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Chapter IV.

Mechanical technology of nonwovens Department of nonwovens. Chapter IV. Wet laid, Air laid, and Random laid. Mechanical technology of nonwovens Department of nonwovens. Wet laid - Principle.

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Chapter IV.

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  1. Mechanical technology of nonwovens Department of nonwovens Chapter IV. Wet laid, Air laid, and Random laid

  2. Mechanical technology of nonwovens Department of nonwovens Wet laid - Principle • This topic is disskused in subject „ Thermal and chemical technology of nonwovens“ because wetlaid fabricks are usually chemical bonded. • Wet laid nonwovens are made by a modified papermaking process. That is, the fibers to be used are suspended in water, which is subsequently taken out. • In terms of wet laid technology compared with dry laid technology is possible to process short and smooth fibers (for example glass microfibers). • The typical features of airlaid and wetlaid fabrics are: • Random orientation of fibers on the fabric surface • Wider range of area density compared with dry laid technology

  3. Mechanical technology of nonwovens Department of nonwovens Wetlaid – used material • The wet laid fibers must be miscible in water so their main feature are: • low surface tension (which is possible to adjust by surfactants • small lenght or low ratio between the fiber length and diameter – it is possible to process short fibers (2-50 mm) • low crimpiness – it is possible to proces smooth fibers A major objective of wetlaid nonwovens is to produce structures with textile properties (flexibility, strenght etc...) at speeds similar to papermaking process. Textile fibers tend to be longer, stronger and relatively inert when compared to papermaking fibers, which are short, fine and are able to pack together into a dense structure. The structure, which contains textile fibers, is more open and extensible but preserves the basic strenght and stability of the fabric. Thus wet laid textile is stronger, softer, bulkier, more drapeable, less smooth and more porous than paper.

  4. Mechanical technology of nonwovens Department of nonwovens Wet laid – principle of technology • There 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 Water recycling

  5. Mechanical technology of nonwovens Department of nonwovens Wet laid – examples of end uses of wet laids • Special papers: • synthetic fiber paper, dust filters, liquid filters, overlay paper, stencil paper, tea bag paper, paper for wrapping susage and cooked meats • Industrial nonwovens for: • waterproof sheeting for roofs, shingling, separators, filters, reinforcement material for plastics, backing material, shoe uppers, decoration, interlinings, insulation • Nonwovens similar to textiles: • surgical clothing, bed-linen, table cloths, servittes, towes, household cloths, face cloths, nappy, sanitary articles

  6. Mechanical technology of nonwovens Department of nonwovens 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 • The range of the area weight is wider (15 – 250 g/m2) but the mass uniformity of light air laid (up to 30 g/m2) is bad. • Wide variety of processable fibers

  7. Mechanical technology of nonwovens Department of nonwovens Air laid – production problems • Low level of opening fiber material by lickerin roller • Thus is suitable to use pre-opened fibers or combine air laid with card machine – Random card machine • Various structures of web in width of layer due to irregular air flow close to walls of duct • This problem requires high quality design of duct. • Possible entangling of fibers in air stream • This problem can be reduced by increasing the ratio air/fibers which nevertheless means decrease in performance and increase of energy consumption due to high volume of flowing air. The relation between air flow and performance of device shows the importance of fiber lenght and fiber diameter. QA is air flow, K is device constant, P is performance of device (kg/hour), L is lenght of fiber staple (m) and D is fiber fineness (dtex). Thus is suitable to use short fibers for this technology.

  8. Mechanical technology of nonwovens Department of nonwovens Example of air laid machine Production up to 3 000 kg/hour

  9. Scheme of airlaid line dust controll

  10. Mechanical technology of nonwovens Department of nonwovens Random cards – combination of air laid and carding technology A major objective of this combination is isotropic textile fabric (random orientation of fibers) with good mass uniformity of light fabrics and with high production speed. • The first part – card machine opens perfectly fibrous material so single fibers are as a output. • The second part – air laid system uses the centrifugal force to strip the fibers off a roller and. put them down on an air controlled scrim belt.

  11. Main cylinder Random roller Mechanical technology of nonwovens Department of nonwovens Main variations of random cards I. Airlaid function of random card: 1) Random roller between main cylinder and doffer, which rotate in the opposite direction of the main cylinder.

  12. Mechanical technology of nonwovens Department of nonwovens Main variations of random cards II. 2) Centrifugal force of mean cylinder strips the fibers off Random card Fehrer K12

  13. Mechanical technology of nonwovens Department of nonwovens Example of random card lineFehrer

  14. Mechanical technology of nonwovens Department of nonwovens Air laid and random cards: used fibers synthetic fibres, viscose, cotton and blends thereof;natural fibres such asflax, hemp, sisal etc.;reclaimed textile waste and shoddy,1.7 - 2000dtexmax. 120 mm staple length Air laid and random cards: end products interlinings, shoe linings,„high loft" products for the garment and furniture industries; base material for coating substrates and synthetic leather; waddings;geotextiles, filter materials; needle blankets; carpets and wall coverings; technical feltsinsulation felts;mattress felts, waddings for the upholstery and automotive industry; undercarpets

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