Technical

Textiles
1

Technical Textiles
What is Technical
Textile?
Textile
product
manufactured
primarily for its performance and
functional properties rather than
aesthetic or decorative characteristics

Some of the common products of technical

textiles
Seat-belts are:Airbags
Nylon tier cord fabrics
Seat covers
Car-body covers
Automobile interiors carpets
Helmets
Insulation felts
Sanitary napkins
Diapers
Surgical dressings
Healthcare textiles
Footwear components
Sleeping bags
Ballooning fabrics
Parachute fabrics
Fire-retardant fabrics
Fire-retardant upholstery
Ballistic protective clothing
Bullet-poof jackets

SEGMENTS OF TECHNICAL
TEXTILES
Agro tech
Agriculture, horticulture and forestry

BUILD tech
Building and construction

CLOTH tech
Technical components of shoes and clothing

GEO tech
Geotextiles, civil engineering

HOME tech

Components of furniture, household textiles

and floor coverings

INDU tech

Filtration, cleaning and other industrial usage

MEDI tech
Hygiene and medical

MOBIL tech
Automobiles, shipping, railways and
aerospace

OEKO tech
Environmental protection

PACK tech
Packaging

PRO tech
Personal and property protection

SPORT tech
Sport and leisure

MATERIALS FOR TECHNICAL

TEXTILES
1. Regular/Generic fibers
.
.
.

Natural fibers: Cotton, silk, wool, jute, hamp, ramie, flax

Regenerated fibers: Viscose, Lyocell.
Synthetic fibers: Nylon, PET, PP, Acrylic.

2. Specialty variants of
regular/generic fibers
.
.
.
.

Flame retardant
Super absorbent
Antimicro bacterial
Ultra fine fibers. etc.

3. High tech/high performance fibers:

.
.

High chemical- and combustion-resistant organic fibres: Nomex, Kevlar

High performance inorganic fibres: Glass, Asbestos, Carbon

Generic
Fibers

Specialty variants of regular/generic fibers

Viscose

Basic
Characteristic
s

Specialty
Variant

Polyester

Basic
Characteristic

Specialty
Variant

Other fibres

Fibre

Additional
Characteristic

Very good
softness

Viscose for
nonwovens

High melting
point, high heat
and chemical
resistance

High
Tenacity
PET

Superabsorbent
fibre
(acrylic)

High absorbency

Excellent
absorbency

Viscose with
tri-lobal crosssection

Very low
moisture
absorbency

trilobal
crosssection

High
Density
Polyethyle
ne (HDPE)

High tensile
strength

Added
strength and
moderate
abrasion
resistance

Temperature
regulating
Viscose
(Outlast )

High strength,
Good abrasion
resistance,,
Good resiliency

Hollow fiber

High
Modulus
PE (HMPE)

Higher modulus

Relatively
poor strength
wet

Short cut
PET/Viscose

Inert,
biocompatible
& flexible

Flame
retardant

High
Tenacity
Nylon

High tenacity and

low shrinkage

Low resiliency

Anti-microbial,
Anti-bacterial
viscose fibers.

Antimicrobial,
Anti-fungal,
Antibacterial
PET fibers.

High
Tenacity
PP

High strength and

stability

HIGH-TECH FIBRE

Fiber

Characteristics

Applications

Key players

Meta
Aramid
(Nomex)

Heat Resistance, high

strength and high
impact absorbing
capacity

Fire retardant
apparel, bullet
proof jackets,
helmets, gloves
etc.

Dupont (USA), Teijin Twaron

(Japan), SRO Group (China), Yantai
Spandex (China), Kermel (France)

Para
Aramid
(Kevlar)

High strength to
weight ratio,
Excellent thermal &
chemical stability

Fire retardant
apparel, bullet
proof jackets,
helmets, gloves
etc.

Dupont (USA), Teijin Twaron

(Japan), Yantai Spandex (China)

Carbon

Low weight and high

strength

Air craft body,

wind mill wings,
racing cars.

Toray Industries (Japan), Toho

Tenax (Japan), Mitsubishi Rayon
(Japan), Zoltek (USA), Hexcelcorp
(USA), SGL Carbon AG (Germany) ,
Kemrock (India)

Polypheny
lene
sulfide
Fibres
(PPS)

Highly resistance to
heat, acid and
alkaline

Electrical
products, liquid
filters, dryer
canvas.

