Investigation of the Physical, Mechanical, and Liquid Management Properties of the Novel Through-Air Bonded/Airlaid Nonwoven Composites

ABSTRACT Nonwoven composites are multilayer or multicomponent structures that use different raw materials (polypropylene, polyethylene, polyester, bicomponent, etc.) and different processes (spunbond, meltblown, wetlaid, etc.) that are designed and developed based on targeted products. This study focuses on a new technique for the development of nonwoven composites to be produced at different production stages than the currently produced nonwoven composite structures. In this study, nonwoven composites were formed by through-air bonded/airlaid nonwoven bonding in the airlaid nonwoven production line and did not require a separate bonding process. As part of the study, the nonwoven composites were produced step by step. In the first stage, through-air bonded nonwovens with three different basis weights (20 g/m2, 30 g/m2, 45 g/m2) were used and the basis weight was determined. Then, different chemical binder (latex) ratios (9 %, 12 %, and 15 %) were used in the composite structure and the latex ratio was determined. In the next step, different super absorbent polymer (SAP) ratios (30 %, 22 %, 10 %, and 0 %) were used and determined in the composite structure. Finally, the physical (basis weight, thickness, air permeability), mechanical (breaking force, elongation, bond force, bending rigidity), and liquid management (liquid strike-through time, wetback, liquid absorption capacity, and retention) properties of all nonwoven composite samples were tested and the results were analyzed. One-way analysis of variance was performed to determine whether basis weight, chemical binder (latex) ratio, and SAP ratio had a statistically significant effect on the physical, mechanical, and liquid management properties of the nonwoven composites.