Nonwovens for technical applications

NONWOVENS FOR
TECHNICAL
APPLICATIONS
Infoday. April 22nd, 2015. Gaziantep
(Turkey)
Oscar Calvo
R&D Group on Textile
Finishing, Health and
Environment

1. INTRODUCTION TO AITEX’s RESOURCES ON NW TECHNOLOGIES
2. NONWOVEN MANUFACTURING TECHNOLOGIES
3. MARKET TRENDS FOR TECHNICAL APPLICATIONS OF NWs
4. CASE STUDIES AND SUCCESSFUL STORIES
5. CONCLUSIONS
Infoday. April 22nd, 2015. Gaziantep (Turkey)
Nonwovens for technical
applications2
SUMMARY

When nonwovens are involved in textile applications, in most cases
some auxiliary processes are also required (technical finishing
processes/technologies), and some of them are available at AITEX:
3
Coating
Lamination / bonding
Surface treatments
Electrospinning
applicationsInfoday. April 22nd, 2015. Gaziantep (Turkey)
Air-laid
Wet-laid
Nonwoven-based
technical application

2 main technologies are available for lab trials and testing of new
fibers for innovative nonwovens:
4
Nonwoven production (lab scale)
Air-laid technology: very short fiber material can be applied.
Wet-laid technology: dispersion of the short fibers using water.

Our pilot plant can apply wet finishing on textiles by padding
(impregnation) or by knife coating (on air and over roll) techniques.
Maximum width: 50 cm; it can works in a speed range of 1 - 10 m/min;
drying-curing temperatures: 30 - 200ºC; pressure for padding (control of
the pick-up/uptake) can be applied in the range of 1 - 6 bar.
5
Auxiliary technologies: coating/padding
Knitted / weaved fabrics but also
nonwovens can be processed,
using some polymeric binders
(acrylics, PUs…) or some
functional finishing formulations
(liquid repellents, antimicrobial,
FRs, UV protectors…).
applications

Hotmelt lamination technologies are based in the use of adhesives that
are applied in a melted state (from 60 - 80 to 220ºC depending the
adhesive type) solidifying again quickly when are cooled down. Hotmelt
adhesives are dry compounds (solid content: 100%) and are applied
without the use of water or solvents. Pilot plant for trials:
Speed: 2 - 18 m/min.
Width: 250 mm.
*Different gravure rollers: 10, 15, 30 g/m2
Thermoplastic adhesives:
- polyolefins (PE, PP).
- etilen-vynil-acetate (EVA).
- copolyamides (PA).
- copolyesters (PES).
- thermoplastic polyurethanes (TPUs).
Reactive adhesives:
- reactive polyurethanes (PUR).
- reactive polyolefins (APAO).
6
Engraved* roller system available
FOR BONDING
DIFFERENT
MATERIALS
(including NWs)
applications
Auxiliary technologies: hotmelt lamination/bonding

applications
Plasma technology (dry process using only gas as raw material) is a
kind of surface treatment that activates polymeric materials (including
yarns, fabrics or membranes) increasing their reactivity. Plasma
treatments only modify the performance of the surface (not other
properties of the bulky material).
Activation of the textile surface (to improve wettability/adhesion
behavior) or possibilities to develop repellent nanocoatings on the
fabric surface (by plasmapolimerization) can be achieved. 2 pilot plants.
7
Surface treatments (by plasma technologies)
Low pressure plasma
Atmospheric (corona
discharge) plasma
To improve wettability:
Inorganic gasses (O2, N2)
To obtain repellency:
Organic monomers that
can polymerize
Power source:
100W to 1400W
Speed process:
5 to 50 m/min

Electrospinning is used for the production of nanofibers, starting from a
polymer solution. Method: high voltage is applied to a polymer solution
(some electroconductive performance). One electrode of the voltage
source is placed into the solution and the other is connected to the
collector of nanofibers (usually a NW). When charges within the solution
reached a critical amount, a fluid jet will erupt from the droplet at the tip of
the needle resulting in the formation of a Taylor cone. The electrospinning
jet will travel towards the region of lower potential, which in most cases, is
a grounded collector. A web of solid randomly oriented nanofibers is
deposited on the surface of the grounded collector. 4 pilot plants available.
8
Electrospinning technologies
Taylor cone
Nanofibers (NF) web
Randomly oriented
Collector (micro)
NF web (nano)
applications

9
Nonwovens (also for coating and laminating) is a growing worldwide
market.
The key processes to manufacture nonwovens are:
• Spunbond + meltblown.
• Needlepunch.
• Thermal or chemical bond.
• Spunlace / hydroentanglement.
• Air-laid.
• Wet-laid.
Taken from KELLIE SOLUTIONS. TCL 2012.

