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Web Lay System

The document discusses different methods for laying webs of fibers to form nonwoven materials. There are dry and wet laying technologies. Dry laying includes parallel laying, cross laying (horizontal and vertical/camel back laying), vertical laying, and air/electrostatic laying. Parallel laying involves placing carded webs on top of each other to orient fibers in the machine direction. Cross laying deposits fibers at right angles to achieve strength in both directions. Wet laying is similar to papermaking and uses water to deposit randomly arranged fibers. The chosen laying method impacts fiber orientation and resulting material properties.

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322 views19 pages

Web Lay System

The document discusses different methods for laying webs of fibers to form nonwoven materials. There are dry and wet laying technologies. Dry laying includes parallel laying, cross laying (horizontal and vertical/camel back laying), vertical laying, and air/electrostatic laying. Parallel laying involves placing carded webs on top of each other to orient fibers in the machine direction. Cross laying deposits fibers at right angles to achieve strength in both directions. Wet laying is similar to papermaking and uses water to deposit randomly arranged fibers. The chosen laying method impacts fiber orientation and resulting material properties.

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WEB LAYING SYSTEMS in NONWOVENS

(From card web/ opened fiber to web lay/Batt)

DEVARAJA.H.M
9513870937
E-mail: devutex@gmail.com
OBJECTIVES OF WEB LAYING SYSTEM
• After, the web is formed from openers, carding, web is laid
for orientation of fibres in different direction.

Different web laying systems are used to achieve the


following
• To align/ arrange/ orient the fibers of the web for the
required direction.
• To get the required Mass per unit area(GSM)
• To achieve required permeability
• To achieve the required strength in different directions
• To increase the web width
• To get the consistent Uniformity & quality
• To decide for the suitable end use
MACHINE DIRECTION (MD) & TRANSVERSE DIRECTION(TD)
• The Machine direction (MD) is the direction that the
film moves through the machine from start to finish.
• The Transverse direction (TD) is
the direction perpendicular to the machine direction. It
is usually the same as the width of the film
DIFFERENT METHODS OF WEB LAYING
DRY LAYING TECHNOLOGIES
(Mostly for staple fibers of natural or synthetic)
 Parallel laying
 Cross laying
Horizontal laying &
Vertical (Camel Back) laying
 Vertical laying
 Air/ Aerodynamic laying
 Electro static web laying

WET LAYING TECHNOLOGIES (Mostly for staple fibers)


 Wet laying(Similar to paper technology)

LAYING OF FILAMENTS FROM EXTRUSION


 Spun bond laying
 Melt blow laying
1. PARALLEL LAYING
• Several carding machines are placed one behind
another in a long line
• The webs from the cards are allowed to fall on one
on the other on a conveyor.
• The process of each web formation card is adjusted
to achieve the mass per unit area(GSM)
• This system is used extensively for adhesive bonded
non woven for cleaning wipes
PARALLEL LAYING…..
• Fibers in the parallel laid web structures were
parallel to the machine direction which caused
fiber uniformity in terms of fiber orientation in the
fabric.
• For this reason, the tensile strength in the
machine direction (MD) was high and the
elongation at break is low. On the contrary, in the
fabric width direction (CD), the breaking strength
was low and the elongation at break was high.
Other tests, water absorption and air permeability
results were also low due to parallel orientation of
the fibers in the web structure.
2. CROSS LAYING METHODS
• The cross laying, the web deposited on an inclined lattice or
conveyor aprons as it leaves the card and subsequently laid in
cross wise manner on a wider lattice which is moving in a
direction at right angle to the original directional of laying.
• The area of weight of the resulting layer depends on the feeding
velocity and area weight of carded web on the width of layer
and on the velocity of the output belt. These are two types:
The functions of cross-lay process are as follows:
 To obtain batt with higher basis weight than that of card web
 To obtain batt with higher width than that of card web
 To obtain batt with fibres oriented along the transverse
direction
Two methods of cross laying are
• 1. Horizontal laying
• 2. Vertical laying or Camel back lay.
2 A. CROSS LAYING (HORIZONTAL)

.
2 B. CROSS LAYING(VERTICAL / CAMEL BACK)
The camel back laying is shown below. In camel back laying, a
conveyor transports the emerging web from a card, upwards to a pivot
point from which the conveyor system reciprocates to layer the web
onto a cross conveyor. Such systems utilized simple harmonic motion
to reciprocate the web layering conveyor and as such, produced heavy
edges at the end of each traverse due to overfeed of the web as the
mechanism decelerated and then accelerated at the sides. Here, the
laying width can be changed and it depends on machine height and
the machine throughput is constant.
CROSS LAYING……
• As the fibers in the cross-direction direction were
placed more homogeneously in the fabric than that
in the parallel, the tensile strength in the machine
direction (MD) was low and the elongation at break
was high.
• In the fabric width direction (CD), the breaking
strength was high and elongation at break was low.
Air permeability and water absorption rates of the
cross layed fabrics were high compared to the
cross/parallel layed fabrics
PERPENDICULAR (RECIPROCATING LAPPER)LAYING
. The perpendicular-lay process is considered as a special laying
process to obtain significant z-directional orientation of fibres in the
batt. The resulting batt, often thermally bonded, offers excellent
compression-recovery properties that make them suitable for
automobile seat squab and sound insulation applications. The
perpendicular-laid batt can be obtained by reciprocating lapper (Struto
technology) or rotary lapper (Wave maker technology).
PERPENDICULAR (WAVE MAKER) LAYING
The wave maker technology is shown below. Here, a rotary lapping
device is used to continuously consolidate the carded web into a
vertically folded batt which is bonded by for through-air bonding. It has
relatively high rate of production. The resulting structure of the batt is
displayed in Figure.
VERTICAL LAYING(WAVE MAKER)

.
BENEFITS AND LIMITATIONS OF AIR-LAY PROCESS
The benefits of air-lay process are It delivers
webs with high isotropy, high loft (if required),
and high porosity. It can utilize short
fibres which are not possible to be processed by
using carding technology.
The limitations of air-lay process are The
fibres configuration in the air-aid web is
relatively poor. The basis weight uniformity of
the produced webs is in generally poor.
.
.
WET LAYING PROCESS
• The wet laid web forming technique is similar to paper making
technique.
• In paper making uses pulp, but in wet laid uses long fibers perhaps
with wood pulp.
• If more than 70% of the wood pulp, then that is paper.
• 5-10% non woven are produced by this method.
• The fibers are dispersed in water & then laid on wire mesh to filter
the liquid from the web.
• Web is transferred to drying felt and cure
• This method produces web in which the fibers are super imposed
and randomly arranged.
• Techniques are used for short fibers and large scale production of a
particular quality.
• The production cost is low.
• Fabrics are limited durability.
• Wide ranges of natural, mineral, synthetic and fibers are used
• These fabrics are used for Disposable end products include
handkerchiefs, napkins, aprons, gloves, tea bags, & surgical
gauges.
DISTINGUISH OF PL, CL, AL

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