Armoco Fabrics & Fibres Co (USA),

Toyobo (Japan), Toray Industries
(Japan), etc

Glass
fiber

Thermal insulation
properties with high
strength and low

Automotive
bodies, hockey
sticks, boats,

Owens-Corning Fibreglas,
Nicofiber (USA), Fibreglass
9
(Canada), Asahi
Fibre Glass Co

HIGH-TECH FIBRE
Fiber

Characteristi
cs

Applications

Key players

Polytetraflu
oroethylen
e (PTFE)

Excellent
dielectric
properties, high
melting point.

Nonstick coating
of pans,
laboratory
containers,
magnetic stirrer.

DuPont (USA), Newton Filaments, Inc

(USA), Albany Internation Inc. (USA),
Toyobo (Japan)

Phenolic
fiber

High strength

Automotive and
electrical
components.

Phenco (USA), The Vermont Organic

Fiber Company (USA)

Conductive
fiber

Electric
conductive

Military garments,
intelligent
garments.

Shakespeare Conductive Fibres LLC and

Bekaert , Bakaert India (India)

PBI
(Polybenzi
midazole)

High strength
and does not
burn or melt.

Automotive parts,
aircraft parts,
insulation shield
etc.

Celanese Acetate

Alginate
fiber

Highly
absorbent

Wound dressing,
textile printing
etc.

Speciality Fibres and Materials Ltd (UK),

FMC Biopolymer (USA), Degussa
Texturant Systems (Germany), Danisco
Cultor (Denmark), Kimica Corporation
(Japan), China Seaweed Industrial
Association (China)

PBO fiberZylon

Highest strength
among fibers.

Protective
clothing and

10

Toyobo Co. Ltd. (Japan)

SEGMENT WISE CONSUMPTION

OF FIBRES

11

Clothing Textiles

Technical components of shoes and clothing

e.g. linings

All the natural, man made and Synthetic Fibers

12

Technical components of
Home Textiles
furniture, household
textiles & floorcoverings
Acetates, acrylics, polyester,
natural fibers..

13

Geo
Geotexiles and civil
textiles engineering materials

Jute, coir, Polypropylene,

Polyester, Polyethylene,
polyvinyl chloride, Polyamide,
Aramids

14

15

Industrial
textiles

Filtration, conveying,
cleaning etc
Nylon, polyester,
polypropylene, glass
fibers.

16

Medical Textiles
Hygiene and medical
products
Polyester, Cotton,
polypropylene, silk etc

17

Wound dressing
Chronic wounds: 6.5
million people - $25
billion

Naturally derived
compounds?

Impaired healing Inflammation

stage is prolonged

Resistance to
antibiotics

Alternative metals, e.g. zinc as

well as non-metal bactericides

Silver impregnated
dressings

18

Extracorporeal devices-

artificial kidney, liver,

heart pacer and lung

19

Implantable materials- sutures, vascular

grafts, artificial ligaments, cartilages, artificial
joints, heart valves etc

20

21

Resorb

22


Personal and property
Protective Textiles
protection
Nomex, kevlar fibers

23

Sport

Sport and leisure

TextilesE.g Yatcht, Hot air
balloons
Polyester, nylon,
spandex, glass
fibers..

24

25

Packaging
Textiles

Packaging materials
Polyethylene,
polypropylene, glass
fibers..

26

Transportation
Textiles

Automobiles,
shipping, railways
and aerospace
Polyester, nylon,
glass, UHMWPE,
aramids compsites,
carbon fibers

27

Agro
Textiles

Agriculture, horticulture,
forestry and aquaculture
textiles
Polypropylene, polyester,
polyethylene etc

28

Construction Textiles

Building and
construction textiles
Kevlar, nomex, carbon
fibers

29

Eco textile
Textiles

Environmental
protection
Carbon fibers..

30

Summary of Segment wise consumption of

different fibres
Cott
on

Jut
e

Agrotech

Meditec
h

Mobiltec
h

PE
T

Nyl
on

PP

Sporttec
h

Buildtec
h

Clothtec
h

Hometec
h

Glas Carb
s
on

Packtech

Protech

Visco
se

LDP
HDP E/
Aram
E
LLDP id
E

31

APPLICATION STAGES OF TECHNICAL TEXTILES

Fiber stage
Yarn stage
Fabric stage
Wet processing stage
Technology at fibre, yarn,
fabric and end conversion
stage
32

TECHNICAL FIBERS

33

E OF NATURAL FIBERS AS TECHNICAL FIBER

Cotton
Egyptians and Chinese used papyrus mats in foundation for
reinforcement of buildings
In recent past, synthetic fibers were used in floods in 1953 in
Netherlands, it could be seen as start of geotextile
Cotton bales in foundation for earthquake protection

