WOODHEAD PUBLISHING SERIES IN TEXTILES Composite Nonwoven Materials Structure,Properties and Applications Edited by Dipayan Das and Behnam Pourdeyhimi WP WOODHEAD The Textile Institute PUBLISHING
The Textile Institute and Woodhead Publishing The Textile Institute is a unique organisation in textiles,clothing and footwear. Incorporated in England by a Royal Charter granted in 1925,the Institute has individual and corporate members in over 90 countries.The aim of the Institute is to facilitate learning,recognise achievement,reward excellence and disseminate information within the global textiles,clothing and footwear industries. Historically,The Textile Institute has published books of interest to its members and the textile industry.To maintain this policy,the Institute has entered into partnership with Woodhead Publishing Limited to ensure that Institute members and the textile industry continue to have access to high calibre titles on textile science and technology. Most Woodhead titles on textiles are now published in collaboration with The Textile Institute.Through this arrangement,the Institute provides an Editorial Board which advises Woodhead on appropriate titles for future publication and suggests possible editors and authors for these books.Each book published under this arrangement carries the Institute's logo. Woodhead books published in collaboration with The Textile Institute are offered to Textile Institute members at a substantial discount.These books,together with those published by The Textile Institute that are still in print,are offered on the Elsevier website at:http://store.elsevier.com/.Textile Institute books still in print are alsoavailable directly from the Institute's website at:www.textileinstitutebooks. com. A list of Woodhead books on textiles science and technology,most of which have been published in collaboration with The Textile Institute,can be found towards the end of the contents pages
The Textile Institute and Woodhead Publishing The Textile Institute is a unique organisation in textiles, clothing and footwear. Incorporated in England by a Royal Charter granted in 1925, the Institute has individual and corporate members in over 90 countries. The aim of the Institute is to facilitate learning, recognise achievement, reward excellence and disseminate information within the global textiles, clothing and footwear industries. Historically, The Textile Institute has published books of interest to its members and the textile industry. To maintain this policy, the Institute has entered into partnership with Woodhead Publishing Limited to ensure that Institute members and the textile industry continue to have access to high calibre titles on textile science and technology. Most Woodhead titles on textiles are now published in collaboration with The Textile Institute. Through this arrangement, the Institute provides an Editorial Board which advises Woodhead on appropriate titles for future publication and suggests possible editors and authors for these books. Each book published under this arrangement carries the Institute’s logo. Woodhead books published in collaboration with The Textile Institute are offered to Textile Institute members at a substantial discount. These books, together with those published by The Textile Institute that are still in print, are offered on the Elsevier website at: http://store.elsevier.com/ . Textile Institute books still in print are also available directly from the Institute’s web site at: www.textileinstitutebooks. com . A list of Woodhead books on textiles science and technology, most of which have been published in collaboration with The Textile Institute, can be found towards the end of the contents pages
