Value Addition through Research and Innovation in Nonwovens

Dr. V. K. KothariEmeritus ProfessorDept. of Textile TechnologyIndian Institute of Technology, Delhi

Manufacturing, the transformation of materials into products, is no longer a primary source of prosperity.

The last few years have seen intense R&D and Innovation activity in the area of nonwovens with convergence and close cooperation between different fields.

Innovation – What it means?

Bring in new methods, ideas or make changes which results in significant improvements, new products or processes.

The act of introducing something new. Change that creates new dimension of performance.

Innovation• Technological Innovation covers –

Creative ideas, research & development, creating something new & Commercialization.

• Benefits may include quality improvement, process improvement, addition of new functionalities and/or cost reduction.

Research & Development and Innovation,

new products and knowledge based product

differentiation and specialization are

essential for value addition in nonwoven

fabrics in order to succeed in present

competitive world.

R&D and Innovation Areas and Major Trendso Materials

- Permanently Hydrophilic Polypropylene/Polyesters - New sustainable materials – PLA, Bio PET, Kenaf - Bicomponent Staple Fibers

o Processes • Innovative SpunMelt

- Bicomponent meltblown/spunbond products• New Innovative/Combined processes – Composites

•3 D Nonwovens o Post-Processes

• Surface treatments • Coatings/laminations

o Product Innovations

• Composites

Functionalizing Surfaces

Topical Finishes• staple fibers ( typically done by fiber producer) • SpunMelt fabrics

- require an added step in the process

Surface Modifications

• Atmospheric Plasma

• Cold Plasma

• Electron Beam

Increased Surface Area

• Smaller Fibres – Micro and Nano fibres

Melt Additives • Staple fibers • SpunMelt fabrics

Fiber Formation Technologies

Fiber Modification for Functional Applications

Bicomponent Fibers

Cross sections of Bicomponent Fibers

Meltblown for Bicomponent & Multicomponent

REICOFIL BICO MELTBLOWN TECHNOLOGY REICOFIL MULTICO MELTBLOWN TECHNOLOGY

Increased Surface Area

…… The New Generation of Microfiber

…… The Technological Revolution

Nonwoven Spacer Fabric - The Concept3D

Nonwoven Spacer Fabric

Corrugated Nonwoven Malimo Process NAPCO

Struto, Wavemaker / Santafleece, Rotis

Kunit, Multiknit / Caliweb

Vibration vertical laying

Nonwoven Spacer Fabrics - STRUTO

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

Wavemaker Working Principle, Set-up at ITV Dekendrof

WAVEMAKER / SANTAFLEECE

Rotationally Vertical Laying

Kunit, Multiknit, Caliweb

CALIWEB

KUNIT

MULTIKNIT

Needle Punched Spacer Nonwovens – NAPCO

A, B - Pre-needled webs

1, 2 - Needle boards

Needle Punched Spacer Nonwovens – NAPCO

1,2 nonwovens3 bundle of fiber4,5 formation of funnels6 feed space7 space between rows of needles8 direction of process9 space between nonwovens

HydrospaceTM Technology

HydrospaceTM spunlace fabrics have cavities within the material of a

predefined shape and size which can be filled with solids, liquids, waxes or

gels. The fabric surfaces can be tailored to control the rate of delivery of the

cavity contents in a specific direction. The commercial potential of this new

fabric is vast with applications in numerous fields including:

Wipes – household, medical, cosmetic,

baby, industrial and

domestic use

Filters – filtration of blood, air, gas,

petrol, chemical,

etc.

Protective – clothing, shields and blinds

Insulation - acoustic and thermal Nonwoven Innovation & Research Institute

HydrospaceTM Technology

Nonwoven Innovation & Research Institute

HydrotubeTM Technology

HydroTube™ fabrics are lightweight hydroentangled (spunlaced)

fabrics which are produced as continuous seamless tubes. The tube

diameter can be varied and the interior can be either left hollow or filled

with gels, waxes, cosmetics, detergents and solid particles to

functionalise the fabric as the tube is formed. Potential applications

include reinforced hoses and pipes, electronics,

telecommunications, protective seals and medical dressings.

Nonwoven Innovation & Research Institute

HydrotubeTM Technology

Nonwoven Innovation & Research Institute

Flushability Wipes …. A New Era

For a product to be flushable it must:

♦ Clear toilets and properly maintained drainage pipe systems under

expected

product usage conditions;

♦ Be compatible with existing wastewater conveyance, treatment, reuse

and disposal

systems; and

♦ Become unrecognizable in a reasonable period of time and be safe in

the natural

receiving environments.

Definition of Flushability

Flushable Wipes – How They Works ?

Three major players who met the INDA/ EDANA norms for flushable wipes

are :

Kimberly-Clark’s ion triggered airlaid

Suominen’s Hydraspun (spunlaced wetlaid base web)

Buckeye’s Flushable Airspun (non triggered airlaid)Kimberly-Clark’s ion triggered latex

bonded airlaid uses an acrylic binder that

forms ionic bonds in the presence of certain

water-soluble ions, which can be added to the

wipe’s lotion; these bonds are reversible,

disappearing if the level of these ions falls below

a certain level (as in excess water in a toilet).

The reduction of ion concentration “triggers” a

significant reduction in wet strength, allowing

the shear from normal “flushing” to cause the

nonwoven to disintegrate or disperse. 

Nonwoven Abrasives

Nonwoven products are manufactured in a continuous treatment process in

which the basic fibres are carded, coated and needled to form the

nonwoven. In the second work step, a mixture of binder and abrasive grains is sprayed

onto this three-dimensional backing so that it penetrates the nonwoven.

Nonwoven Abrasives

Advantages -Nonwoven abrasives are highly conformable.

The abrasive grains are distributed evenly through the product,

ensuring a consistent cut and finish throughout its life.

Open structure reduces clogging significantly.

Nonwoven abrasives can be used wet, dry, with solvents or with

cutting fluids

Nonwoven Abrasives Application Areas

.

COMPOSITE NONWOVENS

Economical solution:

Eliminate steps

One product replaces two or more Best technical solution –Engineered solution Profit improvement

Specialized solution

Why Composites ?

COMPOSITE NONWOVENS

3 Layer Composite Fiber –Pulp - Fiber

a. Highly absorbent b. Lower cost

c. Improved appearance d. Softness improved

SPUNBOND + SPUNLACE - HYDROKNIT® (KC)

Rieter

Rieter Spunjet

Spunlace Jetlace 3000

SpunbondPerfobond 3000 Winder

Air Through

DryerPerfodry

3000

Integrated technology: Spunbond & Spunlace

Coform ……A Great Invention

3M Thinsulate Insulation

Thinsulate® from 3M composed of large fibers + sub-denier fibers

PCM + Nonwoven

PCM widely used in patented

technologies of temperature-

regulation.

Adaptive comfort - a milestone

achieved by the use of

Thermocules®

Reduces thermal spiking –

overheating and excessive

cooling

Thermocules® Technology

Outer durable shell

Thermocules® PCM – Hydrophilic

Microscopic size (3 Million per cm2)

Stretchable Nonwovens

Driving forces for innovation of Stretchable Nonwovens

Increasing demand of :

Better fit

Comfort

Elasticity

Recovery

Innovative products are developed to incorporate more stretch in the designs of hygiene, medical and industrial products.