Introduction to The Nonwovens Institute Established 1991 as a NSF State I/UCRC NAFA 2014 Technical Seminar Genevieve Garland, Ph. D Director – Partnership and Market Intelligence Copyright - NWI, NC State University - 1991 -2014 1
NC State University w North Carolina State University is a Research I University with more than 34, 000 students and nearly 8, 000 faculty and staff. w North Carolina State University is a comprehensive university known for its leadership in education and research, and globally recognized for its science, technology, engineering and mathematics leadership. Copyright - NWI, NC State University - 1991 -2014 2
History of Nonwovens at NC State w The Nonwovens Cooperative Research Center (NCRC) was founded in 1991 as a State-IURC from grants from the United State National Science Foundation (NSF), the State of North Carolina, and Industry. NCRC Graduated from NSF in 1998. w NCRC has grown to be the largest industry cooperative research center in the Nation. w The Nonwovens Institute (NWI) was established on February 15, 2007. Copyright - NWI, NC State University - 1991 -2014 3
The Nonwovens Institute is a university-wide unit that works with the faculty in the participating colleges and partner universities and member companies to support the various industrial sectors that it represents… and train future leaders for the industry… Copyright - NWI, NC State University - 1991 -2014 ce n e ci r. S pe Pa En gi Nonwovens Institute ne er in g Textiles Fiber & Polymer Science Chemical Engineering Paper Science & Engineering 4
What We Actually Do at NWI? Testing & Fabrication Education • • • Funded by NWI Ph. D Research Graduate Certificate Short Courses In-plant Training 37+ Ph. D Students Faculty Meet twice/year Project monitoring Typically no IP, but Bylaws define IP rights • • Copyright - NWI, NC State University - 1991 -2014 Funded by Sponsor No student/faculty involvement Research Staff only Confidential Sponsor present at trial Sponsor defines protocol Simple Agreement with no IP terms Enabler for innovation New Product Development Incubation LINC, LL • Funded by • • • Sponsor No student involvement Research scientists Meet monthly Reporting requirement Project monitoring Option to License IP generated Assistance with commercialization • • • Funded by Sponsor Help commercialize technologies developed at NWI Manufacture on a limited basis products Identify companies who can produce the products Transfer technology to client LINC is a non-profit affiliated entity of NC State… 5
Market Impact Education & Outreach Initiatives Medical & Hygiene Filtration Automotive Wipes Building & Industrial Emerging Durables Platform Translation Technologies Materials & Process Technologies Surface & Bulk Engineering Micro and Macro Modeling Nonwovens, Fiber & Polymer Science and Eng. , and Paper Science Copyright - NWI, NC State University - 1991 -2014 Platform Technologies Benefits to Members Market Segments Training Future Leaders Open Innovation Network 6
Members Full Members 3 M Ahlstrom Andritz Nonwovens Attends Healthcare (Domtar) Baiksan BASF BSN Medical Braskem Cardinal Health Cotton Inc. Cummins Filtration Dow Chemical Donaldson Du. Pont Eastman Chemical Exxon. Mobil First Quality Copyright - NWI, NC State University - 1991 -2014 Full Members Fiber. Visions Flanders Fiber. Tex Freudenberg Nonwovens Groz-Beckert Hills Inc. Hollingsworth & Vose Inno. Pad Janesville Acoustics Johnson & Johnson Kimberly-Clark Kraton Polymers MANN+HUMMEL GMBH EMD Millipore Nature. Works, LLC NATICK Soldier Center Nike Covers the whole value chain, small to large Full Members Pall Corp. Pentair Inc. PGI Nonwovens Ply. Gem Procter & Gamble Riefenhauser REICOFil Schlumberger Solvay Specialty Polymers Techmer PM Trützschler Nonwovens Veolia Voith VTT Welspun Xerium 7
Members Affiliate Members Accu. Sentry, Inc. Allasso Industries ANSYS Biax Fiber. Film CHA Research Dilo Inc. Fi-Tech Industrial Microwave Systems JSAM LIST Mini. FIBERS, Inc. Nano Filtration Technologies SNS Nano Fibers TTRI U. S. Pacific Nonwovens Copyright - NWI, NC State University - 1991 -2014 Covers the whole value chain, small to large and more… Start-up Members The Colberg Company, LLC Supporting Orgs. AATCC EDANA INDA TAPPI Membership dues are exclusively used to support our multi-disciplinary, but fundamental shared research, initiated and monitored by our membership 8
Knowledge Creation: Core Research w 37+ Ph. D students w Meet twice/year with all members w Reporting requirement w Project progress monitoring w Typically no IP generated; Bylaws define IP rights w Results only shared with the members until results are published or student graduates Copyright - NWI, NC State University - 1991 -2014 9