Contents Contributor contact details ix Woodhead Publishing Series in Textiles xi 1 Introduction to composite nonwovens 1 D.DAs,Indian Institute of Technology Delhi,India 1.1 Introduction 1 1.2 Classification of composite nonwovens 5 1.3 Processing,markets and applications 13 1.4 Conclusion and future trends 15 1.5 Sources of further information and advice 16 1.6 References 16 2 Natural and synthetic fibres for composite nonwovens 20 S.MUKHOPADHYAY,Indian Institute of Technology Delhi,India 2.1 Introduction 20 2.2 Natural and biodegradable fibres for nonwovens 20 2.3 Polypropylene and polyester fibres 2 2.4 Polyethylene and nylon fibres 23 2.5 Bicomponent fibres 24 2.6 References 28 3 Structure of composite nonwovens 30 D.DAs,Indian Institute of Technology Delhi,India and B.NECKAR,Technical University of Liberec,Czech Republic 3.1 Introduction 30 3.2 Fibre characteristics in composite nonwovens 30 3.3 Fibre packing in composite nonwovens 41 3.4 Fibre orientation in composite nonwovens 4 3.5 Pore characteristics in composite nonwovens 52 3.6 Conclusion 5
v Contributor contact details ix Woodhead Publishing Series in Textiles xi 1 Introduction to composite nonwovens 1 D. DAS, Indian Institute of Technology Delhi, India 1.1 Introduction 1 1.2 Classifi cation of composite nonwovens 5 1.3 Processing, markets and applications 13 1.4 Conclusion and future trends 15 1.5 Sources of further information and advice 16 1.6 References 16 2 Natural and synthetic fi bres for composite nonwovens 20 S. MUKHOPADHYAY, Indian Institute of Technology Delhi, India 2.1 Introduction 20 2.2 Natural and biodegradable fi bres for nonwovens 20 2.3 Polypropylene and polyester fi bres 22 2.4 Polyethylene and nylon fi bres 23 2.5 Bicomponent fi bres 24 2.6 References 28 3 Structure of composite nonwovens 30 D. DAS, Indian Institute of Technology Delhi, India and B. NECKÁŘ, Technical University of Liberec, Czech Republic 3.1 Introduction 30 3.2 Fibre characteristics in composite nonwovens 30 3.3 Fibre packing in composite nonwovens 41 3.4 Fibre orientation in composite nonwovens 44 3.5 Pore characteristics in composite nonwovens 52 3.6 Conclusion 56 Contents
VI Contents 3.7 Sources of further information and advice 5 3.8 References 7 4 Properties of composite nonwovens 58 D.DAs,Indian Institute of Technology Delhi,India 4.1 Introduction 58 4.2 Mechanical properties of composite nonwovens 58 4.3 Fluid permeability of composite nonwovens 60 4.4 Thermal properties of composite nonwovens 64 4.5 Liquid sorption characteristics of composite nonwovens 65 4.6 Particle filtration behaviour of composite nonwovens 66 4.7 Conclusion 71 4.8 Sources of further information and advice 71 4.9 References 1 5 Composite nonwovens in absorbent hygiene products 74 D.DAS,Indian Institute of Technology Delhi,India 5.1 Introduction 74 5.2 Key material requirements 5 5.3 Baby diapers 76 5.4 Feminine sanitary pads 81 5.5 Adult incontinence pads 84 5.6 Conclusion and future trends 86 5.7 Sources of further information and advice 87 5.8 References 87 6 Composite nonwovens in wipes 89 R.S.RENGASAMY,Indian Institute of Technology Delhi,India 6.1 Introduction 89 6.2 Materials in wipes 90 6.3 Wet wipes 91 6.4 Web forming technologies for wipes 92 6.5 Web bonding processes for wipes 95 6.6 Surface texturing of wipes 6 6.7 Composite nonwoven wipes 97 6.8 Multi-fibre composite nonwoven wipes 98 6.9 Multilayer composite latex bonded nonwoven wipes 100 6.10 Hydroentangled(spunlaced)multilayer composite nonwoven wipes 100 6.11 Thermobonded multilayer composite nonwoven wipes 109 6.12 Needlepunched composite nonwoven wipes 112 6.13 Other multilayer nonwoven wipes 113