34

Wool
Wool, a protein fiber, consumption second to cotton
High extensible, natural waviness, trap air, low thermal
conductivity, high thermal resistance, gives comfort and warmth
Due to morphology of wool, some technical fibers have been
produced
Wool is comparatively fire retardant
Zirconium-and titanium-treated wool has much higher for example
Zirpro (IWS) wool used for fire proof padding in aero planes

35

Flax, Jute, Hemp, Ramie

Not very common under use
Jute is used in geotextile, where biodegradable fibers
are required

36

Silk
Protein-based fiber produced naturally by
the silkworm,
Structurally similar to wool
High tenacity, high luster and good
dimensional stability.
Used as luxury item,
Biocompatibility and gradual
disintegration an advantage in in medical
textiles

Silk used for military clothing, due to light weight and for
protection from arrows. Commonly used by Mongolian armies
as wound dressing was very common by Chinese and Egyptian
37

REGENERATED FIBERS

Viscose rayon

Viscose rayon was regenerated fibers in the early 1920s. Has inferior
physical properties to cotton

Improved shape has better tenacity in wet and dry conditions

Textured and hollow viscose fibers are comparable to cotton

Fire-retardant (FR) viscose introduced in the 1960s organophosphorous

compounds

38

Lyocell
Latest addition is Lyocell also known as
Tencel (Acordis) environmentally friendly
production method (non-toxic N-methyl
morpholine oxide solvent recyclable)
The fibre has relatively high uniformity,
tenacity (16 30 cN/tex) and modulus,
especially if impregnated with rubber. Its
moisture content is about 3 % and 16 22
% extension at breake.
Applications in -automotive industry
(timing), production of hygienic and
sanitary products via nonwoven 39

Made from coal or oil

SYNTHETIC FIBERS

Nylon

Used in carpets, clothing, curtain,

packaging

Nylon 6.6 first fiber in

1939 by
DuPont
Many nylon fibers known as
polyamides produced by using melt
extrusion, many cross-sectional shapes
are possible
High extensibility, significant recovery,
more dimensional stability, low
moisture

40

 characterized by high tenacity (35 90

cN/tex), elasticity (15 60 %), resistance
to abrasion and moisture (3 5 %).
Capability of energy resilience is a
condition for an application in
manufacturing climbing ropes and linen for
parachutes and sail fabrics.
The typical application of polyamide is for
reinforcing tires for use at low quality
roads and of road vehicles
41

Polyester (PET)

Introduced as Dacron by DuPont in Glass transition temperature is

approximately 70 C, resistance to
1951. Now second major fiber
heat and chemical degradation, good
for Technical Textile
Made by condensation polymerization
of ethylene glycol and terephthalic
acid followed

Flame-retardant Trevira CS and

Trevira high tenacity, developed by
Durability and compatibility with Trevira GmbH in Germany
cotton in blend, low moisture
absorbency, resilience and good
dimensional stability are additional
qualities.

42

Acrylic
Polyacrylic fibers produced by
the
polymerization of acrylonitrile
Orlon14 was produced by DuPont.
Acrilan15 produced by Monsanto
and Courtelle, Wool-like
characteristics.
Chemically modified acrylics has
low burning behavior and having
high absorbency, applicable in
hygiene and medical care

43

Polyolefin fibers
Include both polyethylene and polypropylene made by addition polymerization
of ethylene and propylene
Polyethylene has moderate physical properties with a low melting temperature
of about 110 C for its low density form and about 140 C for its high density
form which severely restricts its application in low temperature applications.
Polypropylene has better mechanical properties and can withstand temperatures of up
to 140 C before melting at about 170C.

Polyolefine fibres are low price, low specific gravity (0.90 0.96 gcm3), good
abrasion resistance, and low moisture content (0 %).
Replaced jute in packing equipment, ropes, base fabric for floor coverings, linings for
upholstery, technical nets etc
44

 Low melting temperature of polyolefines is an

advantage for application in manufacturing of
nonwoven by thermal bonding.
Both polymers have a density less than that of water
which allows them to float as ropes, nets and other
similar applications.
The availability, low cost and good resistance to acid
and alkaline environments of polypropylene has
greatly influenced its growth and substantial use in
geotextile applications
High water repellency of PP finds application in
45

manufacturing of diapers and special thermo-

PE and PP

46

Spandex Yarn
Polyurethane structure, can stretch Formation, during knitting, yarn is

more than 8 times

Rubber-like properties,

Used in combination with other

also produced by twisting with

spandex yarn

fibers

Produced by DuPont in 1959

(Lycra).