Knowledge Creation: Core Research w Nonwovens Materials & Process Technologies n n Fibers, Additives, Coatings Material-process-performance interactions w Surface & Bulk Engineering n n Controlling functionality – e. g. , ion-exchange, electret, … Controlling behavior – e. g. , shape memory, … w Micro and Macro Modeling n n Structure modeling, Performance modeling, etc… Copyright - NWI, NC State University - 1991 -2014 10
Knowledge Creation: Core Research Materials & Process Technologies Project ID Title 06 -89 NC Solution Blowing Fundamentals 08 -111 Melt Electrospinning with Adhesive Polymers 08 -115 Investigating Polymer/Polymer Interface 09 -118 Fabrication and Modeling of Conductive Nonwovens 09 -124 NC Photovoltaic Polymer and Ceramic Nanocomposite Materials 09 -125 NC Hybrid Woven/Nonwoven Composite for Protection 10 -132 Structure of Needle Punched Fabrics & Needling Mechanism 11 -136 Interconnected Micropores in Hollow Nonwoven Fibers 12 -139 Structure-Property Relationships of Nonwovens Filled with Calcium Carbonate 12 -140 Cellulose Nanocrystals as Additive and Reinforcing Agent in of PE and PP 12 -142 -A &B PVDF Multifunctional Microfiber Spunbond Nonwovens 12 -144 SB 12 -145 -NC 12 -147 -NC 13 -148 -NC 13 -149 Spinning Fibers below 50 nm Behavior and Limitations of Novel Filler Loading in Polymeric Materials Nonwovens as Replacement for Membranes in Water Filtration Conductive Nonwovens Modeling of Meltblowing Process Conditions Copyright - NWI, NC State University - 1991 -2014 11
Knowledge Creation: Core Research Functionalization Project ID Title 08 -113 Durable Nanolayer Graft Polymerization of functional Finishes Using Plasma 10 -131 11 -135 Ion Exchanger Formation via Sulfonated Block Copolymer Fluid Absorption and Release of Nonwovens and their Response to Compression 08 -114 Electrostatic charged polymer filter media with melt additives 11 -133 NC Inorganic/Organic Hybrid Processes for Nonwovens 11 -134 Vapor Surface Modification of Nonwovens 12 -137 NC Novel Block Ionomer Fiber Coatings for Controlled Pore Size 12 -141 13 -151 Development of anti-biofouling coatings on PET nonwovens for specific attachment of biological antibodies and for removal of heavy metals The First Predictive Theory to Estimate the Thickness and Porosity of Nanofiber Nonwoven Mats Materials for Sensing and Analysis of Nonwoven Structures 13 -153 Surface Modification Material Platform via Functional Powder Coating Technology 13 -155 Durable, Self-extinguishing, and Halogen-free Flame Retardants for Nonwovens 13 -150 -SB Copyright - NWI, NC State University - 1991 -2014 12
Knowledge Creation: Core Research Modeling/Structure-Property Relationships Project ID Title 07 -99 08 -110 Simulating Multi-component Aerosol Filters via Geometrical Modeling and Volumetric Imaging Investigating the Bonding/Fiber-fracturing performance of Hydroentangling 09 -120 Composite Nonwoven Materials in Heat Insulation 09 -122 NC Hybrid Composite Liquid Filters 10 -127 Melt-Spun Bi/Tricomponent Fibers Exhibiting Shape Memory: A Mesoscale to Macroscale Experimental and Theoretical Study Deformation and Failure Mechanisms of Low-Density Nonwoven 10 -129 10 -130 13 -152 Fundamental Study of Hydrophobic and Hydrophilic Fibers in Filtration Media and their Effect on Droplet Impact, Coalescence and Penetration A Systematic Investigation of the Factors that Trigger Thermal Decomposition During the Processing of Industrially-Relevant Polymers Micro-and Macro-Scale Modeling of Filter Aging: Effects of Particle Deposition on Filter Performance Parametric Modeling of Compression Performance of Nonwovens 13 -150 -SB Predictive Theory to Estimate the Thickness and Porosity of Nanofiber Nonwovens 13 -154 Cold-Draw Shape-Memory Bi/Tricomponent Fibers: Elucidating the Polymer/Polymer Interface and Adding Sensory Functionality 12 -138 12 -143 Copyright - NWI, NC State University - 1991 -2014 13
Training Future Leaders NW 203 – Materials used in nonwovens NW 305 – introduction to processes and products NW 405 – Advanced nonwoven processing NW 407 – Characterization methods in nonwovens NW 408 – Nonwoven product development NW 503 – Materials used in nonwovens NW 405 – introduction to processes and products NW 505 – Advanced nonwoven processing NW 507 – Characterization methods in nonwovens NW 508 – Nonwoven product development Graduate Certificate in Nonwovens The students who complete the above 5 graduate courses, can receive a university graduate certificate in Nonwovens Science and Engineering. This is the only program of its kind in the world Ph. D Fiber & Polymer Science, Chemical and Biomolecular Engineering Materials Science and Engineering, Bioengineering, and others Our Goal is to have 5 dedicated tenure-track faculty in NWI by 2017. Member Benefit: Free online access to all courses materials Copyright - NWI, NC State University - 1991 -2014 14