vi Contents 3.7 Sources of further information and advice 56 3.8 References 57 4 Properties of composite nonwovens 58 D. DAS, Indian Institute of Technology Delhi, India 4.1 Introduction 58 4.2 Mechanical properties of composite nonwovens 58 4.3 Fluid permeability of composite nonwovens 60 4.4 Thermal properties of composite nonwovens 64 4.5 Liquid sorption characteristics of composite nonwovens 65 4.6 Particle fi ltration behaviour of composite nonwovens 66 4.7 Conclusion 71 4.8 Sources of further information and advice 71 4.9 References 71 5 Composite nonwovens in absorbent hygiene products 74 D. DAS, Indian Institute of Technology Delhi, India 5.1 Introduction 74 5.2 Key material requirements 75 5.3 Baby diapers 76 5.4 Feminine sanitary pads 81 5.5 Adult incontinence pads 84 5.6 Conclusion and future trends 86 5.7 Sources of further information and advice 87 5.8 References 87 6 Composite nonwovens in wipes 89 R. S. RENGASAMY, Indian Institute of Technology Delhi, India 6.1 Introduction 89 6.2 Materials in wipes 90 6.3 Wet wipes 91 6.4 Web forming technologies for wipes 92 6.5 Web bonding processes for wipes 95 6.6 Surface texturing of wipes 96 6.7 Composite nonwoven wipes 97 6.8 Multi- fi bre composite nonwoven wipes 98 6.9 Multilayer composite latex bonded nonwoven wipes 100 6.10 Hydroentangled (spunlaced) multilayer composite nonwoven wipes 100 6.11 Thermobonded multilayer composite nonwoven wipes 109 6.12 Needlepunched composite nonwoven wipes 112 6.13 Other multilayer nonwoven wipes 113
Contents vil 6.14 Conclusion and future trends 113 6.15 References 118 7 Composite nonwovens in filters:theory 120 A.MUKHOPADHYAY,National Institute of Technology Jalandhar,India 7.1 Introduction 120 7.2 Mechanisms of filtration:general 125 7.3 Mechanisms of filtration:particle capture entrapment 126 7.4 Adsorption 140 7.5 Absorption 141 7.6 Coalescing 141 7.7 Media for gel removal 144 7.8 Mechanisms of filtration:electro-filtration 146 7.9 Separation by antimicrobial media 147 7.10 Extraction 147 7.11 Key requirements for filtration media 147 7.12 Characteristics of nonwoven filters 151 7.13 Types of nonwoven filter 152 7.14 Conclusion 160 7.15 References 161 8 Composite nonwovens in filters:applications 164 A.MUKHOPADHYAY,National Institute of Technology Jalandhar,India 8.1 Introduction 164 8.2 The role of composite nonwovens in filters:combining mechanical support and durability with filtration 166 8.3 The role of composite nonwovens in filters:providing two or more layers of different filtration efficiency 181 8.4 The role of composite nonwovens in filters:combining different separation technologies/functionality into one filter medium 182 8.5 Applications of composite nonwovens 190 8.6 Applications in air/gas filtration 192 8.7 Applications in liquid filtration 198 8.8 Applications in engine filtration 200 8.9 Conclusion 204 8.10 References 204 9 Composite nonwovens in medical applications 211 S.GHOSH,Indian Institute of Technology Delhi,India 9.1 Introduction 211 9.2 Surgical gowns 212 9.3 Surgical facemasks and other clinical wearable products 213 9.4 Wipes 214
