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 20. 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 21. HydrotubeTM Technology Nonwoven Innovation & Research Institute 22. 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 23. Three major players who met the INDA/ EDANA norms for flushable wipes are : Kimberly-Clarks ion triggered airlaid Suominens Hydraspun (spunlaced wetlaid base web) Buckeyes Flushable Airspun (non triggered airlaid) Kimberly-Clarks 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 wipes 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. 24. Suominens 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 25. Buckeyes 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 wipes dry weight) to solubilize enough binder to reduce the strength in use significantly, but in a toilet with excess water (several thousand times the wipes dry weight) the binder solubilizes and the wipe disperses. 26. 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. 27. 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 28. Nonwoven Abrasives Application Areas 29. . Economical solution: Eliminate steps One product replaces two or more Best technical solution Engineered solution Profit improvement Specialized solution 30. 3 Layer Composite Fiber Pulp - Fiber a. Highly absorbent b. Lower cost c. Improved appearance d. Softness improved 31. Rieter Spunjet Spunlace Jetlace 3000 Spunbond Perfobond 3000 Winder Air Through Dryer Perfodry 3000 Integrated technology: Spunbond & Spunlace 32. 3M Thinsulate Insulation Thinsulate from 3M composed of large fibers + sub-denier fibers 33. 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 34. Thermocules Technology Outer durable shell Thermocules PCM Hydrophilic Microscopic size (3 Million per cm2) 35. 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 36. Areas of Application 37. 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. 38. 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