Needle-punched Nonwoven Fabrics Research Articles

PTFE foam coating ultrafine glass fiber composite filtration material with Ultra-Clean emissions

Bag filters are widely used for dust removal in the industrial applications with filtration materials serving as the critical component. It is meaningful to develop filtration materials with ultra-clean emission effect, as the emitted gas can be proceeded directly by carbon capture technologies. In this study, we introduced a novel approach to fabricate a kind of gradient-structured filtration material by wet-laying ultrafine glass fibers on the surface of aramid fiber needle-punched nonwoven fabrics, followed by PTFE emulsion foam coating. Our PTFE foam coating ultrafine glass fiber composite filtration material demonstrated remarkable filtration performance, achieving a high filtration efficiency up to 99.86 % and a low pressure drop of 87.54 Pa. After undergoing 30 cycles of filtration, the particulate emission concentration was 0.4327 mg m−3. Significantly, this innovative filtration material exhibited exceptional stability, primarily attributable to the surface filtration effect of the PTFE foam coating layer. This innovative design provided a kind of new direction for the flue gas filtration and the emitted clean air can be capture by carbon capture technologies directly.

Blend of Fibres to Improve the Mechanical Properties of Needle-Punched Nonwovens for PM2.5 Air Filtration

This research investigated the innovative synthesis achieved through blending five distinct fibres (Polyacrylonitrile (PAN), Polyester (PET), Polylactic acid (PLA), Polypropylene (PP), and Polyphenylene sulfide (PPS)) in the production of needle-punched nonwoven fabrics tailored for air filtration applications. The study investigated the effects of needle-punched nonwovens made with up to five fibres on the physical and mechanical properties, addressing a gap in existing literature. The method involved manual and machine opening, blending, and carding of fibre s, followed by producing three samples with different web arrangements (cross laid web, parallel laid web, and pre needled parallel lad web). The study employed standard test methods to characterize physical and mechanical properties. Results indicated that web arrangement and pre-needling significantly influenced various properties, with cross and parallel-laid web arrangements having minimal impact on thickness and bursting stretch. The parallel arrangement, whether pre-needled or not, showed no significant effect on GSM, fabric density, bursting strength, tear strength, abrasion resistance, and filtration efficiency. The highest abrasion resistance, lower pressure drop, highest fabric stiffness, moderate tensile strength, and higher bursting strength were observed in a cross-web arrangement. This study contributed valuable insights into the intricate interplay of fibre composition, web arrangement, and pre-needling in the design of advanced needle-punched nonwoven fabrics for air filtration. The findings provided a nuanced understanding of how these factors collectively impact the mechanical and physical characteristics of the material, paving the way for enhanced efficiency, durability, and versatility in air filtration applications.

A comparative study of physical properties of nonwoven fabrics produced by uni- and bi-directional needles using response surface methodology

In the production of needle-punched nonwoven fabrics, the direction of needle barbs is towards the tip of the needle. When the needle penetrates into the fabric, the barbs carry some fibres into the fabric and when it returns the barbs are empty. This means that, the needle works when it penetrates into the fabric and doesn’t work when it returns. Using a bi-directional barb needle in the needle-punch process was proposed as an idea with the theory that, the needle also works when returning (leaving the layer). This study investigates the physical properties of needle-punched nonwoven fabrics produced with unidirectional and bi-directional needle types. Effects of needle penetration depth (NPD), strokes per minute (SPM), and needle type (N1, N2) on properties such as gram per square meter (GSM), thickness, fabric density (FD), and static puncture resistance (SPR) are examined. An experiment with 19 runs was designed using response surface methodology and optimal design with two quantitative factors, including NPD and SPM, and one qualitative factor containing needle types. In addition, four responses were measured and reported, including GSM, thickness, FD, and SPR. Test results show that needle N2 produces a fabric with lower FD, higher GSM, thickness, and SPR in comparison to needle N1, and was selected in optimization process with a desirability value of 0.872 against 0.688 for needle N1. The improved fabric properties of needle N2 may be exploited for the economic benefits of the nonwoven fabric producers or textile industry.

