.
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OMNIplus 800 TCThe most advanced tire cord weaving machine
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Knitted technical textiles
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Definition • Warp knitting is a method of making a fabric by normal
knitting means, in which the loops made from each warp are formed substantially along the length of the fabric
• Weft knitting is a method of making a fabric by normal knitting means, in which the loops made by each weft thread are formed substantially across the width of the fabric.
• Single-jersey fabric is a weft-knitted fabric made on one set of needles.
• Double-jersey fabric is a weft-knitted fabric made on two sets of needles,
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Needles
• Basically latch and beard needles used, others are compound
Bearded needles -expensive to manufacture, can be producedin finer gauges and supposedly knit tighter and more uniform stitches comparedwith latch needles, but have limitations with regard to the types of material thatcan be processed as well as the range of structures that can be knitted on them.
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End use products
• Flat bar machines: Cleaning clothes, three-dimensional and fashioned products for technical applications, multiaxial machines are under development
• Circular machines: Hose machines: seam free hose, tights, industrial use dye bags, knit-de-knit yarns, industrial fabrics
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Warp knitting• Higher machine speeds, (up to 3500cpm)• Finer gauges (up to 40 needles per inch)• Wider machines (up to 260 inches)• Some speciality raschel machines such as Co-we-nit and Jacquard
machines• More recently, redesigned full-width weft insertion raschel and
tricot machines• Stable constructions, such as sharkskins, queenscord, etc.• Various net constructions utilising synthetic yarns• Mono-, bi-, tri- and multiaxial structures for technical applications• Three-dimensional and shaped (fashioned) structures for medical
and other high technology products.
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• Tricot machines: car seats, technical fabrics• Raschel machines:nets, fishing nets, sports
nets, technical fabrics, curtain lace, power nets, tablecloths, bed covers, elastic bandages, cleaning cloths, upholstery, drapes, velvets, carpets, fruit and vegetable bags, geotextiles, medical textiles.
End use
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NONWOVEN and their APPLICATION
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Defination of nonwoven• Structure produced by bonding or interlacement of fiber or
both accomplished by mechanical , chemical ,thermal or solvent mean and the combination of techniques .
Term does not include paper or fabric that are woven, knitted or tufted or those made by other felting process.
or we can say that nonwoven is direct conversion of fiber
to fabric.
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Why to go for nonwoven????• Due to high production a versality of use of
different fibres to produce final product having required properties according to final product and also elimination of spinning and weaving process
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Manufacturing ProcessManufacturing Process
Various techniques are used for manufacturing of nonwovens but some of the techniques that are used specially for the Medical applications point of view are as follows:
Spun bonding Spunlacing Meltblowing Needle punching Wet laid Dry laid
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Spun bondingSpun bonding
Spun bonding is used when more strong webs are needed.
Webs produced are soft, porous and dimensionally stable.
Spun bonding is mostly used for products like :- Face masks Head wears Shoe covers Bed linens and Disposable clothing .
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Flow chart of Spun bonding Processes
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Manufacturing Processes
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Wet laid – principle of technologyThere 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
Fiber swelling and dispersion
Suspension transport
Web formation
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Wet laid
Wet-laid nonwovens are nonwoven fabrics made by a modified papermaking process, that is, the fibers to be used are suspended in water, and specialized paper machines separate the water from the fibers to form a uniform sheet of material which is then bonded and dried to produce rolls of product.
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Air laid - principle
The fiber material is at first opened by rotating cylinder named lickerin. Then single fibers are dispersed into the air stream and condensed on the perforated cylinder or belt.
Air laid fabric compared with carding technology has these features:
• The fibers are oriented randomly on the fabric surface – isotropic structure.
• Voluminious webs can be produced
• Wide variety of processable fibers
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The Bonding Process is the essence of Nonwoven Technology. Mechanical Bonding
Needle Punching
Stitch Bonding
Hydro-entanglement (Spun-lace)
Chemical Bonding Binder Application – Wet
Powder Application – Dry
Thermal Bonding Calendar
Hot Air
Spun Bonding / Melt Blown
Bonding technologies
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Thermal bonding Wet-laid webs may be thermally bonded by
the application of heat providing the web contains a fiber or an additive that will fuse at the selected bonding temperature and will flow between the fiber junctions. On cooling, the binder material locks the fiber network together.
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Melt blown
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Application Area 1)Sanitary and Medical uses
1.Feminine Hygiene
2.Diapers3.Patient Apparel4.Surgical gown/ mask
2) House hold textiles 1.Floor & wall covering2.Blankets 3.Pillow covers, Bed sheets4.Towels5.Luggage & Table cloth6.House hold wipes
3)Civil Engg. Application 1.Geotextiles water proofing2.Roofing material
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4)FOOTWEAR APPLICATIONS
1.Shoe cover 2.Lining 3.Sole
5) APPARELS 1.Interlinings 2.Protective clothing 3.Laboratory aprons
6)OTHER UTILITY MATERIAL
1.Decorative textiles 2.Book covers 3.Tea bags 4.Tents
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Applications of nonwovens in medical Applications of nonwovens in medical textilestextiles
Bandages Simple bandages Light support bandages Orthopedic bandages
Cotton pads, wound dressings and adhesive tapes
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Contd.Contd.
Disposable surgical clothing:
Gowns Caps Masks
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Contd.Contd.
Disposable surgical coverings:• Blankets• Floor coverings of hospitals (anti-bacterial)• Cloths/ wipes
Drapes Bed coverings
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Contd.Contd.
Nonwovens are used to replace or repair different organs, bones like artificial kidney, liver, heart, mechanical lung, ligaments, vascular grafts, heart valves, blood vessels, artificial skins, nasal strips etc.
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Properties of the medical nonwoven
The main criteria for determining the suitability of textile products are :-
• – barrier efficiency toward bacteria, viruses, liquids and dust particles
• – capacity to absorb and store body fluids• – resistance to mechanical influences
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• Nonwoven fabrics can be used in the following household textile applications:
• – floor coverings• – sub-upholstery materials• – webbings Materials for use in the contract sector have to
meet legal specifications regarding their flammability.
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NONWOVEN HOUSEHOLD PRODUCT
Nonwoven wall hanging China nonwoven carpet
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NONWOVEN IN PROTECTIVE CLOTHING
FLAME RESISTANCE NONWOVEN GLOVES
NONWOVEN USED RESIST TO CHEMICAL
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Filter fabrics
• Pulsejet fabric filters are widely used in many industries like solid, fuel, Fired power generation.
• e.g. for industrial dust removal or for cleaning atmospheric air.
• Conveyor belts, seal gasket, other industrial equipment.
• nonwoven fabrics are to be used as filter media for both wet and dry filtration.
• The end-use-specific textile physical and general physical parameters should also be determined:-
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Geo Textiles
• Nonwoven geotextiles:- nonwoven geotextiles are thicker and made either from short
and continuous filaments, carded or laid in even patterns and then mechanically (needle punched) or thermally bonded.
Woven geotextiles Nonwoven geotextiles
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Benefits of nonwoven geotextiles
• Cheap and easy to manufacture.• Superior chemical resistance in even the
aggressive environment application.• Highly porous structure• Staple fibres needle punched together to form
fabric capable of withstanding construction installation stresses.
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GEO NONWOVEN
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