Contents vii 6.14 Conclusion and future trends 113 6.15 References 118 7 Composite nonwovens in fi lters: theory 120 A. MUKHOPADHYAY, National Institute of Technology Jalandhar, India 7.1 Introduction 120 7.2 Mechanisms of fi ltration: general 125 7.3 Mechanisms of fi ltration: particle capture entrapment 126 7.4 Adsorption 140 7.5 Absorption 141 7.6 Coalescing 141 7.7 Media for gel removal 144 7.8 Mechanisms of fi ltration: electro- fi ltration 146 7.9 Separation by antimicrobial media 147 7.10 Extraction 147 7.11 Key requirements for fi ltration media 147 7.12 Characteristics of nonwoven fi lters 151 7.13 Types of nonwoven fi lter 152 7.14 Conclusion 160 7.15 References 161 8 Composite nonwovens in fi lters: applications 164 A. MUKHOPADHYAY, National Institute of Technology Jalandhar, India 8.1 Introduction 164 8.2 The role of composite nonwovens in fi lters: combining mechanical support and durability with fi ltration 166 8.3 The role of composite nonwovens in fi lters: providing two or more layers of different fi ltration effi ciency 181 8.4 The role of composite nonwovens in fi lters: combining different separation technologies/functionality into one fi lter medium 182 8.5 Applications of composite nonwovens 190 8.6 Applications in air/gas fi ltration 192 8.7 Applications in liquid fi ltration 198 8.8 Applications in engine fi ltration 200 8.9 Conclusion 204 8.10 References 204 9 Composite nonwovens in medical applications 211 S. GHOSH, Indian Institute of Technology Delhi, India 9.1 Introduction 211 9.2 Surgical gowns 212 9.3 Surgical facemasks and other clinical wearable products 213 9.4 Wipes 214
vii Contents 9.5 Wound dressings,pads and swabs 214 9.6 Scaffolds for tissue engineering 216 9.7 Hernia meshes 218 9.8 Filtration materials for medical applications 219 9.9 Incontinence products 220 9.10 Conclusion and future trends 220 9.11 References 220 9.12 Appendix:recent patents based on composite nonwovens for medical applications 223 Index 225
viii Contents 9.5 Wound dressings, pads and swabs 214 9.6 Scaffolds for tissue engineering 216 9.7 Hernia meshes 218 9.8 Filtration materials for medical applications 219 9.9 Incontinence products 220 9.10 Conclusion and future trends 220 9.11 References 220 9.12 Appendix: recent patents based on composite nonwovens for medical applications 223 Index 225
Contributor contact details (*main contact) Editors Chapter 2 D.Das Department of Textile Technology S.Mukhopadhyay Indian Institute of Technology Delhi Department of Textile Technology Hauz Khas Indian Institute of Technology Delhi New Delhi 110016,India Hauz Khas New Delhi 110016,India E-mail:dipayan@textile.iitd.ac.in E-mail:samrat@textile.iitd.ac.in B.Pourdeyhimi North Carolina State University 2200 Hillsborough Chapter 3 Raleigh,NC 27695,USA D.Das* Department of Textile Technology E-mail:bpourdey@ncsu.edu Indian Institute of Technology Delhi Hauz Khas Chapter 1 New Delhi 110016,India D.Das E-mail:dipayan@textile.iitd.ac.in Department of Textile Technology Indian Institute of Technology B.Neckar Delhi Hauz Khas Department of Textile Technology Faculty of Textiles New Delhi 110016,India Technical University of Liberec Studentska 2,461 17 Liberec 1 E-mail:dipayan@textile.iitd.ac.in Czech Republic E-mail:bohuslav.neckar@tul.cz ix
ix Contributor contact details Editors D. Das Department of Textile Technology Indian Institute of Technology Delhi Hauz Khas New Delhi 110016, India E-mail: dipayan@textile.iitd.ac.in B. Pourdeyhimi North Carolina State University 2200 Hillsborough Raleigh, NC 27695, USA E-mail: bpourdey@ncsu.edu Chapter 1 D. Das Department of Textile Technology Indian Institute of Technology Delhi Hauz Khas New Delhi 110016, India E-mail: dipayan@textile.iitd.ac.in Chapter 2 S. Mukhopadhyay Department of Textile Technology Indian Institute of Technology Delhi Hauz Khas New Delhi 110016, India E-mail: samrat@textile.iitd.ac.in Chapter 3 D. Das* Department of Textile Technology Indian Institute of Technology Delhi Hauz Khas New Delhi 110016, India E-mail: dipayan@textile.iitd.ac.in B. Neckář Department of Textile Technology Faculty of Textiles Technical University of Liberec Studentská 2, 461 17 Liberec 1 Czech Republic E-mail: bohuslav.neckar@tul.cz (* = main contact)
