Inda, Association of the Nonwoven Fabrics Industry Ted Wirtz President

This part of the study aims to investigate the role of fiber finish during processing on the needlepunching machine. Certain key response parameters like dynamic needling forces and needlepunched fabric properties are analyzed for any possible effect of finish level and its uniformity on these responses. The experiments were performed using polyester and polypropylene, two of the most commonly used fibers in needlepunched products, to investigate the difference response due to fiber type. While the results published in Part 2 of this study showed that finish uniformity fail to show any effect on carding processability, it was found to have a significant effect on needlepunching forces and needled fabric properties. Introduction Needlepunching, a nonwoven technology of fabric formation, is used in the manufacturing of several commercial products such as home and automobile upholstery, carpeting, medical and hygiene products, industrial filters and many other high performance applications. Structural integrity of the fabric is provided by means of fiber entanglements, caused by the repeated punching of a board of needles through a layer of loosely held fiberweb. The resultant fabric properties are determined by the type of fiber and fiber properties such as length, fineness, coefficient of friction and flexural rigidity. Additionally fiberweb parameters such as basis weight, thickness and number of layers, and machine parameters such as needling density, draft, depth of penetration of needle and needle design parameters significantly impact fabric properties [3-10]. Due to the nature of the feed material, finish applied on the fibers to aid its mechanical processing during the preparatory process such as carding is carried over to the needlepunching process. Often the finish treatment is not optimized for the needlepunching process and hence results in differences in processability depending on the finish treatment. Optimization of the finish treatment will ensure a fiber friction low enough to permit realignment of fibers and high enough to impart sufficient strength to the fabric after needlepunching. The fiber-to-metal friction should also be optimized to reduce wear on the needles. One such study conducted by Wagner and Ahles, on Kevlar aramid fibers have shown a considerable reduction in needle breakage [16]. The study used a more static form of measurement of needling forces and the needle breakage was recorded over a long period of time. Kevlar by nature is also a very rigid fiber compared to other fibers used for needlepunching such as polyester and polypropylene. There has also been no study conducted on the effect of finish uniformity on the needling process. Since the response to finish treatment differs from fiber to fiber, a study of the effect of friction and its uniformity on the dynamic needling forces and fabric properties should provide a better understanding of the role of fiber finish in needlepunching. Experimental Approach Two fiber types, namely polyester and polypropylene, were used to study the effect of finish level and finish uniformity. Polyester of 3 denier and 38mm was provided by Wellman Inc., and polypropylene of 9 denier and 38mm was provided by Fibervision Inc. The finish used on both fibers is of a generic kind, formulated by Goulston Tech. The finish is composed of 90% lubricant (PEG(400) Monolaurate) and 10% antistat (Amine neutralized linear alkyl phosphate). The effect of finish level is studied by processing different Role of Fiber Finish In The Conversion Of Fiber To Nonwovens Part 3: Finish Performance As A Mechanical Processing Aid In Needlepunching By Abdelfattah M. Seyam and Thomas J. Proffitt, Jr., Nonwoven Cooperative Research Center, College of Textiles, N.C. State University, Raleigh, NC; and Murali Velmurugan, Uno International, Cary, NC ORIGINAL PAPER/PEER-REVIEWED