1. InnovativeNonwovens
Dr. V. K. Kothari
Professor, Dept. of Textile Technology
Indian Institute of Technology, Delhi

2. Fiber Formation Technologies

3. Fiber Modification for Functional Applications

4. POLYMER
POLYMER SOLUTION MELT POLYMER
NANOFIBER

5. Three main components of electrospinning

6. SEM : 250X 900X 4000X 11000X

7. Bicomponent Fibers

8. Cross sections of Bicomponent Fibers

9. Meltblown for Bicomponent & Multicomponent
REICOFIL BICO MELTBLOWN TECHNOLOGY REICOFIL MULTICO MELTBLOWN TECHNOLOGY

10. Increased Surface Area
…… The New Generation of Microfiber

11. …… The Technological Revolution

12. Nonwoven Spacer Fabric - The Concept
Nonwoven Spacer Fabric
Corrugated
Nonwoven Malimo Process NAPCO
Struto, Wavemaker /
Santafleece, Rotis
Kunit, Multiknit / Caliweb

13. 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

14. Wavemaker Working Principle, Set-up at ITV Dekendrof
WAVEMAKER / SANTAFLEECE
Rotationally Vertical Laying

15. Kunit, Multiknit, Caliweb
CALIWEB
KUNIT
MULTIKNIT

16. Needle Punched Spacer Nonwovens – NAPCO
A, B - Pre-needled webs
1, 2 - Needle boards

17. Needle Punched Spacer Nonwovens – NAPCO
1,2 nonwovens
3 bundle of fiber
4,5 formation of funnels
6 feed space
7 space between rows of needles
8 direction of process
9 space between nonwovens

18. HydrospaceTM
Technology
Hydrospace
TM
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

19. HydrospaceTM
Technology
Nonwoven Innovation & Research Institute

21. 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

22. HydrotubeTM
Technology
Nonwoven Innovation & Research Institute

23. 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

24. 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.

25. Suominen’s Hydraspun is composed of about 78% wood pulp, 20% Tencel and
2% bicomponent fiber, formed as a wetlaid web and then hydroentangled. The
Tencel fiber is cut to a shorter length than is usual for spunlace fibers; this allows
some entangling to boost wet strength enough for use, but since so few of these
fibers are used, they form very small, and relatively loosely bonded agglomerates of
fibers. This combination of relatively short fiber hydroentangling, coupled with
very low-level thermal bonding, provides enough in use strength for current
flushable wipes with enough dispersibility for most waste treatment systems.
HYDRASPUN®

26. Buckeye’s Airspun Flushable is essentially a latex bonded airlaid structure. The
binder used has limited water solubility. The wipe also contains some longer fibers
to add strength; in its lotion, there is not enough water (1-3 times the wipe’s dry
weight) to solubilize enough binder to reduce the strength in use significantly, but
in a toilet with excess water (several thousand times the wipe’s dry weight) the
binder solubilizes and the wipe disperses.

28. 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.

29. 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

30. Nonwoven Abrasives Application Areas

31. .
 Economical solution:
Eliminate steps
One product replaces two or more
 Best technical solution –Engineered solution
 Profit improvement
Specialized solution

32. 3 Layer Composite Fiber –Pulp - Fiber
a. Highly absorbent b. Lower cost
c. Improved appearance d. Softness improved

34. Rieter Spunjet
Spunlace
Jetlace 3000
Spunbond
Perfobond 3000
Winder
Air Through
Dryer
Perfodry 3000
Integrated technology: Spunbond & Spunlace

36. 3M Thinsulate Insulation
Thinsulate® from 3M composed of large fibers + sub-denier
fibers

37. 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

38. Thermocules® Technology
Outer durable shell
Thermocules® PCM – Hydrophilic
Microscopic size
(3 Million per cm2)

39. Thermocules® in Rayon fiber Nonwoven
Hydrophilic PCM helps in
moisture management
Absorbs excessive body heat
Releases body heat
Stores body heat in chill
environment
Controls the temperature
fluctuation

40. Areas of Application

41. 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.

42. Manufacturing Technologies for Stretchable Nonwoven
Spunbond and meltblown are the widely used manufacturing
technology for stretchable nonwovens.
Specially designed fully hydrogenated styrene-ethylene/butylene-
styrene block copolymers are used Kraton Polymers to produce
elastic spunbond & meltblown nonwovens.
Meltblown fabric properties
Spunbond fabric properties