Textiles for industrial applications - GBV · Textiles for IndustrialApplications R. SenthilKumar...
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Textiles for Industrial Applications R. Senthil Kumar Department of Textile Technology Kumaraguru College Of Technology Coimbatore, Tamilnadu, India CRC Press Taylor & Francis Croup Boca Raton London New York CRC Press is an imprint of the Taylor & Francis Croup, an Informs business A CHAPMAN & HALL BOOK
Transcript of Textiles for industrial applications - GBV · Textiles for IndustrialApplications R. SenthilKumar...
Textiles for
IndustrialApplications
R. Senthil KumarDepartment of Textile TechnologyKumaraguru College Of Technology
Coimbatore, Tamilnadu, India
CRC PressTaylor&Francis CroupBoca Raton London NewYork
CRC Press is an imprint of the
Taylor & Francis Croup, an Informs business
A CHAPMAN & HALL BOOK
Contents
Preface xvii
Author xix
1. Introduction 1
1.1 Industrial Textiles: An Overview 1
1.2 Industrial Textiles: Definition and Scope 2
1.2.1 Definition 2
1.2.2 Scope 2
1.2.3 Filtration Textiles 3
1.2.4 Hose, Ropes, and Belts 3
1.2.5 Composites 3
1.2.6 Technical Needled Fabrics 4
1.2.7 Air Bags 4
1.2.8 Other Textile-Based Industrial Products 4
1.3 Industrial Textiles: Market Scenario 5
1.4 Future Trends of Industrial Textiles 6
1.5 Technology and Material Trends 8
Bibliography 9
2. Fiber, Yarn, and Fabric Structures Used in Industrial Textiles 11
2.1 Fibers in Used Industrial Textiles 11
2.1.1 Natural Fibers 11
2.1.2 Synthetic Fibers 12
2.1.2.1 Viscose Rayon 12
2.1.2.2 Polyamide 12
2.1.2.3 Polyester 13
2.1.2.4 Polyolefin Fibers 13
2.1.2.5 High-Performance Fibers 13
2.1.2.6 Specialty Fibers 14
2.2 Yarn Formation 15
2.2.1 Staple Fiber Yarns 16
2.2.2 Filament Production 17
2.2.3 Textured Yarn Production 17
2.2.4 Doubled Yarn Production 18
2.3 Fabric Structures 18
2.3.1 Fabric Formation 18
2.3.1.1 Weaving 18
2.3.1.2 Woven Structures 19
2.3.2 Noncrimp Fabrics 21
2.3.3 Knitted Fabrics 23
vi Contents
2.3.3.1 Weft-Knitted Fabrics 23
2.3.3.2 Warp-Knitted Fabrics 24
2.3.3.3 Warp Knitting versus Weft Knitting 26
2.3.4 Multiaxial Fabrics 26
2.3.5 Braided Fabrics 27
2.3.5.1 Types of Braided Structures 29
2.3.5.2 Conventional 2-D Braided Structures 30
2.3.5.3 Multiaxial Differentially Oriented
Structures 30
2.3.5.4 Biaxial Structures 31
2.3.5.5 Multiaxial Structures 31
2.3.5.6 Multiaxial Structures for Fiber-Reinforced
Plastics 32
2.3.6 Nonwoven Structures 33
2.3.6.1 Web Formation Methods 34
2.3.6.2 Consolidation Processes 35
2.3.7 Membranes 36
2.3.7.1 Industrial Textile Product ManufacturingProcesses 37
Bibliography 38
3. Medical Textiles 39
3.1 Market Scenario—Medical Textiles 39
3.1.1 World Trade of Medical Textiles 40
3.1.2 Global Consumption of Medical Textiles 41
3.1.2.1 Market Size: Hygiene Textiles 41
3.1.2.2 Market Size: Wound Care Products 41
3.1.2.3 Market Size: Surgical Textiles 41
3.1.2.4 Market Size: Nonwovens—Medical and
Hygiene Textiles 41
3.1.3 Economic Aspects: Market Scenario 42
3.1.3.1 European Textile Sector 42
3.1.4 Asia 43
3.2 Textile Structures and Biomaterials in Healthcare 44
3.2.1 Material Selection and Fiber Types 44
3.2.2 Form of Textile Materials 45
3.2.3 Medical Fabric Structures and Properties 47
3.2.3.1 Woven Fabrics 47
3.2.3.2 Knitted Fabrics 48
3.2.3.3 Braided Fabrics 48
