chapter 7

Question 1

what is a Nonwoven Fabrics

Answer 1

-Textile materials bonded
together by entangling fiber or filaments
mechanically, thermally or chemically.

-made by weaving or knitting and
do not require converting the fibers to yarn.

Question 2

DISPOSABLE

Answer 2

-Is a good one for one use
-not expensive
-mainly used for cleaning products
- The major fiber used for disposable
nonwovens is rayon.

Question 3

DURABLE

Answer 3

-not intended to be
thrown away after a single use.

-Durable nonwovens are often used as a small but
important component of a total garment or
industrial application.

• Durable nonwovens are used for apparel
  interlining, carpet and upholstery fabrics
  (padding and backing), automotive headliners
  and upholstery, insulation, roofing products,

Question 4

3 Methods of Manufacturing

Nonwovens

Answer 4

• Dry laid system
• Wet laid system
• Polymer laid

Question 5

Dry laid system

Answer 5

The material structure is formed by manipulating the fibers while in a dry state. This is the most used system worldwide.

Question 6

Wet laid system

Answer 6

The material structure is formed by having the fibers manipulated while in a wet state. (similar to paper making)

Question 7

Polymer laid

Answer 7

The material structure is formed by blowing thermoplastic fibers onto a collection surface as the fibers are being extruded.

Question 8

Needle-punched nonwovens

Answer 8

This material is produced by passing a fibrous (dry-laid) web into a needle punch machine equipped with groups of specially designed needles.

Question 9

Bonded-Web Nonwovens

Answer 9

-Bonded webs can be made with any staple
fiber and are produced by forming a web of
fibers (web can be formed by carding
machine), air blowing fibers (dry-laid) or with
liquid (wet-laid).

- Fibers are bonded with an adhesive or with
heat fusion (if the fibers are thermoplastic).

Question 10

End Uses of Bonded-Web

Nonwovens

Answer 10

-Bonded-web nonwovens can be unidirectional,
cross laid, or random web.

• Bonded nonwovens are used in disposable items
  such as:
• Hospital protective gowns, disposable bed
  sheets, towels, tablecloths, cooks hats.
• Brand names include Vileda®, Webril®,
  Hydraspun

Question 11

Spunlaced Nonwovens

Answer 11

• formed by the entanglement of staple fibers, using needlelike, high pressure water jets on the web
  (wet-laid).
• The fibers knot or curl around each other,
  causing mechanical binding. No binders are
  used.
• End uses include medical robes, mattress pads,
  backing of quilted tablecloths and sanitary
  products.
• Brand names include Sontara® by Dupont.

Question 12

Spunbonded Nonwovens

Answer 12

-Spunbonded nonwovens are made immediately
after fibers are extruded from spinnerets.
(polymer laid)

• They consist of randomly oriented filament
  fibers laid down on a fast moving conveyer
  belt, consolidated by thermal bonding,
  mechanical entanglement, adhesive bonding or
  etched filament surfaces to interlock the
  fibers.
• Since the fabric production is combined with
  fiber production, the process is generally more
  economical than when using staple fiber to
  make nonwoven fabrics.

Question 13

End uses of Spunbonded Nonwovens

Answer 13

-carpet backing, geotextiles, clothing
interliners, shoelinings, envelopes (Tyvek®), disposable
medical products.

• This method produces the second largest amount of
  nonwovens.

Question 14

Melt-Blown Nonwovens

Answer 14

-made by extruding the polymer through a single-extrusion orifice into a high-velocity, heated-air stream that
reduces the filaments to microdenier size and breaks the filaments into staple fibers.

-The fibers are propelled onto a collection
surface and are held together by a
combination of fiber interlacing and thermal
bonding.

-The fiberweb strength is low and abrasion
resistance is low.

Question 15

Melt-Blown Nonwovens end-use

Answer 15

insulation (Thinsulate®),

hospital/medical products,battery separators.

