Blend of Fibres to Improve the Mechanical Properties of Needle-Punched Nonwovens for PM2.5 Air Filtration

Abstract

This research investigated the innovative synthesis achieved through blending five distinct fibres (Polyacrylonitrile (PAN), Polyester (PET), Polylactic acid (PLA), Polypropylene (PP), and Polyphenylene sulfide (PPS)) in the production of needle-punched nonwoven fabrics tailored for air filtration applications. The study investigated the effects of needle-punched nonwovens made with up to five fibres on the physical and mechanical properties, addressing a gap in existing literature. The method involved manual and machine opening, blending, and carding of fibre s, followed by producing three samples with different web arrangements (cross laid web, parallel laid web, and pre needled parallel lad web). The study employed standard test methods to characterize physical and mechanical properties. Results indicated that web arrangement and pre-needling significantly influenced various properties, with cross and parallel-laid web arrangements having minimal impact on thickness and bursting stretch. The parallel arrangement, whether pre-needled or not, showed no significant effect on GSM, fabric density, bursting strength, tear strength, abrasion resistance, and filtration efficiency. The highest abrasion resistance, lower pressure drop, highest fabric stiffness, moderate tensile strength, and higher bursting strength were observed in a cross-web arrangement. This study contributed valuable insights into the intricate interplay of fibre composition, web arrangement, and pre-needling in the design of advanced needle-punched nonwoven fabrics for air filtration. The findings provided a nuanced understanding of how these factors collectively impact the mechanical and physical characteristics of the material, paving the way for enhanced efficiency, durability, and versatility in air filtration applications.

Fibre Blend and Web Arrangement for Optimized Dust-Holding, Hydrophobic, and Thermal Properties of Needle-Punched Nonwovens

“…Sample N2 underwent eight needling processes, whereas the other samples underwent six needling processes. This information has been explained clearly in our previously published paper [1].…”

“…In this study, polyester (PET), polypropylene (PP), polyacrylonitrile (PAN), polylactic acid (PLA), and polyphenylene sulfide (PPS) were not selected randomly; rather, they were deliberately chosen from the numerous fibres utilized in the manufacturing of needlepunched nonwoven fabrics. FTIR analysis of the sample nonwovens, referenced in our previous publication https://doi.org/10.31881/TLR.2024.047 [1], confirmed the presence of all fibres within the sample structure. Hydrophobic and moisture-wicking fibres like PP, PET, and PPS are blended to control the amount of moisture in the nonwoven filter and minimise liquid buildup that can impair filtration efficiency.…”

“…Suzhou Makeit Technology Co. (Suzhou, China) was used as the fibre supplier. Table 1 provides an inventory of fibre specifics [1].…”

“…Studies have shown that blending different fibres into nonwoven fabrics can lead to improved properties [1][2][3][4][5][6]. Additionally, the use of multi-fibre blends in needle-punched nonwoven fabrics demonstrated improved sound absorption properties, indicating their potential for acoustic product manufacturing [7,8].…”