10
The melted filaments are swirled around and then deposited on the wire
mesh belt as a random nonwoven. This web is transferred to a bonding
calender that uses heat and pressure.
TECHNOLOGIES:
NONWOVEN
TECHNOLOGIES
SPUNBOND &
MELTBLOWN
NEEDLEPUNCH
THERMAL / CHEMICAL
BONDING
SPUNLACE
AIR-LAID
WET-LAID
- Quite high air permeability.
- Good mechanical & wear properties.
- Soft and comfortable.
- Average weight is 10 to 150 g/m2.
- Mainly for hygiene products.
- Protective apparel.
- Construction, agrotextiles…
- Battery separators.
applications

11
Mechanical bonding method: fibers are transported with felting needles
and interlocked in the nonwoven structure. This procedure increases
the friction between the fibers, which reinforces the nonwoven.
TECHNOLOGIES:
NONWOVEN
TECHNOLOGIES
SPUNBOND &
MELTBLOWN
NEEDLEPUNCH
THERMAL / CHEMICAL
BONDING
SPUNLACE
AIR-LAID
WET-LAID
- High speeds (> 150 m/min).
- It permits the use of recycled material.
- Fiber count ranging from 1 - 200 dtex.
- Average weight is 30 to 3.000 g/m2.
- Cleaning wipes, home textiles…
- Medical and hygiene products.
- Automotive, composites…
- Filters, geotextiles, protective apparel...
applications

12
The nonwoven web is consolidated in a thermal (hot calendering) or
chemical way (impregnation). Thermal bonding uses the thermoplastic
properties of certain synthetic fibres to form bonds under controlled
heating; chemical bonding is based on the application of a liquid
(bonding agent).
TECHNOLOGIES:
NONWOVEN
TECHNOLOGIES
SPUNBOND &
MELTBLOWN
NEEDLEPUNCH
THERMAL / CHEMICAL
BONDING
SPUNLACE
AIR-LAID
WET-LAID
- Mixture of natural / synthetic fibers.
- Different liquids for impregnation.
- Medium speeds for production.
- Industrial applications, composites…
- Automotive, acoustics, agriculture…
- Electrical insulation, coating/flocking…
applications
THERMAL
CHEMICAL

13
Spunlacing uses high-speed jets of water to strike a web to intermingle
the fibers. A vacuum within the roll removes used water from the product,
preventing flooding of the product. Spunlacing can be carried out using
natural or man-made fibers, or blends. Water recyclability of the system
should be high.
TECHNOLOGIES:
NONWOVEN
TECHNOLOGIES
SPUNBOND &
MELTBLOWN
NEEDLEPUNCH
THERMAL / CHEMICAL
BONDING
SPUNLACE
AIR-LAID
WET-LAID
- High-water-pressure machines are used.
- Softness and comfortable hand.
- Weight: 20-800g/m2; speed: 5-300 m/min
- Wipes, medical & surgical, cotton pads.
- Roofing felts and geotextiles.
- Apparel.
applications

14
Major advantage: very short fiber material can be applied. This is of
special interest for recycled fiber material such as cotton waste (e.g.
from spinning and yarn material). The fibers are fed into an air stream and
from there to a moving belt or perforated drum: they form a randomly
oriented web.
TECHNOLOGIES:
NONWOVEN
TECHNOLOGIES
SPUNBOND &
MELTBLOWN
NEEDLEPUNCH
THERMAL / CHEMICAL
BONDING
SPUNLACE
AIR-LAID
WET-LAID
- Air-laid webs have a low density.
- Greater softness.
- Absence of laminar structure.
- Automotive and transport applications.
- Composites, geotextiles, agriculture…
- Roofing felts.
applications

