Impact of needle penetration depth, needle type and fibre linear density on properties of needle-punched viscose nonwovens: a multifactorial statistical approach

What the paper says

The structure and mechanical properties of needle-punched nonwovens are determined by an interplay between fibre properties and processing parameters. This work examined the individual and combined effects of three selected variables on the structural and mechanical properties of viscose-based nonwovens. The studied variables include fibre linear density (3.3dtex and 1.7dtex), needle penetration depth (5 mm and 4 mm), and needle type (Standard and EcoStar). The properties evaluated include GSM, thickness, bulk density, air permeability, pore size distribution, tensile stress, elongation, and bursting strength. Multifactorial statistical analysis confirmed that all three variables had main and interdependent effects on nonwoven performance. Significant interactions between penetration depth and fibre linear density were the most dominant, showing that fibre fineness largely determined how nonwoven properties responded to needle penetration depth. Coarser 3.3dtex fibres produced nonwovens with lower bulk density, higher air permeability, and enhanced strength properties. In comparison, finer 1.7dtex fibres yielded nonwovens with higher bulk density, lower air permeability and lower mechanical performance. Needle penetration depth and needle type also influenced mechanical performance. EcoStar needles generally improved tensile stress and bursting properties, particularly in the nonwovens produced from coarser fibres. This study provides valuable insights that can guide the selection of fibre and needle punching parameters to improve the performance of viscose-based nonwovens.