Nanoclay Reinforced Fibers and Nonwovens

In this research, polypropylene fibers and nonwoven samples were produced with the commercial samples of nanoclay additives in semi-commercial processing machinery. Influence of two different types of nanoclay additives, at different add on levels on processing, structure and morphology of nonwovens is studied. The WAXD and DSC data showed some change in crystallinity and melting behavior indicating changes in the fiber morphology towards improved mechanical properties. Presence and extent of exfoliation of nanoclay in the polymer was verified using transmission electron microscopy (TEM). TEM image reveals intercalated and exfoliated morphology of nanocomposites. About 10 to 20 % increase in tensile strength and modulus in both machine and cross directions is observed. This increase in strength is not accompanied by a decrease in breaking elongation as is the case for most of the fibers. Similarly 10 to 25 % increase in web stiffness and 20 to 80 % increase in web burst strength was observed. Furthermore there is improvement in other performance properties of the spunbond nonwovens. SEM images showed improved thermal bonding in the presence of nanoclay additives. The main advantage of this process is that these fabrics can be produced without any need for change in the processing equipment. This study has shown that by using a suitable compounding method, nanoparticle reinforced fibers and fibrous products with improved performance properties can be produced using conventional production machinery.