Orientation of Fibers in Needle-Punched Nonwoven Fabrics

Orientation of Fibers in Needle-Punched Nonwoven Fabrics

Viscose nonwoven fabric with copper and its multifunctional properties

The antimicrobial functionalization of textile structures with copper and its compounds carried out by various methods increased significantly during the SARS-CoV-2 pandemic. So far, in order to obtain antiviral properties the magnetron technique using copper was applied mainly to flat textile structures; polypropylene, polyester and cotton nonwovens, and polyester and cotton woven fabrics. In this study, magnetron sputtering with copper was applied to modify the spatial viscose needle-punched nonwoven fabric. We found that the spatial nonwoven structure made of regenerated cellulose fibers and one-side sputtered with copper has strong antimicrobial activity against Gram-positive Staphylococcus aureus and Gram-negative Klebsiella pneumoniae. In the case of herpes simplex virus type 1 (HSV-1) McKrae strain, vaccinia virus (VACV) WR strain, influenza A virus H1N1 (IFV) and mouse coronavirus (MHV) JHV strain used in the study, Cu modified nonwoven fabric has only weak activity against herpes simplex virus type 1 (HSV-1). It also has no significant toxicity compared to the control medium and pristine nonwoven fabric. The modified nonwoven fabric is characterized also by hydrophobic properties, high electrical conductivity, good air and water vapor permeability, and meets the requirements of breathing resistance for all protection classes (FFP1, FFP2 and FFP3) specified in the EN 149-2001 standard.

Investigation of the performance of needle-punched nonwoven fabrics using Triumfetta cordifolia and thermoplastic fibers, compared to other commercial bast fibers used in preformed biosourced composites

In an attempt to increase biodiversity in natural plant fiber nonwovens, new sources of natural fibers must be discovered. Nonwoven fabric is a promising commercial product for upgrading the new bast fiber Triumfetta cordifolia (TCF) and giving it an opportunity to be used in composite nonwoven applications. Two types of TCF nonwoven mats blended with polylactide fibers for one and polypropylene fibers for the other at a mass ratio of 50 : 50 were manufactured using carding and needling technology. The aim of the present work is to compare the different types of TCF-based nonwovens with other nonwovens based on commercial bast fibers, namely flax and hemp, known for their use in automotive interiors. The nonwoven fabrics were characterized in terms of weight per unit area, thickness, tensile strength and flexural rigidity. In addition, morphological aspects of fiber organization, density and distribution within the nonwoven reinforcement were observed using Scanning Electron Microscopy. The results revealed great variability in terms of surface density and thickness. Increasing the surface mass of nonwovens led to an increase in mechanical performance in terms of strength and stiffness, while retaining anisotropy in terms of fiber orientation, which has a significant effect on mechanical behavior due to the preferential fiber orientation generated during carding. In addition, the type of thermoplastic polymer fiber in the nonwoven mat has an influence on the characteristics evaluated. The results obtained showed that TCFs are good candidates, given their competitive performance and availability compared with flax and hemp fibers, and that they can be used in the same composite applications. Such a non-woven mattress based on TCFs from the tropical African region, manufactured using carding and needling technology, could open up opportunities to create new value-added products that can benefit these countries from an economic and ecological point of view.

Nonwoven Fabrics from Agricultural and Industrial Waste for Acoustic and Thermal Insulation Applications

Natural fibers are increasingly being used to make nonwoven fabrics, substituting synthetic materials for environmental and economic reasons. In this study, a series of needle-punched nonwoven fabrics were made by extracting fibers from coffee husks and blending them with a proportion of spinning waste consisting of cotton fibers and another five different natural fibers. This work investigates the coefficient of sound absorption, thermal conductivity, areal density, thickness, and air permeability. Overall, the sound absorption properties of the produced nonwoven fabric depend on the blend proportion and the number of layers. The results from the fabric containing nettle and banana fibers demonstrate a much-improved sound absorption coefficient. These results have been compared with those of commercially available nonwoven fabrics that are manufactured from polyester and polyurethane foam. The thermal conductivities of the fabrics made with nettle and coir were the highest and lowest, respectively. This is because of the fiber linear density, but all in all, fibers extracted from coffee husks show significantly promising potential for scaling up to replace existing synthetic fibers.