Contributor contact details Chapter 4 Chapter 7 D.Das A.Mukhopadhyay Department of Textile Technology Department of Textile Technology Indian Institute of Technology Delhi National Institute of Technology Hauz Khas Jalandhar New Delhi 110016,India Jalandhar 144011,India E-mail:dipayan@textile.iitd.ac.in E-mail:arunangshu@nitj.ac.in Chapter 5 Chapter 8 D.Das A.Mukhopadhyay Department of Textile Technology Department of Textile Technology Indian Institute of Technology Delhi National Institute of Technology Hauz Khas Jalandhar New Delhi 110016,India Jalandhar 144011,India E-mail:dipayan@textile.iitd.ac.in E-mail:arunangshu@nitj.ac.in Chapter 6 Chapter 9 R.S.Rengasamy S.Ghosh Department of Textile Technology Department of Textile Technology Indian Institute of Technology Delhi Indian Institute of Technology Delhi Hauz Khas Hauz Khas New Delhi 110016.India New Delhi 110016.India E-mail:rsr@textile.iitd.ac.in E-mail:sghosh08@textile.iitd.ac.in
x Contributor contact details Chapter 4 D. Das Department of Textile Technology Indian Institute of Technology Delhi Hauz Khas New Delhi 110016, India E-mail: dipayan@textile.iitd.ac.in Chapter 5 D. Das Department of Textile Technology Indian Institute of Technology Delhi Hauz Khas New Delhi 110016, India E-mail: dipayan@textile.iitd.ac.in Chapter 6 R. S. Rengasamy Department of Textile Technology Indian Institute of Technology Delhi Hauz Khas New Delhi 110016, India E-mail: rsr@textile.iitd.ac.in Chapter 7 A. Mukhopadhyay Department of Textile Technology National Institute of Technology Jalandhar Jalandhar 144011, India E-mail: arunangshu@nitj.ac.in Chapter 8 A. Mukhopadhyay Department of Textile Technology National Institute of Technology Jalandhar Jalandhar 144011, India E-mail: arunangshu@nitj.ac.in Chapter 9 S. Ghosh Department of Textile Technology Indian Institute of Technology Delhi Hauz Khas New Delhi 110016, India E-mail: sghosh08@textile.iitd.ac.in
Woodhead Publishing Series in Textiles 1 Watson's textile design and colour Seventh edition Edited by Z.Grosicki 2 Watson's advanced textile design Edited by Z.Grosicki 3 Weaving Second edition P.R.Lord and M.H.Mohamed 4 Handbook of textile fibres Volume 1:Natural fibres J.Gordon Cook 5 Handbook of textile fibres Volume 2:Man-made fibres J.Gordon Cook 6 Recycling textile and plastic waste Edited by A.R.Horrocks 7 New fibres Second edition T.Hongu and G.O.Phillips 8 Atlas of fibre fracture and damage to textiles Second edition J.W.S.Hearle,B.Lomas and W.D.Cooke 9 Ecotextile'98 Edited by A.R.Horrocks 10 Physical testing of textiles B.P.Saville 11 Geometric symmetry in patterns and tilings C.E.Horne 12 Handbook of technical textiles Edited by A.R.Horrocks and S.C.Anand 13 Textiles in automotive engineering W.Fung and J.M.Hardcastle 14 Handbook of textile design J.Wilson 15 High-performance fibres Edited by J.W.S.Hearle 16 Knitting technology Third edition D.J.Spencer 17 Medical textiles Edited by S.C.Anand 18 Regenerated cellulose fibres Edited by C.Woodings 19 Silk,mohair,cashmere and other luxury fibres Edited by R.R.Franck xi
xi 1 Watson’s textile design and colour Seventh edition Edited by Z. Grosicki 2 Watson’s advanced textile design Edited by Z. Grosicki 3 Weaving Second edition P. R. Lord and M. H. Mohamed 4 Handbook of textile fi bres Volume 1: Natural fi bres J. Gordon Cook 5 Handbook of textile fi bres Volume 2: Man- made fi bres J. Gordon Cook 6 Recycling textile and plastic waste Edited by A. R. Horrocks 7 New fi bres Second edition T. Hongu and G. O. Phillips 8 Atlas of fi bre fracture and damage to textiles Second edition J. W. S. Hearle, B. Lomas and W. D. Cooke 9 Ecotextile ’98 Edited