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Abstract:
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In the needlepunched segment of the automotive market, textile producers have
recently begun utilizing an additional thermobonding procedure which increases fiber bonding
within the web to enhance the physical characteristics of the fabric such as strength, abrasion
resistance, and dimensional stability. However, not much is known of the effect certain
variables have on these fabric characteristics and what the optimum combination of variables
might be for a given fabric specification. This thesis investigated the interaction of selected
variables in an attempt to optimize the physical characteristics of the nonwoven fabric formed
by the combined needlepunch / thermobond procedure.
To determine the effects of polyethylene binder fiber blend level, needlepunch density
and polypropylene fiber length, thirty-six fabric conditions, which encompassed all variable
combinations, were produced. These fabrics were then subjected to a finisher needling
process held constant for all fabric samples. Following this process the fabrics were
thermobonded in a through-air oven where the polyethylene binder fiber was activated.
Each fabric condition was tested and values for strength, elongation, stiffness,
dimensional stability, and abrasion resistance were recorded. These results were analyzed to
determine which independent variables had a significant effect on resulting fabric
characteristics. Regression equations, relating fabric characteristics to the independent
variables, were then constructed.
The following general results were noted:
1. As the amount of binder fiber in the blend was increased:
Fabric strength increased to a point and then began to decline. Fabric elongation continued to increase.
Fabric stiffness showed a significant increase, until a certain level was reached.
Beyond that point the increase in stiffness was negligible.
Fabric stretch and set characteristics demonstrated a significant improvement as binder
fiber was added, to a point. Beyond that optimum level the change in fabric
behavior was negligible.
Fabric shrinkage was reduced to zero with the addition of binder fiber.
Fiber loss due to abrasion was held to a minimum.
2. As needlepunch density was increased:
Fabric strength increased at higher levels of needlepunch density.
Fabric stretch and set characteristics also displayed improvement at higher levels of
needlepunch density.
3. As polypropylene fiber length was increased:
Fabric strength continued to increase.
Fabric stretch and set characteristics, in general, displayed an improvement.
Based on this study it is recommended that further study be performed to detail the effects
that needlepunching with forked needles has on fabric properties.
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