Expensive fiber, used in fabric

47

Functional and High

Performance
Fibers
Driven
by special technical
functions
Posses unique properties
Some of the most prominent of these properties
High tensile strength and stiffness
High temperature resistance
High flame retardant ability
High chemical resistance

FIBRE
The latest technologies
PRODUCTION

for

performance fibers are

Dry-Jet-Wet Spinning
Gel-Spinning Processes.

spinning

48

of

high

HIGH
PERFORMANCE
ORGANIC FIBERS
49

Dry-jet- wet spinning

Rigid-Rod Polymers are the starting materials
Often liquid crystalline polymers

50

Gel spinning
Special process used to obtain high strength or other
special fiber properties
The polymer is not in a true liquid state during
extrusion
UHMW and Super drawing

51

Aramid Fibers
Long-chain synthetic polyamide at least 85% amide (CO-NH-) linkages are attached directly between two
aromatic ring.
Molecular structure made of linked Benzene rings and
amide bonds
Aromatic Polyamides
O

C
H2N

R
Amid
e

Aromatic

Aromatic polyamide
52

TYPES OF ARAMID
Basically araimd fiber could be classified in two types.
A) Para aramide fiber
B) Meta aramide fiber
They are chemically same but difference is in structure.
A) Para aramide fiber
Kevlar
Twaron
Technora
Sulfron
B) Meta aramide fiber
Nomex or Mylar Nomex
Teijinconex
New star
Kermel
53

Structurally
M-aramide

P-aramide

C-aramide

54

Dry-jet Wet Spinning

Spinning Solution
10-20 wt% polymer
100% H2SO4 (H2O free)

Liquid crystal in
pure
sulphuric
acid
at 850C

Specific points:
Solvent: pure H2SO4
Polymer concentration 20%
General orientation
Platinum capillary 65 n the capillary
Extra orientation in
the air gap
air gap 10 mm with
elongational stretch (6x) Coagulation in cooled
diluted sulfuric acid
coagulation
bath at 100C
removal of
sulfuric acid
56

CHARACTERSTICS OF ARAMIDS

High strength
Low elongation at break
Sensitive to acids and salts
No melting point, 500C
Sensitive to ultraviolet radiation
Low Electrical Conductivity
Prone to static build-up unless
High Chemical Resistance
finished
Low Thermal Shrinkage
Structure dependent
High Toughness
Meta vs. Para linkages
Excellent
Dimensional
Structure
of
aromatic
Stability
backbone
Flame
Resistant,
Self Absorbency
Extinguishing
Weight
Copolymer
Flexibility
Compared to meta
Weavablelity
(1) Greater tensile strength
(2) Greater chemical resistance and
(3) Lower moisture regain.
Compared to para
(4) Greater chemical, elongation and
abrasion properties
57
(5) (2) Lower moisture regain.

van der Waals forces

e source of strength:H-Bond

Order
Orientation

58

APPLICATION
OF ARAMIDS
Heat and fire protection
products
Cut-protection products
Ballistic-protection products
Civil engineering products
Elastomer reinforcements
Engineering plastics
Friction products
Optical fiber cables
Reinforced pipes
Bullet and explosion protection products
Ropes and cables
Adhesives, sealant and coatings
Specialty paper products
Composites
59
Tires,

60

ParaAramid
Bullet
Proof

Strength

61

Sulfron
62

Meta
Fire
Proof
Aramid

Heat Resistant, Absorbency and Flexibility

63

Co Aramid

Low absorbency and Better Strength

64

HPPE and
UHMWPE
Gel-spun polyethylene fibres are ultra-strong, high-modulus
fibres that are based on the simple and flexible polyethylene
molecule.
In the mid of 1970's reports of producing strong and stiff PE
fibres started to appear (modification)
The extension of polymer chains and high longitudinal
orientation is a precondition for accomplishing high
mechanical properties.
The result of this treatment is production of highperformance polyethylene fibre (HPPE)
Ultra-high molecular weight polyethylene (UHMWPE) fibres strongest fibres known, with tensile moduli in excess of
70GNm-2.
15 times stronger than steel and twice as strong as
aromatic polyamides such as Kevlar.
Low in density,
65
Chemically inert

Salient features

Moisture regain

Zero

Attacked by water

none

Resistance to acids

excellent

Resistance to alkalis

excellent

Resistance to UV light

Very good

66

66

Some Applications
Ballistic protection
Cut and puncture resistant: for example cut
resistant gloves, fencing suits and chainssaw hoses.
Composites: Twines and nets:
HPPE fibre is an ideal material for use in
marine environment.
Its density is slightly less than 1,
It does not rot and
Not affected by UV light and seawater
67

HIGH
PERFORMANCE
INORGANIC
FIBERS
68

Organic fibers can withstand only up to

500C
Carbon, glass, asbestos and ceramic
inorganic fibers, can bear high
temperature, bitter in nature, under use
from
centuries, best use is in by mixing with
other materials, plastic sheets one
example made by using glass fiber and
69

CARBON
FIBRES

Also called graphite fiber.