Novel filter material by glass fiber foam laying for nonwoven fabrics

The needle punched nonwoven fabrics are widely used as the flue gas filter materials while continuous efforts have been made to improve the filtration efficiency in order to meet the low emission requirement. In this study, filter materials with high filtration efficiency were developed via glass fiber foam laying and PTFE (polytetrafluoroethylene) emulsion coating process. Influences of surfactant type, fiber diameter and fiber content on the foam-ability and foam stability of glass fibers were analyzed. The resulting filter materials, obtained here for the first time with glass fiber foam laden and PTFE emulsion coated needle punched nonwoven fabrics, were characterized for morphology, pore size, air permeability, wear resistance and filtration properties. The results were compared against structures obtained from needle punched nonwoven fabrics before and PTFE emulsion coating. Remarkably, compared to untreated and PTFE emulsion coated needle punched nonwoven fabrics, the glass fiber foam laden and PTFE emulsion coated fabrics displayed higher filtration efficiency and lower outlet particle concentration. Overall, glass fiber foam laying is found to be effective to improve the filtration performance of needle punched nonwoven fabrics and is promising to be commercialized after optimizing the foam composition and PTFE emulsion coating process.

Mechanical Properties of Moistened Needle-Punched Nonwoven Fabric Based on Blend of Fibers with Various Linear Densities

Mechanical Properties of Moistened Needle-Punched Nonwoven Fabric Based on Blend of Fibers with Various Linear Densities

Filtration performance of needle-punched nonwoven air filter media through dyeing process

Viscose fibre has been dyed with various dye concentrations and the needle-punched nonwoven fabrics are prepared using the dyed fibre, keeping machine parameters the same. The physical properties, such as tenacity & bursting strength, and functional performance properties, such as mean flow pore size, filtration efficiency & pressure drop, are measured. It is found that the dyeing plays a big role in altering the overall performance of the needle-punched nonwoven. The tenacity of the needle-punched nonwoven fabric is reduced as dye concentration is increased. Filtration efficiency is measured for three different sizes of particles, namely 3µm, 5µm, and 10µm. For all three cases, the filtration efficiency is increased initially till 3% dye concentration and beyond that it is reduced.

Structure-property relationship of carbonized needlepunched nonwovens for electromagnetic interference shielding and ohmic heating applications

The structure-property relationship of acrylic and Kevlar fibre derived activated carbon fabrics was investigated for electromagnetic interference shielding and joule heating applications. The single stage carbonization and physical activation of acrylic and Kevlar needlepunched nonwoven fabric was carried out under the modified atmosphere of charcoal layer and nitrogen gas to have gradual reaction with atmospheric air. The effect of 800 °C, 900 °C and 1000 °C carbonization temperature on structural and functional properties was studied. The acrylic-derived activated carbon fabric was found to provide higher carbon yield, less dusting tendency, better mechanical and electrical properties; however poor flexibility and shrinkage properties as compared to Kevlar derived activated carbon fabrics. The formation of more micropores, higher graphitic structure, higher degree of crystallinity, and large surface area was observed in case of both the activated carbon fabrics with rise in carbonization temperature. Furthermore, the activated carbon fabrics derived at 1000 °C exhibited greater electromagnetic interference shielding in high as well as low frequency regions. Lastly, the ohmic heating of carbonized Kevlar fabric showed rapid heating, high electric heating efficiency and faster cooling performance but at increased voltage of 5 V than 3 V of carbonized acrylic fabric.

Layered nonwoven filter embodied with packing density gradient measured by X-ray computed tomography for enhanced filtration performance

This research explores the possibility of tuning the structure of needle-punched nonwoven fabrics by incorporating layers of differently oriented fibres. The fibre orientation in carded batts is regulated with the help of carding parameters viz. feeder, cylinder, and doffer speeds. The carding parameters were optimized by using response surface methodology to obtain carded batts of differently oriented fibers, which were then placed distinctly to form composite layered nonwoven fabrics. The physical, mechanical, and functional properties of layered fabrics were evaluated. X-ray computed tomography technique was used for comprehensive evaluation of the packing densities at incremental thickness of layered fabrics. The obtained trends of packing density were found to be in good agreement with the measured properties of nonwoven fabrics. The creation of an inverse gradient of packing density in a layered nonwoven fabrics displayed close to highest filtration efficiency and close to lowest pressure drop.

