Hybrid mixed media nonwovens composed of macrofibers and microfibers. Part I: three-layer segmented pie configuration

Abstract

Nonwoven fabrics, composed of microdenier fibers, can be easily created by using splittable bicomponents such as segmented pie. Hydroentangling has been shown as a very effective method for mechanically splitting these fibers. Such structures are known to form a densely packed nonwoven fabric with concomitant consequences in low porosity and tear strength. It is not, therefore, uncommon to insert a reinforcing scrim as a "rip-stop" mechanism in the middle of such structures to improve their properties, especially tear resistance. Instead, we propose a hybrid structure where the middle portion consists of solid homocomponent fibers, made from the same polymer as one of the components used in the bicomponent fibers, produced simultaneously during web formation, without causing noticeable changes in the fabrics' overall texture. We report on the production and properties of fabrics composed entirely of bicomponent segmented pie fibers as well as our hybrid fabrics arranged in a three-layer configuration.

Properties of composite nonwovens

“…They concluded that the cube root averaged diameter concept of Tafreshi et al (2009) could be used to design a bimodal fi lter media quite successfully. Jaganathan et al (2008) studied the pressure drop across bi-component fi lter media composed of fi bres showing bimodal diameter distributions. They observed that the area-weighted average of the fi bre diameters in a bimodal fi lter, as proposed by Brown and Thorpe (2001), resulted in a relatively good estimation of an equivalent unimodal fi bre diameter.…”

“…This model was claimed to have good predictive capability. Hollowell et al (2013) investigated the air permeability characteristics of hybrid mixed media nonwovens composed of macro-and micro-fi bres. They developed a series of hybrid mixed media nonwovens by hydroentangling a homo-component spunbond fabric sandwiched between two layers of 16-segmented pie bi-component spunbond fabric.…”

Micro/nano microfiber synthetic leather base with different nanofiber diameters

“…Hollowell et al. [14] combined the biocomponent hollow segmented pie microfiber with homocomponent fiber to form a three-layer structure, which improved the permeability, mechanical properties and porosity of the nonwoven fabric. Zhao et al.…”

The influence of drawing pressure on the properties of PET/PA6 bicomponent spunbonded fibers

“…Previous reports on bicomponent materials were focused on the methods of fibrillation and the mechanical properties [12]. Hollowell et al [13] used hollow pie wedge bicomponent to produce nonwoven fabrics with low porosity and tear strength by hydroentangling. Lu and Qian [14,15] recently investigated the splitting method of bicomponent spunbond fiber and found the hydroentangling was the best.…”