It is in the form of several long strands of a material mainly
composed by carbon atoms.

Carbon fibre variants differ in flexibility, electrical conductivity,

thermal and chemical resistance.
The primary factors governing the physical properties are degree
of carbonization (carbon content, usually greater than 92% by
weight) and orientation of the layered carbon planes.
Different precursors and carbonization processes are used
1. Rayon: high thermal resistance but relatively low strength,
application in aerospace.
2. Acrylic fibre : have higher strength than rayon precursors, used
as reinforcement for a wide variety of plastic composites.
70

Creation
Spinning: A polyacrylonitrile plastic is spun
into fibers which are then washed and
stretched to the desired diameter.
Stabilizing: fibers are heated with O2 to
make their bonding more thermally stable.
Carbonizing: fibers then are heated
without oxygen, they lose non carbon
atoms and bonded carbon crystals are
made.
Treating surface: the surface is slightly
oxidized.
Sizing: fibers are coated and wounded into
bobbins.
71

Advantages
It has the greatest compressive strength of
all reinforcing materials.
High strength to weight ratio.
Low coefficient of thermal
expansion.
Its density is much lower
than the density of steel.

72

Some applications of carbon fibres:

Used to reinforce composite materials
Used structurally in high-temperature
applications.
As an electrode with high surface area and
impeccable corrosion resistance.
Anti-static component.
Composites for military aircraft, commercial
aircraft
Sporting goods,
Medical devices,
Industrial applications and infrastructure,
Tennis rackets, golf club shafts, fishing rods,
skis
Aerospace
73

74

75

GLASS
FIBERS
The first "synthetic" fibre product of the
human intelligence.
They are brittle, basically used in composites.
High-performance composite materials,
including protective materials, various filters,
protective clothing and packing.
Biggest application is the automotive industry
for large-scale production of fibre reinforced
car parts because of great weight savings.

76

 Eglass fibre 90 % of reinforcement.

R glass fibre is used for special
applications, such as, aviation, space
program, and defense due to its special
performances regarding fatigue,
temperature and moisture.
AR type is used for cement reinforcement,
with high content of zirconium oxide,
which gives excellent resistance to alkaline
compounds generated during drying. The
cement reinforced with AR glass fibre has
improved modulus and good durability.
S type has high stiffness and finds its
77
application where high mechanical

ASBESTO
S
crystalline silicates that occur
naturally.
The fibres that are extracted have all the
textile-like properties of fineness,
strength, flexibility and more
importantly, unlike conventional fibres,
good resistance to heat with high
decomposition temperatures of around
550C.
They have carcinogenic problem
78

CERAMIC
FIBERS

Aluminosilicate compounds are mixtures

of aluminium oxide (Al2O) and silicon
oxide (SiO2); their resistance to
temperature depends on the mixing
ratio of the two oxides.
High aluminium oxide content increases
their temperature tolerance from a low
of 1250 C to a maximum of 1400C
Used for insulation of furnaces and
replacement of asbestos fibres in friction
materials, gaskets and packing
79

ULTRA FINE AND NOVELTY

FIBERS

Ultra fine fibers have 1.0 dtex or less

Up to 30000 filaments cm-2, highly
dense, water proof but air and
moisture vapor can pass
Linear density of extra-fine and micro

fine is less than 0.1 dtex

Commonly PET and Nylon are used

First made in Japan e.g. Mitrelle,
Setila, Micrell, Tactel
Once in woven fabric form their fine
diameter and tight weave allows

80

Specialty Materials has made boron prepreg tape with various

cyanate ester and cyanate siloxane resins for space structure
stabilization applications.

Pure boron fibres are too brittle to handle but they can be
81
coated on tungsten or carbon cores

Technical yarns

82

Introduction
These are yarns for making technical textiles
They are made through special yarn
production techniques or through the
election of special fibre blends or a
combination of both
Machines for yarn making
Ring frame
Rotor
Friction
Airjets
83

Staple fiber yarns

Ring spinning most
versatile
wide ranges of linear
density and twist
from a great variety
of fibre materials
Prior material
preparation is
important
84

Ring spinning
Ring-spun yarns have a regular
twist structure and, because of the
good fibre control during roller
drafting, the fibres in the yarn are
well straightened and aligned.
excellent tensile properties, which are
often
important
for
technical
applications.