3.2.3.4 Nonwoven Fabrics 49
3.2.3.5 Medical Fabric Manufacturing: Trends
and Innovations 50
3.2.4 Medical Products 50
Contents vii
3.2.4.1 Vascular Grafts 50
3.2.4.2 Cardiac Support Device 52
3.2.4.3 Embroidered Implants 52
3.2.5 Implantable Medical Textiles 52
3.2.6 Tissue Engineering 54
3.2.7 Biomedical Textiles 56
3.2.8 Tissue Engineering: Cell Scaffolds 57
3.3 Advanced Wound Dressing: Structure and Properties 58
3.3.1 Advanced Polymers and Textiles 60
3.3.2 Specialty of Textile Fibers 60
3.3.3 Structure and Specific Qualities 61
3.3.4 Drawback of Traditional Medical Dressing 61
3.3.5 Function of Modern Wound Dressing 61
3.3.6 Advanced Wound Dressing Products 62
3.3.7 Absorption Characteristics: Textile Structures 63
3.3.8 Textile Architectures for Tissue Engineering 63
3.3.9 Nanotechnology for Advanced Wound Management 64
3.4 Natural and Biopolymer Finishes for Medical Textiles 66
3.4.1 Wound Healing 66
3.4.2 Wound Dressing Products 67
3.4.3 Alginate 67
3.4.4 Chitin 68
3.4.5 Chitosan 68
3.4.6 Alginate Filaments 69
3.4.7 Branan Ferulate 69
3.4.8 Collagen Materials 69
3.5 Healthcare Products in the Hospital Environment 70
3.5.1 Healthcare Textiles 71
3.5.2 Medical Implants and Devices 71
3.5.2.1 Vascular Grafts 71
3.5.2.2 Heart Valves 72
3.5.2.3 Artificial Tendon (Mesh) 72
3.5.2.4 Artificial Joints 72
3.5.2.5 Artificial Kidney 72
3.5.2.6 Cardiovascular 72
3.5.2.7 General Surgery 73
3.5.2.8 Orthopedics 73
3.5.2.9 Bariatric 73
3.5.2.10 Scaffolds: Tissue Growth 73
3.5.2.11 Cosmetic/Reconstructive Surgery 74
3.5.2.12 Dental Implants 74
3.5.3 Other Applications: Healthcare Textiles 74
3.5.3.1 Pressure-Relieving Mattress 74
3.5.4 Current Research in Healthcare Textiles 77
3.5.5 Textile-Based Medical Products Used in Hospitals 78
viii Contents
3.6 Evaluation and Testing of Medical Textiles 80
3.6.1 Protection of the Patient versus Medical Staff 82
3.6.2 Microbiology Tests for Textiles 83
3.6.3 Special Test Methods and Their Importance 85
3.7 Future Medical Textiles 90
3.7.1 Current Medical Textile Research 90
3.7.2 Nanotechnology in Medical Textiles 91
3.7.3 Antibacterial Textiles 92
3.7.4 Antimicrobial Wound Dressings 92
3.7.5 Antiadhesive Wound Dressings 93
3.7.6 Product Examples 93
3.7.7 Medical Smart Textiles 94
3.7.8 Medical Industry Key Players 94
Bibliography 95
4. Finishing of Industrial Textiles 101
4.1 Introduction 101
4.2 Types of Finishing 102
4.2.1 Mechanical Finishing of Industrial Textiles 102
4.2.1.1 Heat Setting 103
4.2.1.2 Calendering 103
4.2.1.3 Sueding or Emerizing 107
4.2.1.4 Raising or Napping 108
4.2.1.5 Singeing 109
4.2.1.6 Perforating and Slitting 110
4.2.1.7 Sanforizing 110
4.2.1.8 Decatizing Ill
4.2.1.9 High-Pressure Water Jet Softening Ill
4.2.2 Chemical Finishing of Industrial Textiles Ill
4.2.2.1 Flame-Retardant Finishes 113
4.2.2.2 Waterproof and Water-Repellent Finishes 115
4.2.2.3 Oil- and Stain-Repellent Finishes 117
4.2.2.4 Antimicrobial Finishes 119
4.2.2.5 Antistatic Finishes 120
4.2.2.6 Ultraviolet Protection Finish 121
4.2.2.7 Other Finishes 123
4.2.3 Plasma Treatment for Industrial Textiles 123
4.2.3.1 Magnetron Sputtering of Textiles 125
4.2.4 Nanofinishes for Industrial Textiles 126
4.2.5 Coating and Lamination Technologies 129
4.2.5.1 Applications of Coating and Laminating in
Industrial Textiles 129
