Development of Disc Shaped Fiberwebs with Circumferential Fiber Orientation
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Date
2007-04-20
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Abstract
Current fiberweb forming systems such as carding, air-lay, wet-lay, and carding and cross-lapping do not provide positive control over the fiber orientation. In these systems, several trials with different process parameters are conducted until fiber orientation with close values to the desired level is achieved.
The main purpose of this research is to develop a new device for the formation of disc shaped fiberwebs with desired fiber orientation using an electrostatic field. To achieve the goal of the research, a new device was designed and built. The device consists of fiber dispensing system, turning disc with speed controller (which was used as a fiber collection surface), high voltage supply for creation of an electrostatic field, fiber lay-down mechanism, and two electrodes. Full description of the device and its components are provided. Additionally, a set of experimental trials with full factorial statistical design was conducted to study the influence of electrostatic potential, distance between the two electrodes, fiber collecting disc rotational speed, and the diameter of fiber lay-down rod and their interactions on the percent number of fiber in the circumferential direction, which was chosen to demonstrate the control of fiber orientation as a target direction. Image analysis was used to measure the fiber orientation distribution. The orientation distribution data was measured in number of fibers as well as percentage for individual ranges of ten degree intervals over 90'a.
Experimentation with the new device showed that the fiber alignment in circumferential direction (other directions are possible) is achievable with the correct levels of the independent parameters (field potential, distance between the two electrodes, disc rotational speed, and the rod diameter). Moreover, statistical analysis of the data revealed that there is significant influence of the main effects and their first order interactions (distance * disc speed and potential * disc speed) on circumferential fiber orientation.
While the device is believed to be capable of handling any type of fibers, trials with carbon fibers were not successful due to matting and cling of these fibers. Additional refinements are required to allow handling of fine fibers and form fiberwebs with high thickness a matter that make the device more acceptable commercially. Proposed solutions to such problems are provided.
Possible applications of disc shaped fiberwebs with controlled fiber orientation are seen in the industrial fields of carbon fiber reinforced brake discs for planes and passenger cars as well as grinding, cutting and sanding pads. An introductory market review for the use of the developed technology as carbon fiber brake discs was undertaken in order to evaluate the economic value of the presented innovation. From the market review study, it can be concluded that the innovation may be successfully marketable if technical problems can be solved, which is the primarily task for future research. While the technology promises great value for the textile industry, additional financial and cost effectiveness concepts need to be provided in order to evaluate the competitiveness of the technology compared to existing products.
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Keywords
nonwoven, FOD, electrostatic, circumferential, fiber orientation distribution, brake disc market study
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Degree
MS
Discipline
Textile Technology Management