15
It’s a modified papermaking process. Main steps: 1) Swelling and
dispersion of the fiber in water and transport of the suspension on a
continuous traveling screen; 2) Continuous web formation on the screen
as a result of filtration; 3) Drying/bonding of the web. Water recyclability
of the system.
TECHNOLOGIES:
NONWOVEN
TECHNOLOGIES
SPUNBOND &
MELTBLOWN
NEEDLEPUNCH
THERMAL / CHEMICAL
BONDING
SPUNLACE
AIR-LAID
WET-LAID
- Innovative technology (5 - 10% of NWs).
- Usually 2 - 30 mm fibers are used.
- Bonding by hot calender or chemicals.
- Composites, reinforcement materials…
- Roofing felts, filters, insulating uses…
- Sanitary and hygiene applications.
applications

16
Nonwovens have a strong influence in the EU-28 textile industry. But
currently Asian countries are increasing their production force.
applications
Taken from KELLIE SOLUTIONS. TCL 2012.

17
The growth of non-wovens and of composites and their relation with
technical textiles.
In the past decade, the Technical Textiles sector has grown by 22%.
The technical textile sector is undergoing significant industrial change with
the growing importance of new applications (medical, sport and leisure,
aeronautics, environment), and a radical move from traditional
technologies (knitting, weaving, etc.) to more recent ones (like composites
or nonwoven-based technologies).
Growth in Europe is mainly driven by two technologies:
•Nonwoven with a growth rate of 60% over the past decade.
•Composites with a growth rate of 75% over the past decade.
And don’t forget the combination with high-tech finishing processes!

18
EU sector of technical textiles
obtained by finishing processes
(coating, laminating) is a highly
technical, very competitive market
and in a constant growth.
For example, in 2011, turnover of
laminating EU companies was
around 8.000M € (nearly 8% of these
companies in the EU were Spanish).
Demand distribution of coated / laminated
technical fabrics at European level, 2011 (Detrell
A. The European Coating and Laminating Sector.
TCL2012).

19
In Europe, hotmelt technology can
be currently considered as a mature
technology, which started to come
into use in the early 2000s, with the
development of new laminating
systems, new membranes and new
adhesives.
Nevertheless, it did take about 10
years to reach its true potential and
the leading technical finishing
companies have invested in new
laminating lines (or they are currently
incorporating it into their production
processes).
Sales evolution (data in M metres) of waterproof-
breathable textile articles in the EU (Detrell A. The
European Coating and Laminating Sector.
TCL2012).
applications

20
More technical properties, more added-value, more end-uses for your
nonwovens with finishing processes:
applications
PADDING KNIFE COATING DYEING PRINTING
EXTRUSION COATING METALLIZATION SPUTTERING
HOTMELT LAMINATION PLASMA TREATMENT THERMOBONDING

21
And the main global opportunities for new nonwoven-based applications
are:
applications
Growing needs of textile solutions from the end-users: comfort and
monitoring solutions for active life style, CO2 emission reduction in
transport (through reduced weight) and building (through thermal
insulation), improvement of medical technology (implants, health
monitoring), etc.
Close cooperation ‘producers + customers’ in order to address very
specific needs (tailor-made solutions) and demand-driven innovation.
Growing demand for recyclability and low weight (e.g. replacement of
foam by nonwovens, or replacing metallic parts by composite materials).
Quick growth of technical textile consumption per capita worldwide
and especially in China, India and Brazil. Emerging markets.

22 Infoday. April 22nd, 2015. Gaziantep (Turkey)
applications
Raw materials consumption. By applying the right forming and bonding
techniques, water consumption is drastically reduced. Also, modern
wetlaid or spunlaced production lines are recycling almost all of the
water consumed in a closed loop. Furthermore, thanks to ongoing
machine improvements, weights are possible down to 10 grams per square
meter, which means reduced fiber consumption.
Biodegradable fibers. Traditional disposables, like hygiene and medical
products, are in real trouble because of tighter environmental laws.
There soon will be no more landfills to handle used disposables. The
industry is challenged: PLA, cellulose-based (Tencel / Lyocell) fibers
and flushability performance (disintegration of towels or wet wipes when
are flushed down the toilet) required.