4.2.5.2 Future Trends 131
Bibliography 132
Contents i*
5. Filtration Textiles 135
5.1 Introduction 135
5.2 Filtration: Market Share 135
5.3 Filtration: Definition 136
5.3.1 Filtration: Terms and Definition 136
5.4 Filtration: Principles of Particle Retention 137
5.4.1 Filtration: Collection Efficiency 140
5.5 Filtration Fundamentals 141
5.5.1 Fluid Flow through Porous Media 142
5.5.2 Particle Settlement 142
5.6 Filtration Types 143
5.6.1 Classification of Filtration 143
5.6.2 Methods of Filtration 145
5.7 Filter Media 145
5.8 Filter Media Design/Selection Criteria 147
5.8.1 Thermal and Chemical Conditions 147
5.8.2 Filtration Requirements 149
5.8.3 Equipment Considerations 151
5.8.4 Cost 152
5.9 Yarn Construction and Properties 152
5.9.1 Monofilament 152
5.9.2 Multifilament 154
5.9.3 Staple Yarns 154
5.9.4 Fibrillated Tape Yarns 154
5.10 Fabric Construction and Properties 155
5.10.1 Woven Fabric Filters 155
5.10.1.1 Properties of Woven Filter Fabric 157
5.10.2 Nonwoven Filtration Media 159
5.10.2.1 Dry-Laid Media 160
5.10.2.2 Wet-Laid Media 160
5.10.2.3 Characteristics of Nonwoven Filter Media 161
5.10.2.4 Factors Influencing the Air Permeabilityof Nonwoven Filter 161
5.11 Finishing Treatments 162
5.11.1 Heat Setting 162
5.11.2 Singeing 162
5.11.3 Calendering 163
5.11.4 Raising or Napping 163
5.11.5 Antistatic Finish 163
5.12 Nanofiltration 163
Bibliography 165
6. Textiles in Hoses 167
6.1 Introduction 167
6.2 Hose: Definition 167
X Contents
6.2.1 Factors Governing Hose Selection 167
6.2.1.1 Pressure 167
6.2.1.2 Temperature 168
6.2.1.3 Fluid Compatibility 168
6.2.1.4 Size 168
6.2.1.5 Environment 168
6.2.1.6 Mechanical Loads 169
6.2.1.7 Abrasion 169
6.2.1.8 Electrical Conductivity 169
6.2.1.9 Hose Length 170
6.3 Hose: Construction 170
6.3.1 Reinforcement and Its Functions 171
6.3.2 Fibers Used in Hose Reinforcement 171
6.3.3 Yarn Structure in Hose Reinforcement 172
6.3.4 Reinforcement Fabric Structures 173
6.3.5 Hose Components Manufacture 173
6.3.5.1 Tube 173
6.3.5.2 Reinforcement: Types 175
6.4 Hose: Manufacturing 178
6.4.1 Nonmandrel Style 178
6.4.2 Flexible Mandrel Style 179
6.4.3 Rigid Mandrel Style 179
6.5 Application of Textile-Reinforced Hoses in Different Sector 179
6.6 Pressure and Bursting Pressure in Hose 180
Bibliography 180
7. Textiles in Transmission and Conveyor Belts 181
7.1 Introduction 181
7.2 Transmission Belts 181
7.2.1 V-Belts 181
7.2.1.1 V-Belt Construction 182
7.2.2 Flat Belts 182
7.2.3 Timing Belts 183
7.2.3.1 Characteristics of Reinforcing Fibers 184
7.3 Conveyor Belts 185
7.3.1 Conveyor Belt: Construction 185
7.3.2 Conveyor Belt: Types 187
7.3.3 Conveyor Belt: Property Requirements 188
7.3.4 Carcass Constructions 191
7.3.4.1 Factors Influencing Carcass Selection 192
7.3.5 Belt Covers 192
7.3.6 PVC Impregnation 192
7.3.7 Conveyer Belts: Applications 194
7.3.8 Specialty Conveyor Belts 195
Bibliography 196
Contents xi
8. Textiles in Ropes 197
8.1 Introduction 197
8.2 Ropes: Definition and Types 197
8.3 Fibers Used in Rope Construction 198
8.4 Rope Construction 200
8.4.1 Twisted Ropes 200
8.4.2 Braided Ropes 201
8.4.2.1 Solid Braid Ropes 202
8.4.2.2 Diamond Braid 202
8.4.2.3 Double Braid 203
8.4.2.4 Kernmantle Ropes 204
8.5 Properties of Rope 204
8.5.1 Rope Size 204
8.5.2 Rope Strength 205
8.5.3 Rope Elongation 207