Question 16

Fusible Nonwovens

Answer 16

• made from either thermoplastic fibers (thin spiderweb like fabric of thermoplastic filaments) or thermoplastic films.
• Fusible nonwovens are used primarily as
  interling for clothing and have 2 major
  functions:

1. Provide shape to cut parts of garments and
2. To hold garments parts like a skirt hem or
   shirt facing together.

Question 17

Bonded Materials

Answer 17

-made from 2 fabrics that have been adhered together. (swatch#68)

• Bonded fabrics are made from lightweight
  face fabrics that alone are unsuitable as
  apparel fabric. When bonded to a tricot
  backing, they become more stable, and heavier
  and become more suitable for an end use.
• tricot backing is low cost and bonding is fast and economical, bonded fabrics provide the consumer with relatively low cost fabrics that have the appearance and hand of higher cost materials.

Question 18

2 methods of producing bonded fabrics

Answer 18

1. Wet–adhesive process: adhesives are applied
   to the fabric and the fabric is passed between
   hot rollers to activate and set the adhesive.
   (fig. 7.4 pg. 165).
2. Foam-flame bonding: uses an extremely thin
   layer of polyurethane foam that is heated to
   make it tacky and adhesive. The tacky foam is
   then sandwiched between the face and back
   fabric. The foam is heated over gas jets. The
   foam is melted and practically disappears, a
   thin layer of about 1/100 inch remains
   between the face and back and gives body to
   the cloth.

Question 19

Foam-Laminated Fabrics

Answer 19

• Similar to foam-flame bonded materials,
  except a thicker layer of foam is used. The
  foam remains as a laminate when the process
  is completed. Foam laminate size ranges from
  1/8 to 3/16 inch.

-primarily used for clothing insulation. They are lightweight and their cellular structure entraps dead air

• End Uses for foam-laminates include winter
  coats and sportswear.

Question 20

FELT

Answer 20

• Felt is an excellent shock-absorbing and
  sound-absorbing material.
• It has poor drapability, low tensile strength,
  does not return to shape if stretched and a
  propensity to form holes and tears that cannot
  be mended.
• Felt should not really be considered a
  nonwoven fabric as it is the interlocking of the
  fiber surface serrations that holds the fibers
  together, not adhesive, fusion or mechanical
  binding.

Question 21

Mali Fabrics

Answer 21

• Mali (also known as stitch bonding) is a
  technique for producing and reinforcing other
  fabrics.
• Mali fabrics are constructed by a system in
  which needles and threads are used to sew or
  stitch yarns or fibers together.
• Mali fabrics are used mostly in industrial
  fabrics, carpets and upholstery.

Question 22

Lace Fabrics

Answer 22

• 2 other fabrics marketed as lace but not made
  on lace- making machine:
• Raschel lace: a knitted lace made on a Raschel
  knitting machine. Most widely used lace
  material, can be inexpensive or high price
  couture material.
• Schiffli lace: made by the Schiffli machine
  and uses an embroidery technique.

Question 23

Embroidery

Answer 23

• The designs are produced with needles and
  thread, using one or many colours to produce
  raised designs on the fabric.
• Most machine-made embroidery sold in the
  U.S. is made on the Schiffli machine and the
  embroidery is called Schiffli embroidery.

Question 24

Schiffli Embroidery

Answer 24

- Schiffli embroidery is often done on
lightweight fabrics (batiste and lawn) for
delicate embroidery. It can also embroider
heavier fabrics.

• When Schiffli embroidery is done on net
  fabrics, the fabric is called Schiffli lace.

Question 25

Net Fabrics

Answer 25

-Nets are created by looping and knotting a continuous strand of yarn into an open mesh. - Most netted fabrics are made with either a square or diamond-shaped mesh. The decoration of the net can be increased by embroidering designs on the open mesh. - Machine-made nets are manufactured on a bobbinet lace machine. Raschel knitting machines also produce fabrics similar in appearance but with different structures.

Question 26

Tufted Fabrics

Answer 26

- Tufted fabrics are a type of pile fabric but they are not woven or knitted. - Tufting is the process of punching a first component, loops of yarn, through a second component, a woven or nonwoven backing material. - Hand tufting is used in “hooking” rugs.