Uniformity Comparison of Selected Spunbond Fabrics
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1 Uniformity Comparison of Selected Spunbond Fabrics AFS 2017 Spring Conference April 12, 2017
2 Purpose of Study Compare uniformity of flat spunbond nylon fabric to flat spunbond polyester fabric Optically Using previously presented Avintiv Uniformity Indices Using transmitted light data Discuss advantages of more uniform fabric
3 Optical Comparison (20 gsm spunbond fabrics) Polyester Nylon Sample size is 17 cm by 15 cm
4 Optical Comparison (34 gsm spunbond fabrics) Nylon Polyester Subjectively, most people agree that the optical uniformity of nylon is better than polyester Sample size is 17 cm by 15 cm
5 Avintiv Uniformity Indices M2 = (s basis weight + s thickness ) * 100 M3 = (s basis weight + s thickness + s air permeability ) * 100 More uniform fabrics have a Lower index These indices were developed by Avintiv to compare materials Reference: Impact of Substrates on Nanofiber Formation Betty J. Wells; AFS 2015 Fall Conference October 7, 2015
6 Sampling Plan and Test Methods Commercially available polyester spunbond fabrics were purchased at a minimum width of 64 inches Basis weights between 20 and 51 gsm 10 samples taken in the machine direction Cross directional samples taken every 30 cm ASTM Test Methods Basis Weight Thickness Air Perm D3776 D1777 D737
7 Basis Weight Standard Deviation (gsm) Basis Weight Variability Standard Deviation of Basis Weight Measurements for Nylon and Polyester Spunbond Fabrics Basis Wt Std dev (gsm) 4 dpf Nylon Basis Wt Std dev (gsm) 4 dpf PET Basis Wt Std dev (gsm) 2 dpf Polyester Basis Weight (gsm) Mass distribution of 4 dpf nylon spunbond fabrics is less variable than 2 or 4 dpf polyester fabrics
8 Thickness Standard Deviation (mils) Thickness Variability 1.3 Standard Deviation of Thickness Measurements for Nylon and Polyester Spunbond Fabrics Thickness Std dev (mils) 4 dpf Nylon Thickness Std dev (mils) 4 dpf Polyester Thickness Std dev (mils) 2 dpf Polyester Basis Weight (gsm) Thickness variability of nylon fabrics is considerably less than polyester fabrics
9 M2 Index M2 Uniformity Index (s basis weight + s thickness ) * dpf Nylon 4 dpf Polyester dpf Polyester Basis Weight (gsm) M2 uniformity index of nylon spunbond is much lower than polyester spunbond indicating the nylon has a more uniform filament distribution
10 Air Permeability Standard Deviation (ft 3 /min/ft 2 ) Air Permeability Variability 300 Standard Deviation of Air Permeability Measurements for Nylon and Polyester Spunbonds Air Perm Std dev 4 dpf Nylon Air Perm Std dev 4 dpf Polyester Air Perm Std dev 2 dpf Polyester Basis weight (gsm) Air permeability variability of nylon fabrics is less variable than polyester fabrics
11 M3 Index M3 Uniformity Index (s basis weight + s thickness + s air permeability ) * dpf Nylon 4 dpf Polyester 2 dpf Polyester Basis Weight (gsm) Nylon spunbond s M3 index is less than half that of polyester spunbond fabric confirming nylon has a much more uniform filament structure
12 On-Line Camera Inspection system On-line camera system provides grey scale output of transmitted light showing thick and thin spots on fabrics
13 Frequency Optical Representation of Fabrics Histogram of transmitted light intensity for 20 gsm spunbond fabrics Nylon Std Dev: 5.8 Variance: Polyester Std Dev: 9.5 Variance: Transmitted light Intensity Variance (σ 2 ) of transmitted light intensity for 20 gsm nylon spunbond is 63% lower than for polyester spunbond.
14 Frequency Optical Representation of Fabrics 120 Histogram of transmitted light intensity for 34 gsm spunbond fabrics Nylon Std Dev: 8.4 Variance: Polyester Std Dev: 12.1 Variance: Intensity Variance of transmitted light intensity for 34 gsm nylon spunbond is less than half that of polyester
15 Summary Nylon Compared to Polyester Visually more consistent Nylon Polyester Lower variability of physical properties Avintiv M2 and M3 indices are better Lower variability of transmitted light
16 Case Study Nanofiber Application Similar Process Conditions TSI lpm (0.3 μ particle) Efficiency 34 gsm Cerex 46 gsm Polyester Average Std Dev Variance When nanofibers are applied to a lighter weight nylon substrate, the variance of efficiency measurements is 75% lower than that of the same media substituting a heavier weight PET substrate
17 FAILURE MINIMUM EFFICIENCY SPEC Benefits of using nylon substrate to form nanofibers Nanofiber media made with 34 gsm nylon and 46 gsm polyester with different efficiencies Nylon Substrate STD DEV= Polyester Substrate STD DEV= Efficiency (%) Nylon s higher uniformity allows the use of a lighter substrate to achieve the same minimum design performance
18 Potential benefits for filtration applications Improved uniformity in nylon. Increases consistency in filter media performance in nanofiber, meltblown and membrane casting production Minimizes downstream fiber migration, contaminate shedding and channeling in dynamic flow applications Combined with nylon s greater strength, temperature and chemical resistance enables high performance advanced media designs Provides more consistent protection against burst failures during system pulsations and better media protection during pleating
19 Please visit our booth display or contact us for additional information about CEREX Advanced Fabrics high quality spunbond Nylon products. Albert E. Ortega Director of Technology Cerex Advanced Fabrics, Inc.
20 Related Work Previously Presented at AFS Conferences The Advantages of Nylon Nonwovens in Filtration ; Ortega, Carter; AFS 2013 Spring Conference; May 8, 2013 Using Nylon 6,6 Spunbond Fabric to Prevent Catastrophic Filter Media Failure Caused by Ethylene Glycol Contamination ; Ortega, Carter; AFS 2015 Fall Conference: October 7, 2015 Longer Life Nylon Spunbond Fabric For Filtration Media ; Forcucci; AFS 2016 Fall Conference; October 25, 2016
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