8.5.4 Energy Absorption 207
8.5.5 Rope Recovery from Stretch 208
8.5.6 Creep 208
8.5.7 Fatigue and Flexing Endurance 209
8.5.8 Abrasion Resistance and Friction 209
8.5.9 Environmental Protection 210
8.5.10 Shrinkage, Spliceability, and Knot Retention 210
8.6 Production of Rope 210
8.6.1 Production Routes of Modern Ropes 211
8.6.1.1 Yarn Manufacture 211
8.6.1.2 Strand Manufacture 212
Bibliography 214
9. Textiles in Civil Engineering 217
9.1 Introduction 217
9.2 Geotextiles 217
9.2.1 Classification of Geotextiles Based on Manufacture 218
9.2.2 Functions of Geotextiles 222
9.2.2.1 Separation 222
9.2.2.2 Filtration 224
9.2.2.3 Drainage 225
9.2.2.4 Moisture and Liquid Barrier 225
9.2.2.5 Erosion Control 227
9.2.2.6 Reinforcement 228
9.2.2.7 Survivability of Geotextiles 229
9.2.3 Design of Geotextiles 229
9.2.4 Properties of Geotextiles 230
9.2.4.1 Physical Properties 231
9.2.4.2 Mechanical Properties 231
9.2.4.3 Hydraulic Properties 233
Contents
9.2.4.4 Endurance, Degradation, and SurvivabilityProperties 234
9.2.4.5 Durability 235
9.2.5 Raw Materials of Geotextiles 235
9.2.6 Applications of Geotextiles 236
9.2.7 Limited-Life Geotextiles 237
9.3 Textile-Reinforced Concrete 237
9.4 Textiles in Architecture 239
9.5 Nanotextiles in Civil Engineering Applications 242
Bibliography 242
10. Textiles in Automobiles 245
10.1 Introduction 245
10.2 Automobile Industry: Global Scenario 245
10.2.1 Automotive Textiles: Market Scenario 246
10.3 Major Components of Automotive Textiles 248
10.3.1 Seat Belts 248
10.3.1.1 Seat Belts: Market Scenario 248
10.3.1.2 Seat Belts: A Lifesaving Guard 248
10.3.1.3 Seat Belts: Classification 248
10.3.1.4 Seat Belts: Dynamics 248
10.3.1.5 Seat Belts: Critical Characteristics 252
10.3.1.6 Seat Belts: Fibers and Fabric Structure 252
10.3.1.7 Seat Belts: Manufacturing Method 253
10.3.1.8 Seat Belts: Finishing 253
10.3.1.9 Seat Belts: Quality Requirements 253
10.3.1.10 Performance Tests and Standards for Seat
Belt Webbing 254
10.3.1.11 Seat Belts: Various Defects 254
10.3.1.12 Inflatable Belts 254
10.3.2 Air Bags 255
10.3.2.1 Air Bag: Market Scenario 256
10.3.2.2 Air Bag: Principle of Operation 256
10.3.2.3 Laws of Motion 256
10.3.2.4 Air Bag Inflation 258
10.3.2.5 Types of Air Bags 259
10.3.2.6 Raw Materials (Fibers) for Air Bags 260
10.3.2.7 Manufacturing of Air Bag Fabrics 262
10.3.3 Automotive Filters 262
10.3.3.1 Materials and Functions of Filters 262
10.3.3.2 Air Filters 263
10.3.3.3 Oil Filters 265
10.3.3.4 Fuel Filters 267
10.3.3.5 Cabin Filters 270
10.3.4 Tire Cords 271
Contents xiii
10.3.4.1 Functions of Tires 272
10.3.4.2 Tire: Parts 272
10.3.4.3 Reinforcement Materials 275
10.3.4.4 Tire Cords 277
10.3.4.5 Weaving of Tire Fabrics 278
10.3.4.6 Heat Treatment 279
10.3.5 Automotive Interiors 280
10.3.5.1 Automotive Seats 280
10.3.5.2 Door Trims, Roof Trims, and Floor
Coverings 284
10.3.6 Other Textile Applications in Automobiles 284
10.4 Nonwovens in Automotive Applications 28610.4.1 Nonwovens Used in Cars 286
10.5 Natural/Biodegradable Fibers in Automotive Textiles 287
10.6 Nanotechnology in Automotive Textiles 288
10.6.1 Applications of Nanotechnologyin Automotive Textiles 289
10.6.2 Future Scope of Nanotechnologyin Automotive Textiles 289
Bibliography 290
11. Miscellaneous Applications in Industrial Textiles 293