85

 The ring spinning system can be

used for spinning cover yarns combination of technical properties.
high strength yarn with good comfort
characteristics may be spun from a high
strength filament core with natural fibre
covering.
technical yarns, such as flame-retardant
and antistatic yarns can also be made
by incorporating flame-retardant and
electricity conductive fibres. 86

 Limitations low production, high

drafting and spinning tension
(problem for low tension fibers)

87

Rotor spinning
Yarns are of lower
strength than ring spurn
Better evenness

Advantage of speed, cost reduction

88

Friction spinning
The main application
-industrial yarns and for
spinning from recycled
fibres.
It can be used to produce
yarns from aramid and
glass fibres and with
various core components
including wires.
Application - tents,
protective fabrics, backing
material, belts, insulation
and filter materials.

89

Wrap spinning
Wrap spinning is a yarn formation
process in which a twistless staple
fibre strand is wrapped by a
continuous binder
Core yarns,mostly filaments, can
be added to the feed.This can be
used to provide extra yarn strength
or other special yarn features
carbon-coated nylon filament yarn
can be used to produce yarns for
antistatic fabrics.
Soluble binders can be used for
making yarns for medical
applications.
90

Ply yarns
For high strength and modulus yarns
for technical and industrial
applications, ply yarns are often
needed.
These are co-twisted yarns

91

Filament yarns
Aramide filament yarns
Kevlar and nomex
Aramid yarns are more flexible and easier to use in subsequent
fabric making processes, be it weaving, knitting, or braiding
Glass filament yarns
widely used in the manufacture of reinforcement for composites.
E-glass has very high resistance to attack by moisture and has
high electrical and heat resistance. It is commonly used in glassreinforced plastics in the form of woven fabrics.
C-glass is known for its chemical resistance to both acids and
alkalis. - chemical filtration.
S-glass is a high strength glass fibre and is used in composite
manufacturing.

92

 Carbon filament yarns

From rayon and arcylic
Oxidative (200-300oC) carbonization (1000oC)
graphitization (3000oC)
Brittle and conductive

HDPE filament yarns

Produced by gel spinning process from
polyethylene with an extra high molecular
weight.
Characterized by high paralyzing and crystalline
93

Technical Fabrics
Fabrics manufactured primarily for
their
technical
performance
and
functional properties rather than their
aesthetic or decorative characteristics

94

Methods for producing

fabrics

Weaving
Knitting
Lace making
Net making
Felting
Tufting
Non-woven processes

A 3-D Fabric

95

WOVEN FABRICS

96

Warp (Ends) & Weft (Picks)

97

Woven Fabric Specifications

Fabric construction
Warp count x weft count/ ends per inch x
picks per inch

Fabric area density / GSM

Cover factor
Type of weave
Crimp
Fabric width
Thickness
98

Fabric area density

The loom state cloth area density depends on the
weaving specification, that is, yarns, thread spacing
and weave, and on any additives, such as size,
which are used to improve the weaving process.
Finished cloth area density is frequently altered by
chemical treatments .
The area density of the fabric can be varied by
changing the linear density or count of the yarns
used and by altering the thread spacing, which
affects the area covered by the yarns in relation to
the total area.

99

Cloth cover factor

Cloth cover factor = warp cover factor + weft
cover factor
Cover factor in SI units =
Cover factor formula by Pierce =

Changing the
area density
and/or the
cover factors
may affect:

strength,
stiffness,
stability,
porosity, filtering
quality and
abrasion resistance
of fabrics

100

Area density and cover

factor
Low area density fabrics of open construction
include bandages
Light area density fabrics high cover factor
fabrics include medical filter fabrics
Heavy open cloths include Geotextiles fabrics
Heavy closely woven fabrics include cotton
awnings.
101

Plain weave
90% technical fabrics have plain
weave

102

Other types of weave

Satins and sateen

Twill weave
103

Triaxial weave
Triaxial fabrics are defined as
cloths where the three sets of
threads form a multitude of
equilateral triangles
Two sets of warp yarns are
generally inserted at 60 to the
weft,
Tetra-axial fabrics where four
sets of yarns are inclined at 45
to each other
104

Triaxial weaves
The tear resistance, bursting
resistance of Triaxial fabrics is
greatly superior to that of standard
fabrics
They have a wide range of technical
applications including sailcloths, tyre
fabrics, balloon fabrics.

105

Classification of Weaving
Machines
Single-phase weaving machines
Machines with shuttles (looms):
Hand operated (hand looms)
Non-automatic power looms (weft supply in shuttle
changed by hand)
Automatic weaving machines

Shuttle less weaving machines:

In single phase machines, one weft

Projectile
thread is laid across the full width of the
warp sheet followed by the beat-up and
Rapier
the formation of the next shed in
Jet machines
preparation for the insertion of the next
pick.
air (with or without relay nozzles)
In multiphase machines,
liquid (generally water)
several phases of the working
cycle take place at any instant
so that several
picks are being
106
inserted simultaneously.