New Product Development w Our guiding principals are that such programs must be transformative in that the new product or activity: n n n Challenges what is possible Disrupts existing learning curves Leaps beyond today’s technologies w Funded by Individual Sponsor n n n No student involvement Staff and research scientists Typically IP generated Sponsor receives option to license IP Results only shared with the sponsor Member Benefit: Access to talent and facilities at reduced rates Copyright - NWI, NC State University - 1991 -2014 15
New Product Development Examples w w w w New high surface area fiber New Splittable fiber/spunbond High strength nonwoven for shelters Durable nonwovens for uniforms 3 -D nonwovens Modeling of meltblowing process 3 -D modeling of nonwoven structures New acoustical nonwovens for speakers Copyright - NWI, NC State University - 1991 -2014 16
Technology Transfer and Incubation Leaders in Innovation & Nonwoven Commercialization – LINC, LLC w The challenge with commercializing any new technology is that often, new manufacturing assets are required and capital expenditures are difficult to justify in the absence of significant proven market potential… w LINC is a non-profit affiliated entity of NC State (The Institute). http: //www. lincnonwovens. com/home w LINC acts as an incubator to: n n n Help commercialize technologies developed at the Institute Manufacture on a limited basis products that are not commercially proven to help with the launch of the products Assist in identifying companies who can take on the task of producing the products, and will help transfer the technology Member Benefit: Incubation of new ideas and products to prove commercial feasibility Copyright - NWI, NC State University - 1991 -2014 17
Be The “Go-To” Information Resource Professional Development Regularly Scheduled Custom w Nonwoven Products and w Microscopy and Image w w w Processes Manufacturing Process Fundamentals Spunbonding & Meltblowing Fundamentals Bonding Fundamentals Characterization Methods Product Development Copyright - NWI, NC State University - 1991 -2014 Analysis w Product Development n n n Filtration Wipes Industrial Nonwovens Automotive Nonwovens … w Processing 18
Forecasting Technology and Market Needs w NWI offers services in forecasting technology and market needs through market intelligence. w The market intelligence and technology assessment provides a systematic approach to looking at the current and future direction markets and technologies are moving to provide decision makers with information that helps them anticipate, drive and plan for the research and development that leads to breakthrough technologies and products. w This activity is useful to individual companies but also helps the IAB and the Executive Committee in identifying technology gaps and new research directions for NWI’s core programs. Member Benefit: Access to knowledge and know-how at reduced rates Copyright - NWI, NC State University - 1991 -2014 19
Creating Testbeds w NWI offers to industry diagnostic and testing and pilot production services by creating testbeds and making these available at reasonable fees. w Funded by Individual Sponsor n Daily rate n Confidential n No student involvement n Staff and research scientists n Allows sponsor to reduce their ideas to practice n Sponsor present at trials n Simple agreement with no IP terms n Results only shared with the sponsor Member Benefit: Access to know-how and facilities at reduced rates Copyright - NWI, NC State University - 1991 -2014 20
Testbeds: Current Pilot Testbeds w Fiber Extrusion n Mono, Homo, Bico, Trico w Spunbond n Bico – 60 cm w Meltblown n n Hills Bico – 60 cm Biax – 40 cm Reicofil – 1. 2 m Reicofil – 12. 5 cm Copyright - NWI, NC State University - 1991 -2014 w Carding/calendaring/ crosslapping/needlepunching/thermalbonding n Erko – 1. 5 m w Electrospinning n Nano. Spider – 25 cm w Coating/Laminating n Knife, roll, pad – 80 cm n Gravure roll – 50 cm n Powder – 10 cm 21
What Members Tell Us… w Research Cost Avoidance & Research Amplification n Access to core research programs Access to students, faculty and staff Voting rights to determine research agenda w Technology Transfer n n Option to any IP developed through core research programs Access to online researchives Training programs at a discount Free online course materials w Service/Economic Development n n n Product development Analytical services Discounted use of facilities & testing w Networking n n New members showcase at IAB Marketing on NWI website Industrial networking at semi-annual meeting Networking with various faculty, students and staff Copyright - NWI, NC State University - 1991 -2014 22
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