The Role of Staple Fiber Length on the Performance of Carded, Hydroentangled Nonwovens Produced with Polypropylene Fibers

Carding is a common web-forming process used for staple fibers in the nonwovens industry. Staple fibers may be produced in many different lengths. However, the effect of staple fiber length on the nonwoven carding process and structure–property relationships of carded, hydroentangled nonwoven fabrics is not well understood. During this research, polypropylene fibers with lengths ranging from 2.54 to 15.24 cm were produced, carded, and bonded by hydroentangling. All fiber lengths used during this research were successfully carded. Fabrics were characterized via scanning electron microscopy analysis as well as basis weight, thickness, and solid volume fraction measurements. Fabric performance was evaluated with air permeability and burst strength testing. Data sets were statistically evaluated with one-way and two-way analysis of variance to determine whether fiber length significantly affected fabric structure and properties. In general, the fabrics’ solid volume fractions and burst strengths were not significantly affected by fiber length. However, air permeability of the samples did show significant change with fiber length.