Thesis (Ph. D.)--Auburn University, 2008. / Abstract. Vita. Includes bibliographical references (p. 255).

This study is divided in to two main parts. The first part deals with the optimization of process parameters of needle-punched non-woven fabrics for achieving maximum sound absorption by employing a Box-Behnken factorial design. The influence of fibre type, depth of needle penetration and stroke frequency on sound absorption properties were studied. These parameters were varied at three levels during experimental trials. From multiple regression analysis, it was observed that the depth of needle penetration alone was the most dominant factor among the selected parameters, which was followed by the interaction between depth of needle penetration and stroke frequency. Fibre type was the least dominant parameter affecting sound absorption. A maximum sound absorption coefficient of 47% (0.47) was obtained from the selected parameters. The results showed that for a process such as needle-punching, which is influenced by multiple variables, it is important to also study the interactive effects of process parameters for achieving optimum sound absorption. The second part of the study deals with the effect of type of natural fibre (fineness), and the blending ratio (with PET fibres) on the air permeability of the needle-punched non-woven fabrics and then it proceeds to study the effect of the air-gap, type of natural fibre (fineness) and blending ratio (with PET fibres) on sound absorption of needle-punched non-woven fabrics. These parameters are tested individually and their two way interaction (synergy) effect using ANOVA. The air-gap was varied from 0mm to 25mm with 5mm increments, three natural fibre types were used and all were blended with polyester fibres at three blending ratios for each natural fibre type. The Univariate Tests of Significance shows that all three parameters have a significant effect on sound absorption together with two two-way interactions, with the exception of the Blend Ratio × Air Gap two-way interaction which was not significant. It was found that the sound absorption improves with the increase in the air-gap size up to 15mm after which sound absorption decreased slightly with the further increase in the air-gap up to 25mm.

The aim of this research was to establish the optimum processing conditions and parameters for producing nonwoven fabrics best suited for application in disposable and protective wear for surgical gowns, drapes and laboratory coats. Carded and crosslapped webs, of three basic weights (80, 120, and 150g/m2), from greige (unscoured and unbleached) cotton, viscose and polyester fibres, were hydroentangled, using three different waterjet pressures (60, 100 and 120 bars), on a Fleissner Aquajet hydroentanglement machine. An antibacterial agent (Ruco-Coat FC 9005) and a fluorochemical water repellent agent (Ruco Bac-AGP), were applied in one bath using the pad-dry-cure technique, to impart both antibacterial and water repellent properties to the fabrics, SEM photomicrographs indicating that the finished polymers were evenly dispersed on the fabric surface. The effect of waterjet pressure, fabric weight and type and treatment on the structure of the nonwoven produced, was evaluated by measuring the relevant characteristics of the fabrics. As expected, there was an interrelationship between fabric weight, thickness, and density, the fabric thickness and mass density increasing with fabric weight. An increase in waterjet pressure decreased the fabric thickness and increased the fabric density. The water repellent and antibacterial treatment increased the fabric weight and thickness. The antimicrobial activity of the fabrics was assessed by determining the percentage reduction in Staphylococcus aureus and Escherichia coli bacteria population. The maximum percent reduction at 24hrs contact time for both bacteria ranged from 99.5 to 99.6 percent for all the fabric types. The standard spray test ratings for the three treated fabrics ranged from 80-90 percent, whereas that of the untreated water repellent fabric was zero, while the contact angles for all the fabric types exceeded 90 degrees, indicating good resistance to wetting. It was found that the tensile strength of the fabric in the cross-machine direction was higher than that in the machine direction, for both the treated and untreated fabrics, with the tensile strengths in both the MD and CD of the treated fabrics were greater than that of the untreated fabrics, the reverse being true for the extension at break. An increase in waterjet pressure increased the tensile strength but decreased the extension at break, for both the treated and untreated fabrics. The finishing treatment decreased the mean pore size of all the fabrics, the mean pore size decreasing with an increase in fabric weight and waterjet pressure. An increase in waterjet pressure and fabric weight decreased the air and water vapour permeability, as did the finishing treatment, although the differences were not always statistically significant. The polyester fabrics had the highest water and air permeability. Hence low weight fabrics of 80 g/m2, which were hydroentangled at low water jet pressures of 60 bars, were suitable for use in this study due to their higher air and water vapour permeability as well as higher pore size distribution. These group of fabrics thus meet the requirements for surgical gowns, drapes, nurses’ uniforms and laboratory coats.