Acoustic behaviour of needle punched nonwoven structures produced from various natural and synthetic fibers

Porous materials are an excellent example of passive materials, which reduces sound energy by dissipating heat energy due to the presence of a void structure. In textiles, nonwovens are highly porous and less expensive materials compared to woven and knitted structures. The present research investigates the effect of fiber type, fiber fineness, fiber cross-sectional shape, and fabric areal density on the acoustic properties of needle punched nonwoven fabrics produced from flax comber noil and jute caddies and polyester staple fibers of circular, hollow, and hollow conjugated cross-sections. The study reveals that hollow conjugated cross section exhibits maximum noise absorption. Nonwoven made from biodegradable and recyclable jute caddies, and flax comber noil shows considerable noise absorption properties compared to polyester synthetic fiber, although they are inexpensive. Higher punch density results in better compactness of nonwoven fabric leading to improved sound absorption property. Layered nonwoven structures are responsible for better sound absorption properties due to the presence of an air layer.

Comparison of tensile properties of needle punched nonwoven fabric produced by bi-directional and unidirectional barb needles employing response surface methodology

In production of needle punched nonwoven fabrics, direction of needle barbs is towards the tip of the needle. When the needle penetrates into the fabric, the barbs carry some fibres into the fabric and when it returns the barbs are empty. This means that the needle works when it penetrates into the fabric and doesn’t work when it returns. Using a bi-directional barb needle in the needle-punch process was proposed as an idea with the theory that the needle also works when returning (leaving the fabric). In this study, the test specimens were prepared by two type of needles in an industrial needle machine. Fibre displacement at fabric cross-section was examined by optic and scanning electron microscopy for two types of needles. An experiment with 190 samples was produced using the response surface methodology and optimal design with two quantitative factors, including the number of strokes per minute and needle penetration depth, and one qualitative factor containing needle types. In addition, six responses were measured and reported in the machine direction and cross direction, including breaking load, extension, and tenacity. According to the findings, the tensile characteristics of non-woven (NW) fabrics generated produced by bi-directional barbed needles were higher than those produced by unidirectional barbed needles.

Oil sorption properties of cotton comber noil/recycled polyester blended needle punched nonwoven fabrics- An optimization study

Oil spill pollution is a constant threat to the environment nowadays. The treatment of an oil spill remains a challenge to environmental scientists. Among the various cleanup methods available, the use of sorbents for oil spill cleanups is a popular approach. In this work, an attempt has been made to produce cotton comber noil /recycled polyester needle punched nonwoven fabrics for the oil spill clean-up process. Box–Behnken experimental design is used to optimise the parameters such as cotton comber noil /recycled polyester blend proportion, needle punching density and areal density for maximum oil sorption capacity. At 70:30 cotton comber noil /recycled polyester blend proportion, 64.94 needle punching density and 100 GSM, maximum oil sorption was achieved. The maximum oil sorption achieved in the case of crude oil and vegetable oil is 45.90 g/g and 32.30 g/g respectively. The cotton comber noil/recycled polyester needle punched nonwoven fabric showed a stable water bead morphology with a static contact angle of 133.6. The present work indicates that the cotton comber noil/recycled polyester needle punched nonwoven fabric (70/30) is a potential sustainable product for oil spill removal applications.

Stab/Puncture Resistance Performance of Needle Punched Nonwoven Fabrics: Effects of Filament Reinforcement and Thermal Bonding

Stab/Puncture Resistance Performance of Needle Punched Nonwoven Fabrics: Effects of Filament Reinforcement and Thermal Bonding

