Exploration based design methodology using the theory of constraints in extending plastics manufacturing for novel high performing fabrics
Date
2022
Authors
Shekoni, Aderemi, author
Troxell, Wade, advisor
Simske, Steve, committee member
Young, Peter, committee member
Prieto, Amy, committee member
Journal Title
Journal ISSN
Volume Title
Abstract
The world of textiles is comprised of several materials. From the conventional, such as cotton and silk, to the contemporary, such as polyester and nylon, textiles have changed over time. Nonwovens, a category of material frequently referred to as the "third-generation" of textiles, have emerged as one of the most exciting breakthroughs in the textile industry during the past few years. Nonwovens, which are frequently confused with fibers, yarns, and fabrics, have evolved as a new category of versatile material with medicinal and industrial applications. An issue associated with the use of lightweight nonwovens is their single-use, in which a fabric weight category can be employed for only one product. The number of products per weight class that can be utilized in businesses that utilize the materials is limited. Therefore, companies utilizing these textiles in their operations must engage with plastic producers to plan, implement, and develop a single weight class for a single product. This procedure is time-consuming and generates plastic waste because of unfinished fabrics. By creating a multipurpose nonwoven fabric, organizations will be able to improve their operations by saving time and energy, improving profits, decreasing plastic waste, and enabling process innovation. To use a fabric with the same weight and similar physical properties in a different product, a different fabric is manufactured for that process, despite the similarity in weight and physical properties between the fabric used in the previous process and the fabric needed for the new process. Due to this limitation, the concept of redesigning nonwoven materials for different applications was conceived. Air Permeability, a barrier to airflow, is a significant component in the inability to support numerous uses. When a fabric's desired attribute is not satisfied, the fabric's air permeability can be optimized by utilizing a variety of process approaches to attain the appropriate performance qualities. This permits the use of a single fabric in a variety of items. Due to the fabric's weight and volume, the usage of nonwoven in aviation and public works has expanded drastically. Thermal insulation is one of the most prevalent applications of nonwoven materials in the aviation industry. Nonwoven fabrics are also utilized as dynamic biofilters for filtration in public works, with an aerobic layer that aids in the recovery of alkalinity in the filtration systems used in these facilities. The two significant outcomes of this research are (1) Improvement of the airflow barrier, also known as air permeability (AP), which enables the use of a single weight class to make several goods as opposed to a single weight class for a single product, and the addition of a thermal barrier to the fabric. Permeability enhancements in nonwovens enhance the fabric's sound absorption, filtration, and heat absorption. (2) The capacity to recycle undesired nonwoven fabrics following production, as opposed to disposing of the plastic components in landfills. Nonwovens are semi-crystalline polypropylene plastics that are not easily biodegradable due to the strong chemical bond between the polypropylene polymers. Because polypropylenes, which are plastics, are not biodegradable, unused nonwoven fabrics are landfilled. It was through the process of prototyping that a subsystem alteration was made that enabled the development of nonwoven fabric with better air permeability. Design as Exploration concepts are used to accomplish this. Reicofil I, II, III, and IV are the four nonwoven production systems used in this research to develop the novel fabric. In addition, this study has handled another issue by reusing and recycling unwanted fabrics to reduce the amount of plastic waste in landfills. An extrusion method that recycles rejected and waste fabrics were the result of these approaches. The innovative method used in developing the new nonwoven fabric is being explored for use in the production of plastic films to improve the quality of goods made with polyethylene plastic polymers.