Multiphase weaving machines

Projectile looms
They are used not only for weaving a vast
range of standard fabrics but also for heavy
industrial fabrics of up to 8m wide, for
sailcloth,
conveyor belts,
tyre cord fabrics,
awnings,
Geotextiles,
airbags and
a wide range of filter fabrics of varying area
density and porosity.
107

L680W series high-efficiency fibre

glass rapier cross weaving
machine
Suitable for the weaving of various
gridding cloth used in civil
engineering, hydraulic construction,
building materials, chemical
engineering and transportation areas

108

OMNI plus800 air jet weaving

machine
Gauze
Gauze is a lightweight, open-texture fabric
produced in plain weave, used for bandages,
food wrapping etc.

Parachute
Parachute is industrial, heavy-filament, rib
stop cloths made of fine nylon fibre

Tyre cord
Tire cord is a fabric used to reinforce the tires
of vehicles
109

OMNI plus800 air jet weaving

machine
Umbrella cloth
Umbrella cloth is usually made with a
cotton warp and rayon or nylon filling,
which is then treated to make it water
repellent.

Camping tent cloth

Camping tent cloth is a fabric used for
the outer covering of tents for
recreational camping.
110

OptiMax rapier weaving

machine
Conveyer belt
Conveyor belt is a continuously moving
strip or surface for transporting a load of
objects from one place to another.

Filter cloth
Filter cloths are mainly made up of
monofilaments and/or multifilament's.
111

Woven either on
rapierorair-jettechnology
Sail cloth
Sail cloth is any heavy, plain-weave canvas fabric,
usually made of cotton, linen, polyester, jute, nylon
etc. that is used for sails and apparel.

Seat fabrics
Seat fabrics are used to cover seats in the transport
industry (automotive, aviation, etc.)

Air bags
Airbag is a heavy denier nylon fabric for personal
protection in various forms of transportation.
Most airbag fabrics are woven with rapier weaving
technology.
112

OMNIplus800 TC

The most advanced tire cord weaving machine

113

Knitted technical textiles

114

Definition
Warp knitting is a method of making a fabric by
normal knitting means, in which the loops made
from each warp are formed substantially along the
length of the fabric
Weft knitting is a method of making a fabric by
normal knitting means, in which the loops made by
each weft thread are formed substantially across the
width of the fabric.
Single-jersey fabric is a weft-knitted fabric made on
one set of needles.
Double-jersey fabric is a weft-knitted fabric made on
two sets of needles,
115

Needles
Basically latch and beard needles
used, others are compound
Bearded needles
-expensive to manufacture,
can be produced
in finer gauges and
supposedly knit tighter and
more uniform stitches
compared
with latch needles, but have
limitations with regard to the
types of material that
can be processed as well as
the range of structures that
can be knitted on them.
116

End use products

Flat bar machines: Cleaning clothes,
three-dimensional and fashioned
products for technical applications,
multiaxial machines are under
development
Circular machines: Hose machines:
seam free hose, tights, industrial use
dye bags, knit-de-knit yarns,
industrial fabrics
117

Warp knitting

Higher machine speeds, (up to 3500cpm)

Finer gauges (up to 40 needles per inch)
Wider machines (up to 260 inches)
Some speciality raschel machines such as Co-we-nit and
Jacquard machines
More recently, redesigned full-width weft insertion raschel
and tricot machines
Stable constructions, such as sharkskins, queenscord, etc.
Various net constructions utilising synthetic yarns
Mono-, bi-, tri- and multiaxial structures for technical
applications
Three-dimensional and shaped (fashioned) structures for
medical and other high technology products.
118

End use
Tricot machines: car seats, technical
fabrics
Raschel machines:nets, fishing nets,
sports nets, technical fabrics, curtain
lace, power nets, tablecloths, bed
covers, elastic bandages, cleaning
cloths, upholstery, drapes, velvets,
carpets, fruit and vegetable bags,
geotextiles, medical textiles.

119

NONWOVEN and their

APPLICATION

120

Defination of nonwoven
Structure produced by bonding or interlacement
of fiber or both accomplished by mechanical ,
chemical ,thermal or solvent mean and the
combination of techniques .
Term does not include paper or fabric that are
woven, knitted or tufted or those made by other
felting process.

or
we can say that nonwoven is direct

conversion of fiber to fabric.