by A. R. Horrocks 10 Physical testing of textiles B. P. Saville 11 Geometric symmetry in patterns and tilings C. E. Horne 12 Handbook of technical textiles Edited by A. R. Horrocks and S. C. Anand 13 Textiles in automotive engineering W. Fung and J. M. Hardcastle 14 Handbook of textile design J. Wilson 15 High- performance fi bres Edited by J. W. S. Hearle 16 Knitting technology Third edition D. J. Spencer 17 Medical textiles Edited by S. C. Anand 18 Regenerated cellulose fi bres Edited by C. Woodings 19 Silk, mohair, cashmere and other luxury fi bres Edited by R. R. Franck Woodhead Publishing Series in Textiles
xii Woodhead Publishing Series in Textiles 20 Smart fibres,fabrics and clothing Edited by X.M.Tao 21 Yarn texturing technology J.W.S.Hearle.L.Hollick and D.K.Wilson 22 Encvclopedia of textile finishing H-K.Rouette 23 Coated and laminated textiles W.Fung 24 Fancy yarns R.H.Gong and R.M.Wright 25 Wool:Science and technology Edited by W.S.Simpson and G.Crawshaw 26 Dictionary of textile finishing H-K.Rouette 27 Environmental impact of textiles K.Slater 28 Handbook of yarn production P.R.Lord 29 Textile processing with enzymes Edited by A.Cavaco-Paulo and G.Gubitz 30 The China and Hong Kong denim industry Y.Li.L.Yao and K.W.Yeung 31 The World Trade Organization and international denim trading Y.Li.Y.Shen,L.Yao and E.Newton 32 Chemical finishing of textiles W.D.Schindler and P.J.Hauser 33 Clothing appearance and fit J.Fan,W.Yu and L.Hunter 34 Handbook of fibre rope technology H.A.McKenna.J.W.S.Hearle and N.O'Hear 35 Structure and mechanics of woven fabrics J.Hu 36 Synthetic fibres:nylon,polyester,acrylic,polvolefin Edited by J.E.Mclntyre 37 Woollen and worsted woven fabric design E.G.Gilligan 38 Analytical electrochemistry in textiles P.Westbroek.G.Priniotakis and P.Kiekens 39 Bast and other plant fibres R.R.Franck 40 Chemical testing of textiles Edited by O.Fan 41 Design and manufacture of textile composites Edited by A.C.Long 42 Effect of mechanical and physical properties on fabric hand Edited by H.M.Behery 43 New millennium fibres T.Hongu,M.Takigami and G.O.Phillips
xii Woodhead Publishing Series in Textiles 20 Smart fi bres, fabrics and clothing Edited by X. M. Tao 21 Yarn texturing technology J. W. S. Hearle, L. Hollick and D. K. Wilson 22 Encyclopedia of textile fi nishing H-K. Rouette 23 Coated and laminated textiles W. Fung 24 Fancy yarns R. H. Gong and R. M. Wright 25 Wool: Science and technology Edited by W. S. Simpson and G. Crawshaw 26 Dictionary of textile fi nishing H-K. Rouette 27 Environmental impact of textiles K. Slater 28 Handbook of yarn production P. R. Lord 29 Textile processing with enzymes Edited by A. Cavaco-Paulo and G. Gübitz 30 The China and Hong Kong denim industry Y. Li, L. Yao and K. W. Yeung 31 The World Trade Organization and international denim trading Y. Li, Y. Shen, L. Yao and E. Newton 32 Chemical fi nishing of textiles W. D. Schindler and P. J. Hauser 33 Clothing appearance and fi t J. Fan, W. Yu and L. Hunter 34 Handbook of fi bre rope technology H. A. McKenna, J. W. S. Hearle and N. O’Hear 35 Structure and mechanics of woven fabrics J. Hu 36 Synthetic fi bres: nylon, polyester, acrylic, polyolefi n Edited by J. E. McIntyre 37 Woollen and worsted woven fabric design E. G. Gilligan 38 Analytical electrochemistry in textiles P. Westbroek, G. Priniotakis and P. Kiekens 39 Bast and other plant fi bres R. R. Franck 40 Chemical testing of textiles Edited by Q. Fan 41 Design and manufacture of textile composites Edited by A. C. Long 42 Effect of mechanical and physical properties on fabric hand Edited by H. M. Behery 43 New millennium fi bres T. Hongu, M. Takigami and G. O. Phillips