Paul Sawhney, Chuck Allen, Michael Reynolds, Ryan Slopek and Brian Condon
The aim of this research is to develop greige (raw/non-bleached) cotton-containing nonwoven fabrics that likely would be competitive in quality, cost and performance to existing…
Abstract
The aim of this research is to develop greige (raw/non-bleached) cotton-containing nonwoven fabrics that likely would be competitive in quality, cost and performance to existing products that presently and predominantly use man-made fibers and some bleached cotton for wipes and other similar end-use nonwoven products. Since the whiteness and absorbency of these end-use products generally are the most desired and perhaps even critical attributes, the research was mainly focused on attaining these attributes by exploring various choices and optimum use of a variety of cost-effective cotton fibers and the blends thereof with other fibers. Nonwoven fabrics were produced, via a modern hydroentanglement system, with possible choices of using several types of cotton fibers, including the greige cotton lint and certain of its co-products such as gin motes and comber noils, and their various blends with polyester and nylon staple fibers. Bleached cotton was also used to produce an equivalent fabric for comparison. The research has shown that although the desired and perhaps critical properties of whiteness and absorbency of the selected fibers vary considerably among the various fabrics produced, the blends of greige cotton lint with man-made fibers can provide the fabric whiteness and absorbency comparable to those of say, a, bleached cotton fabric. The research results suggest that the greige cotton lint and/or its co-products in blend with polyester fiber may be sensible approaches to the development of functionally acceptable nonwoven wiping products that are also environment friendly.
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Paul Sawhney, Hiram Allen, Michael Reynolds, Ryan Slopek, Brian Condon, David Hui and Suhad Wojkowski
The aim of this study was to determine the effects of two popular web-forming technologies, viz., the Rando air-laid technology and the traditional carding and cross-laying…
Abstract
The aim of this study was to determine the effects of two popular web-forming technologies, viz., the Rando air-laid technology and the traditional carding and cross-laying technology, on properties of the hydroentangled nonwoven fabrics made therewith. A mill-like fiber processing study was conducted in a commercial-grade pilot plant using a variety of short staple fibers and their blends. The fibers used in the study were greige cotton, bleached cotton, cotton derivatives, and cut-staple polyester. The hydroentangled fabrics produced with the two systems were mainly evaluated for their physical and mechanical properties, absorbency, absorbency capacity, and whiteness. The study has shown that, with the exception of greige cotton linters, the greige cotton lint, greige cotton gin motes, and even greige cotton comber noils, either alone or in blend with the other fibers mentioned, can be mechanically processed into hydroentangled nonwoven fabric structures without any insurmountable difficulties. The drop test and sink time followed each other pretty closely, as the drop test time increased so did the sink times. The "whiteness" of fabric, which is significantly more dependent on the fabric's constituent fiber content than on the fabric's surface-based light reflection, obviously varied considerably. However, the whiteness index within the same fiber types and their blends shows no trend of significant difference between the fabric produced with carded fiber web and the fabric produced with random Rando fiber web. Incidentally, the Rando sample of bleached cotton was not available. Since the nonwoven fabrics of this discussion generally are disposable, the optional use of ‘brighteners’ to improve whiteness of certain whiteness-deficient fabrics may be considered as long as the brighteners do not easily bleed from the fabrics.