23
Opportunities in new products and applications for different sectors:
Geotextiles, agrotextiles and construction
applications

24
Geotextiles, agrotextiles and construction
applications

25
Filtration elements
applications

26
Automotive / transport
applications

27
Hygiene, and medical garments and wounds
applications

28
Supporting media / collector for nanofiber-based products
applications

29
Wet-laid technology for advanced nonwoven-based products
applications
Structural applications
when combined with a
conforming process!!!

30
CASE 1: FILTER FOR LUBRICANT OILS (FOR CUTTING
TOOLS)
Objective. Obtaining a needlepunched-based nonwoven for filtration of
lubricant oils, in order to enlarge life cycle of the filtering media and to
enhance possibilities for reusing the oils.
Clogging problems of the filtering media of complex liquids.
applications

31
CASE 1: FILTER FOR LUBRICANT OILS (FOR CUTTING
TOOLS)
Results. Multilayer material combining NW + woven PP substrate.
applications

32
CASE 2: NATURAL-BASED NW FOR SANITIZING GARMENTS
DURING THE WASHING PROCESS
Objective. Fabrics washed using a nonwoven impregnated with neem
extract.
A cellulosic nonwoven (NW) was impregnated -padding system- with
neem oil, and introduced on the washing machine with cotton fabrics. The
main goal was to transfer antimicrobial properties from the NW to the
fabrics.
Garments that are washed with detergents are clean and hygienized (of
course!!!) but they don’t show durable antibacterial properties (they are
not functional).
applications

33
CASE 2: NATURAL-BASED NW FOR SANITIZING GARMENTS
DURING THE WASHING PROCESS
Results. Functionalization of the nonwoven with a natural extract from
plants, and durable functional antibacterial properties on garments
washed with it.
applications

34
Infoday. April 21st, 2015. Denizli (Turkey)
New finishings for innovative
home and technical textiles
CASE 3: NATURAL-BASED ANTIBACTERIAL PROTECTION
FOR NON-WOVENS USED IN AGRICULTURE
Objective and results. Finishing of NW-based substrates used in
agriculture to protect vegetables/fruits from harmful bacteria-fungi. Use of
natural-based compounds for impregnating and finishing.

35
Infoday. April 21st, 2015. Denizli (Turkey)
New finishings for innovative
home and technical textiles
CASE 4: NON-WOVENS AS GROWING SUPPORT FOR SEEDS
Objective and results. Development of a non-woven based substrate
(with biodegradable properties) for supporting seeds during culture period
and growing of vegetables/fruits.

36
CASE 5: NON-WOVEN and NANOFIBER-BASED END-
PRODUCT FOR COSMETIC USE WITH HYDRATATION
PROPERTIES
Objective and results. Development of nanofiber-based webs (even
functionalized with active compounds) supported on a nonwoven, for skin
care and hydratation properties.
applications

5. CONCLUSIONS
37
New systems to develop nonwovens and special machinery with eco-
sustainable performance are available in the market.
New functionalities for develop non-woven based applications can be
obtained combining the NW substrate and a finishing technology.
End applications are in a wide range: from easy-to obtain and common
products (diapers, cleaning wipes, agriculture…) to high-technical end
uses (automotive, FR substrates, filtration systems, biomedicine-based
end applications, tissue engineering and cell culture…).
A wide range of end-products and markets can be reached with a right
combination of fiber + NW technology + functional finishing.
applications

Teşekkürler!!!
Thank you for your attention!!!
María Blanes (mblanes@aitex.es). Team leader of the
R&D Group on Textile Finishing, Health and
Environment.
Oscar Calvo (ocalvo@aitex.es). Researcher.
R&D Group on Textile Finishing, Health and
Environment @ LinkedIn:
https://www.linkedin.com/groups/R-D-Group-on-Textile-
8102442/about
AITEX website: http://www.aitex.es

Nonwovens for technical applications

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