121

Why to go for
nonwoven????
Due to high production a versality of
use of different fibres to produce final
product having required properties
according to final product and also
elimination of spinning and
weaving process

122

Manufacturing Process
Various techniques are used for manufacturing
of nonwovens but some of the techniques that
are used specially for the Medical applications
point of view are as follows:
Spun bonding
Spunlacing
Meltblowing
Needle punching
Wet laid
Dry laid
123

Spun bonding
Spun bonding is used when more strong webs
are needed.
Webs produced are soft, porous and
dimensionally stable.
Spun bonding is mostly used for products like : Face masks
Head wears
Shoe covers
Bed linens and
Disposable clothing .

124

Flow chart of Spun

bonding Processes

125

Manufacturing Processes

126

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
127

Wet laid
Wet-laid nonwovens are nonwoven fabrics made by a
modified papermaking process, that is, the fibers to be
used are suspended in water, and specialized paper
machines separate the water from the fibers to form a
uniform sheet of material which is then bonded and dried
to produce rolls of product.

128

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

Wide variety of processable fibers

129

Bonding technologies

The Bonding Process is the essence of Nonwoven Technology.

Mechanical Bonding

Needle Punching

Stitch Bonding

Hydro-entanglement (Spun-lace)

Chemical Bonding

Binder Application Wet

Powder Application Dry

Thermal Bonding

Calendar

Hot Air

Spun Bonding / Melt Blown

130

131

Thermal bonding
Wet-laid webs may be thermally
bonded by the application of heat
providing the web contains a fiber or
an additive that will fuse at the
selected bonding temperature and
will flow between the fiber junctions.
On cooling, the binder material locks
the fiber network together.
132

133

134

Melt blown

135

Application Area
1)Sanitary and
Medical
uses

1.Feminine Hygiene

2) House hold
textiles

1.Floor & wall covering

2.Blankets

3)Civil Engg.
Application

1.Geotextiles water proofing

2.Roofing material

2.Diapers
3.Patient Apparel
4.Surgical gown/ mask

3.Pillow covers, Bed sheets

4.Towels
5.Luggage & Table cloth
6.House hold wipes

136

4)FOOTWEAR
APPLICATIONS

1.Shoe cover
2.Lining
3.Sole

5) APPARELS

1.Interlinings
2.Protective clothing
3.Laboratory aprons

6)OTHER UTILITY
MATERIAL

1.Decorative textiles
2.Book covers
3.Tea bags
4.Tents

137

Applications of nonwovens in
medical textiles
Bandages
Simple bandages
Light support bandages
Orthopedic bandages
Cotton pads, wound dressings and adhesive
tapes

138

Contd.
Disposable surgical clothing:

Gowns

Caps

Masks
139

Contd.
Disposable surgical coverings:
Blankets
Floor coverings of hospitals (anti-bacterial)
Cloths/ wipes

Drapes

Bed coverings
140

Contd.
Nonwovens are used to replace or
repair different organs, bones like
artificial
kidney,
liver,
heart,
mechanical
lung,
ligaments,
vascular grafts, heart valves, blood
vessels, artificial skins, nasal strips
etc.

141

Properties of the medical nonwoven

The main criteria for determining the
suitability of textile products are : barrier efficiency toward bacteria,
viruses, liquids and dust particles
capacity to absorb and store body
fluids
resistance to mechanical influences

142

Household
textiles
Nonwoven fabrics can be used in the
following household textile applications:
floor coverings
sub-upholstery materials
webbings
Materials for use in the contract sector
have to meet legal specifications
regarding their flammability.
143

NONWOVEN HOUSEHOLD PRODUCT

Nonwoven wall hanging

China nonwoven carpet

144

NONWOVEN IN
PROTECTIVE CLOTHING

NONWOVEN USED
RESIST TO
CHEMICAL

FLAME RESISTANCE NONWOVEN GLOVES

145

Filter fabrics
Pulsejet fabric filters are widely used in many
industries like solid, fuel, Fired power generation.

e.g. for industrial dust removal or for cleaning

atmospheric air.
Conveyor belts, seal gasket, other industrial
equipment.
nonwoven fabrics are to be used as filter media
for both wet and dry filtration.
The end-use-specific textile physical and general
physical parameters should also be determined:-

146

Geo Textiles
Woven
geotextiles

Nonwoven
geotextiles

Nonwoven geotextiles:nonwoven geotextiles are thicker and made

either from short and continuous filaments,
carded or laid in even patterns and then
mechanically (needle punched) or thermally
bonded.

147

Benefits of nonwoven geotextiles

Cheap and easy to manufacture.

Superior chemical resistance in even
the aggressive environment
application.
Highly porous structure
Staple fibres needle punched
together to form fabric capable of
withstanding construction installation
stresses.
148

GEO NONWOVEN

149