Single Process Production of 3D Nonwoven Shell Structures: Part 2 — CFD Modeling of Thermal Bonding Process

Gong, R.H.; Dong, Zhe; Porat, I.

doi:10.1177/1558925001os-1000108

Cited by 6 publications

(17 citation statements)

References 1 publication

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“…In previous work, [3,4] a 3D web forming system was developed, as schematically shown in Figure 1. PP/PET (sheath/core) bi-component staple fibres are opened by an opening unit.…”

Section: Model Descriptionmentioning

confidence: 99%

“…Note that in the new vertical system, the CDHG plane is actually horizontal, but it is shown vertical for easy comparison. Compared with previous studies, [3,4] more complicated fluid flow and related mass transfer phenomena are considered in the present study, which involve multiple moulds rather than a single mould. These moulds are finger-shaped and made of metal meshes.…”

Section: Model Descriptionmentioning

confidence: 99%

“…To date, there have been only a few reports on the production of 3D nonwoven structures. [3][4][5] Efforts in the development of 3D shell structure nonwovens have been mainly devoted to the web forming and bonding techniques. Among these, Bankert et al [6] and Miura and Hosokawa [7] used electrophoretic deposition to fabricate 3D nonwoven shell structures.…”

Section: Introductionmentioning

confidence: 99%

“…[3,4] In this process, the fabrics were directly produced from commercially available polypropylene (PP)/polyester (PET) (sheath/core) bi-component staple fibre. Samples of prepared using this process have been proved to be very even and strong.…”

Section: Introductionmentioning

confidence: 99%

“…Consequently, CFD is now the preferred means of testing alternative designs in many engineering research before final experimental testing takes place. [3,4,[20][21][22][23] It completes traditional testing and experimentation, providing added insight and confidence in the designs.…”

Section: Introductionmentioning

confidence: 99%

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Web‐Forming System Design Using CFD Modelling for Complex 3D Nonwoven Shell Structures

Wang¹,

Gong²,

Dong³

et al. 2006

Macro Materials & Eng

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Summary: CFD modelling has been used to study the unique problem of airflow containing fibres around 3D porous media in nonwoven web forming systems. The related gas‐solid two‐phase flows were simulated using a commercial CFD package, FLUENT. Simulation results revealed that the uniformity of air velocities and fibre concentration around the moulds, particularly for complex‐shaped moulds, could be improved significantly by means of employing vertically oriented web forming system and moulds with controlled porosity. Experimental results indicated that the distribution of the area densities of the 3D nonwovens produced using polypropylene/polyester bi‐component fibre followed the same patterns of the airflow and fibre distributions simulated using the CFD model. The CFD model is a valuable tool for optimising the web forming systems and improving the uniformity of the 3D nonwovens.Area density distribution of the 3D products produced using the vertical system.magnified imageArea density distribution of the 3D products produced using the vertical system.

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“…In previous work, [3,4] a 3D web forming system was developed, as schematically shown in Figure 1. PP/PET (sheath/core) bi-component staple fibres are opened by an opening unit.…”

Section: Model Descriptionmentioning

confidence: 99%

Section: Model Descriptionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Web‐Forming System Design Using CFD Modelling for Complex 3D Nonwoven Shell Structures

Wang¹,

Gong²,

Dong³

et al. 2006

Macro Materials & Eng

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Morphology and Structure of Constituent Fibres in Thermally Bonded Nonwovens

Wang¹,

Gong²

2006

Macro Materials & Eng

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Summary: A new process has been developed to produce three‐dimensional nonwovens directly from staple fibres. In order to establish suitable windows of the process parameters to achieve high‐quality nonwoven products, the effects of thermal bonding temperature, dwell time and mould material on the morphology and structure of the fibre have been investigated using PP/PET bi‐component fibres. It was evident from both scanning electron microscope images and Raman spectra that thermal‐induced shrinkage of the PP sheath fibre occurred in the thermal bonding process, leading to deformation and cracking of the PP sheath and exposure of the PET core. X‐ray diffraction results revealed crystal imperfection and/or less ordered polymer chains, more γ‐form and thermal contraction of the crystal lattice for the PP sheath fibre, while birefringence measurements indicated that both the birefringence and the orientation factor for the PP fibre decreased after the thermal bonding process. The degrees of the thermal‐induced shrinkage increased, and the crystallinity, birefringence and orientation factor of the PP sheath fibre decreased with increasing thermal bonding temperature, dwell time and thermal conductivity of the mould material. All these can be attributed to the different levels of modification of chemical composition caused by thermal oxidative degradation and thermal‐induced relaxation of the orientation during the thermal bonding process.Changes of morphology and crystalline features of PP/PET fibre after thermal bonding process.imageChanges of morphology and crystalline features of PP/PET fibre after thermal bonding process.

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Developments in 3D nonwovens

Gong

2015

Advances in 3D Textiles

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Single Process Production of 3D Nonwoven Shell Structures: Part 2 — CFD Modeling of Thermal Bonding Process

Cited by 6 publications

References 1 publication

Web‐Forming System Design Using CFD Modelling for Complex 3D Nonwoven Shell Structures

Web‐Forming System Design Using CFD Modelling for Complex 3D Nonwoven Shell Structures

Morphology and Structure of Constituent Fibres in Thermally Bonded Nonwovens

Developments in 3D nonwovens

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