Influence of Fiber Blending on Thermal and Acoustic Properties Nonwoven Material

ABSTRACT Natural fibers are sustainable and biodegradable for acoustic product manufacturing. The natural fibers-based nonwoven textiles are utilized as cost-effective soundproof materials. This paper investigated the sound absorption properties of needle punched nonwoven fabric made from natural fibers such as Sansevieria stuckyi, Banana, Hemp, and its blends. All the raw fibers were extracted from the source plant. Twelve different needle-punched non-woven fabrics were produced using blended and non-blended fiber combinations. The investigation was carried out with the sound wave frequencies ranging from 0 Hz to 4000 Hz through the impedance tube method. The important research findings are that the blended fiber-based nonwoven mat yields a maximum sound absorption coefficient than the nonwoven mat produced with mono fibers. Higher hemp fiber proportion and higher nonwoven thickness have yield maximum sound absorption coefficient. SEM analysis was carried out to understand the surface morphologies extracted fibers. The Air permeability, porosity, and thermal conductivity of the nonwoven fabric influenced the sound absorption properties.

Development of Ceramic and Glass Fiber Needle-Punched Nonwoven Fabrics Part I: An Optimization

Abstract The study on the performance of areal density of web, needle punching density, and needle depth of penetration, particularly, the combination of glass and ceramic fiber nonwoven fabrics over the mechanical, thermal, and filtration properties were studied with the Box-Behnken experimental design. For the requirement of filtration behavior, three sets of samples with varying glass fiber areal densities of 250, 300, and 350g/m2 were taken and added with ceramic fibers to achieve sandwich-blend nonwoven materials of 60/40, 50/50, and 40/60 ratios. Then, the processing variables were taken as needle punch density and needle depth of penetration, and three optimized samples were predicted using the Box-Behnken experimental design based on the filtration efficiency of the exhaust along with their mechanical and thermal properties. It is also found that there was significant influence on the properties by the variables taken for the product development for the filters. It was found that there was a significant increase in the tensile properties in the optimized samples, and it was found that the results taken for the optimization process were unaltered.

Liquid-mediated particle capture by nonwoven filter media for automotive engine intake air filtration

This article reports on development, characterization, and performance of liquid-treated nonwoven air filter media for automotive engine intake application. A polypropylene fiber-based needle-punched nonwoven fabric was prepared for treatment with four viscous liquids (glycerol, SAE 20W/50 engine oil, PEG 400, and deionized water) by liquid spraying technique. The filtration performance was evaluated in terms of initial and final gravimetric filtration efficiencies, fractional filtration efficiency, evolution of pressure drop, and dust holding capacity. The liquid-treated filter media registered higher gravimetric as well as fractional filtration efficiency and higher dust holding capacity as compared to the untreated ones. The initial and final gravimetric filtration efficiencies were found to be directly related to liquid add-on via a power law relationship. The liquid-treated filter media also exhibited higher fractional filtration efficiency than their untreated counterparts for all sizes of tested particles. Interestingly, the increase of fractional efficiency was more for smaller particles as compared to larger ones. This was explained quantitatively through single fiber efficiency due to adhesion. The viscosity of liquid was found to be a very crucial parameter as the dust deposition morphology was contingent to the flow of liquid onto the filter media. The stickiest liquid yielded highest filtration efficiencies, displayed slowest rise of pressure drop, and exhibited highest dust holding capacity.

Development of Needle Punched Nonwovens from Natural Fiber Waste for Thermal Insulation Application

ABSTRACT The growing environmental awareness throughout the world has triggered a shift toward developing environmentally friendly materials from renewable resources. This work aims to develop needle punched nonwoven fabrics from textile waste for thermal insulation application and also to analyze the influence of porosity and air permeability of the nonwovens on thermal insulation performance. The needle punched nonwovens were manufactured using comber noil, silk cocoon waste, and polyester/cotton flat strip waste. Also, a nonwoven has been developed by blending comber noil with silk cocoon waste (50/50%). It was found that the nonwoven developed from 100% silk cocoon waste has better thermal insulation value (0.201 m2K/W) compared to 100% comber noil and polyester/cotton flat strip waste. It was also found that blending silk cocoon fiber with comber noil improves the thermal insulation of the nonwovens. 50/50 silk cocoon/ comber noil nonwoven has a good thermal insulation value (0.212 m2K/W) among the developed nonwovens. There is an increase in thermal insulation observed with an increase in porosity of nonwovens. The test results showed that all the developed nonwovens have excellent thermal insulation performance and are comparable with that of conventional insulation materials.