This research develops and tests a methodology for improving quality on a continuous process line. A nonwovens line was chosen as the experimental environment to test this methodology. First the process variables were analyzed and classified and a screening experiment was run to determine which variables had a significant effect on the quality measures--air permeability, caliper, basis weight, and appearance--of the filter media. Then a second experiment was run to study fewer variables in more detail. The data were interpreted with ANOVA and regression models. This research makes three general contributions: a methodology for improving quality on a continuous process line, the cause-and-effect relationships between some of the independent and dependent variables, and the second-order and third-order effects show the complexity of the research environment. / Master of Science

Thesis (M.S.)--Auburn University, 2007. / Abstract. Vita. Includes bibliographic references (ℓ. 70-74)

The purpose of this investigation was to determine the properties that characterise cotton fibres in the various stages in the CPNF process as well as to determine which fibre characteristics a r e required to entangle the fibres to produce a successful CPNF . The criteria adopted in this work for a successful CPNF include: 1. the tensile strength of the fabrics 2. a well-defined pattern 3. absorbency and wicking The properties selected for investigation were 1. the cotton fibre surface (using SEM and DSC analyses) 2. the degree of degradation of the cotton fibre as a result of the CPNF process (using cellulose fluidity measurements) 3. the non-cellulosic content of the fibre (using IR, DSC, and Chemical analyses) 4. fibre friction 5. absorbency and wicking 6. tensile properties Analysis of the results indicates clearly what the fundamental properties of the cotton fibre must be for a successful cotton CPNF to be manufactured. The conclusions also indicate the necessary properties a man-made fibre must have to produce a successful CPNF.

Thermomechanically bonded spunbond nonwoven fabrics contain discrete bonds that are formed by melted and fused fibers. Through equi-biaxial tensile testing and simultaneous image capture, the mechanical response of individual bonds was studied through loading in the preferential fiber direction, the machine direction, and in the direction that is perpendicular, the cross direction, of the fabric web. Independent biaxial force and displacement data were collected and analyzed, and the maximum force and stiffness of the bonds in the machine and cross directions were found to be statistically different. After scaling the maximum force and stiffness by a relative basis weight parameter, a fiber orientation parameter, and the width of the bond itself, the peak force and stiffness in the machine and cross directions were found to no longer be statistically different. This indicates that basis weight, fiber orientation, and bond size dictate the biaxial mechanical behavior of the bonds. Furthermore, significant fiber debonding was observed in all the bonds tested, effectively suggesting bond disintegration into the individual component fibers during testing. Digital image correlation, using the captured images, was utilized to calculate local and average Eulerian strains of the bond during the initial stages of the test. The strain experienced by the bonds in the machine direction was always positive and increasing as the biaxial load increased. The strain in the cross direction, however, experienced increasing and decreasing strain. Local strain maps revealed the highly inhomogeneous strain response of the bonds under biaxial loading. / Master of Science

The purpose of this research was to investigate and compare the liquid transport properties of cotton nonwoven laminates of varying cotton/polypropylene fiber content (80:20, 60:40, 40:60, by weight) with a 100% polypropylene fabric and a 100% polyethylene fabric. Capillary, pressure and impact penetration mechanisms were investigated as well as other measures of fabric wetting, wicking, and liquid retention. A water/surfactant solution of surface tension close to that of the pesticide solution was used in some tests to determine whether it could be used to simulate liquid transport characteristics of the pesticide solution. The effect of volume on capillary and pressure penetration was also evaluated. Results indicated that the 100% polyethylene fabric offered the greatest resistance to all three penetration methods. The 80:20 cotton:polypropylene fabric, exhibited significantly greater amounts of penetration than the other fabrics in capillary penetration. There was no significant difference in the penetration values of the 100% polypropylene and the cotton laminates in the pressure penetration of the water/surfactant. There were no significant differences in the impact penetration values of the cotton laminates, but the 100% polypropylene exhibited significantly lower amounts of impact penetration than the cotton laminates. Pressure penetration was found to result in the most severe form of penetration. A high degree of correlation was obtained between penetration by the pesticide and penetration by the water/surfactant solution, whose surface tension was close to that of the pesticide solution. A higher retention of the pesticide resulted in lesser amounts of penetration of the pesticide solution. However, in the case of retention of water/surfactant, it was found that even though there were no significant differences in the retention values of the water/surfactant, there were significant differences in the penetration values of the water/surfactant. Surface tension of the solution was found to have an effect on the wetting and wicking responses of the fabrics, which affected the amount of capillary penetration. Increasing volume resulted in an increase in the amount of penetration that took place. / Master of Science