11.1 Bolting Cloth 293
11.2 Membrane Fabric 29311.3 Filter System 295
11.4 Tissue Engineering 296
11.5 Acoustic Uses 29611.6 Decatizing Cloth 298
11.7 Printed Circuit Board 298
11.8 Screen for Electronic Printing 29811.9 Battery and Fuel Cell 300
11.10 Smart Woven Fabrics: Renewable Energy 300
11.11 Composites 30111.12 Battery Separators 30211.13 Cigarette Filter 306
11.14 Coated Abrasives 30611.15 Nonwoven Abrasives 309
Bibliography 310
12. Testing of Industrial Textiles 311
12.1 Testing of Filter Fabrics 311
12.1.1 Testing of Filter Media 312
12.1.2 Testing Filtration Characteristics 312
12.1.2.1 Permeability 312
12.1.3 Testing of Mechanical Properties 316
xiv Contents
12.1.3.1 Strength 316
12.1.3.2 Resistance to Abrasion 317
12.1.3.3 Thickness, Compressibility, and Resilience 317
12.1.3.4 Membranes 317
12.2 Testing of Hoses 320
12.2.1 Hydrostatic Pressure Tests 320
12.2.1.1 Destructive Tests 320
12.2.1.2 Nondestructive Tests 320
12.2.2 Design Considerations 322
12.3 Testing of Transmission Belt 322
12.4 Testing of Conveyor Belts 323
12.4.1 Aramid Conveyor Belts 325
12.4.2 DIN (German) 325
12.4.3 ISO (World) 326
12.5 Testing of Ropes 328
12.6 Testing of Composites 330
12.6.1 Types of Loading 331
12.6.1.1 Tensile 331
12.6.1.2 Compression 331
12.6.1.3 Shear 331
12.6.1.4 Flexure 332
12.6.2 Destructive Testing 332
12.6.2.1 Tensile Testing 332
12.6.2.2 Compression Test 334
12.6.2.3 In-Plane and Interlaminar Shear Properties 336
12.6.2.4 Interlaminar Fracture 339
12.6.2.5 Moisture Diffusivity and Moisture
Equilibrium 342
12.6.2.6 Fiber Volume Fraction 343
12.6.2.7 Void Content of Composites 343
12.6.2.8 High-Speed Puncture Multiaxial Impact 344
12.6.2.9 Accelerated Weathering Testing 344
12.7 Nondestructive Testing of Composites 345
Bibliography 345
13. Textile Composites 347
13.1 Introduction to Composites 347
13.2 Composite Materials: Global Scenario 347
13.3 Composite Materials: Definition and Classification 348
13.3.1 Classification of Composites Based on Matrix 348
13.3.1.1 Metal Matrix Composites 348
13.3.1.2 Ceramic Matrix Composites 348
13.3.1.3 Polymer Matrix Composites 349
13.3.2 Classification of Composites Based on
Reinforcement Forms 349
Contents xv
13.3.2.1 Fiber-Reinforced Composites 349
13.3.2.2 Whisker-Reinforced Composites 350
13.3.2.3 Laminar Composites 350
13.3.2.4 Flake Composites 351
13.3.2.5 Filled Composites 351
13.3.2.6 Particulate Composites 351
13.4 Reinforcement: Fibers 351
13.4.1 Reinforcement: Fiber Forms 352
13.4.1.1 Discontinuous Fibers 352
13.4.1.2 Roving and Tow 35313.4.1.3 Mats 354
13.4.1.4 Woven Fabrics 354
13.4.1.5 Hybrid Fabrics 359
13.4.1.6 Noncrimp Fabrics 359
13.4.1.7 Knitted Fabrics 359
13.4.1.8 Multiaxial Fabrics 360
13.4.1.9 Braided Fabrics 360
13.5 Polymer Matrices or Resins 362
13.5.1 Thermoplastic Matrices 362
13.5.2 Thermosetting Resins 363
13.6 Prepregs and Preforms 363
13.6.1 Prepregs 363
13.6.2 Preforms 364
13.7 Composite Manufacturing Technologies 364
13.7.1 Open Mold Process 365
13.7.1.1 Hand Laminating or Hand Layupor Wet Layup 365
13.7.1.2 Spray Layup 365
13.7.1.3 Filament Winding 36513.7.2 Closed Mold Process 366
13.7.2.1 Compression Molding 366
13.7.2.2 Resin Transfer Molding 367
13.7.3 Continuous Mold Process 367
13.7.3.1 Pultrusion 367
13.8 Applications 367
Bibliography 369
Index 371
