High performance nonwovens in technical textile applications

摘要

The aim of this research was to establish the optimum processing conditions and parameters for producing nonwoven fabrics best suited for application in disposable and protective wear for surgical gowns, drapes and laboratory coats. Carded and crosslapped webs, of three basic weights (80, 120, and 150g/m2), from greige (unscoured and unbleached) cotton, viscose and polyester fibres, were hydroentangled, using three different waterjet pressures (60, 100 and 120 bars), on a Fleissner Aquajet hydroentanglement machine. An antibacterial agent (Ruco-Coat FC 9005) and a fluorochemical water repellent agent (Ruco Bac-AGP), were applied in one bath using the pad-dry-cure technique, to impart both antibacterial and water repellent properties to the fabrics, SEM photomicrographs indicating that the finished polymers were evenly dispersed on the fabric surface. The effect of waterjet pressure, fabric weight and type and treatment on the structure of the nonwoven produced, was evaluated by measuring the relevant characteristics of the fabrics. As expected, there was an interrelationship between fabric weight, thickness, and density, the fabric thickness and mass density increasing with fabric weight. An increase in waterjet pressure decreased the fabric thickness and increased the fabric density. The water repellent and antibacterial treatment increased the fabric weight and thickness. The antimicrobial activity of the fabrics was assessed by determining the percentage reduction in Staphylococcus aureus and Escherichia coli bacteria population. The maximum percent reduction at 24hrs contact time for both bacteria ranged from 99.5 to 99.6 percent for all the fabric types. The standard spray test ratings for the three treated fabrics ranged from 80-90 percent, whereas that of the untreated water repellent fabric was zero, while the contact angles for all the fabric types exceeded 90 degrees, indicating good resistance to wetting. It was found that the tensile strength of the fabric in the cross-machine direction was higher than that in the machine direction, for both the treated and untreated fabrics, with the tensile strengths in both the MD and CD of the treated fabrics were greater than that of the untreated fabrics, the reverse being true for the extension at break. An increase in waterjet pressure increased the tensile strength but decreased the extension at break, for both the treated and untreated fabrics. The finishing treatment decreased the mean pore size of all the fabrics, the mean pore size decreasing with an increase in fabric weight and waterjet pressure. An increase in waterjet pressure and fabric weight decreased the air and water vapour permeability, as did the finishing treatment, although the differences were not always statistically significant. The polyester fabrics had the highest water and air permeability. Hence low weight fabrics of 80 g/m2, which were hydroentangled at low water jet pressures of 60 bars, were suitable for use in this study due to their higher air and water vapour permeability as well as higher pore size distribution. These group of fabrics thus meet the requirements for surgical gowns, drapes, nurses’ uniforms and laboratory coats.