Towards …The Engineering Research Center for Innovative Fibrous Materials

Director: Behnam Pourdeyhimi, bpourdey@ncsu.edu, 919-515-1822,

Co-Director: Ruben Carbonell, ruben@ncsu.edu, 919-515-5118,

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Nonwovens – Innovative Fibrous Materials

Nonwovens are Engineered Innovative Fabrics

Nonwovens are manufactured by high-speed, low-cost processes – Large Volume, Low Cost

Nonwovens are in many applications already, but most are hidden and you do not see them

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History…

In 1991, The Nonwovens Cooperative Research Center (NCRC) started as a National Science Foundation Center in the form of a State Industry University Cooperative Research (State I/UCRC) Center.

Funds were to come equally in the amount of $300,000 each from the

State of North Carolina Industry NSF

In 1998, NCRC graduated from the National Science Foundation.

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NCRC’s Growth ContinuesNCRC is the largest I/UCRC in the Nation

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1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006

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1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006

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Non-Core Research & SupportExtension, Engagement, Economic Development

Core Research

Establishment of pilot and analytical facilitiesDevelopment of a model for

Extension, Engagement, Economic Development

Establishment of pilot and analytical facilitiesDevelopment of a model for

Extension, Engagement, Economic Development

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Current NCRC Supported Staff – 16 Five visiting Faculty/Scientists – Teaching and Research

1. Hooman Tafreshi2. Svetlana Verenich3. Eunkyoung Shim4. Benoit Maze5. Bong Yeom

Twelve Full time Staff 1. Sherwood Wallace2. Stephen Sharp3. Ben Lambert4. Alvin Fortner5. William Barnes6. Robert Byron7. John Fry8. Amy Minton9. Susan Pegram10. Wendy Cox11. Don Shiffler12. Bruce Anderson

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Investments in Infrastructure by NCRC

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500000

1000000

1500000

2000000

1999 2000 2001 2002 2003 2004 2005 2006 2007

Year

Inve

stm

ents

($)

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500000

1000000

1500000

2000000

1999 2000 2001 2002 2003 2004 2005 2006 2007

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Inve

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Current Member CompaniesFULL MEMBER I1. BASF2. Clorox3. Colbond4. Cumins Filtration5. Eastman6. First Quality7. Jockey Int.8. KITECH9. MeadWestvaco10. NATICK11. NatureWorks12. Procter & Gamble13. ProMetic14. Rohm and Haas

FULL MEMBER II1. 3-M2. A. Celli 3. Ahlstrom4. Albany Int.5. Arkema6. AstenJohnson7. BBA Fiberweb8. Cintas9. ConvaTec10. Cotton Inc.

AFFILIATE1. AFTECH2. Allasso Industries3. American Truetzschler4. Apexical, Inc.5. Atlantic Mills6. Dophes, Ltd7. Duke Energy8. Fi-Tech9. FlexForm Technologies10. Fluent11. General Nonwovens12. Groz-Beckert13. Herrmann Ultrasonics14. J. D. Hollingsworth15. Jenkins, Wilson & Taylor16. NanoFiber Group17. Nippon Nozzle18. Nonwoven Media Int.19. NSC20. NuTex Concepts21. OMNOVA22. Porous Materials, Inc.23. Progress Energy24. Slack & Parr25. Xymid, LLC

ASSOCIATE1. CSIRO

FULL MEMBER II11. Dow12. DuPont13. FiberVisions14. CHA Technologies (FIT)15. Fleissner16. Freudenberg17. Hills Inc.18. INDA19. Johns Manville20. Kimberly-Clark21. Kuraray22. Milliken23. PGI Nonwovens24. Raytech Composites25. Rieter Textile Systems 26. Sellers Wipes 27. San Fang Chemical28. Sara Lee29. Sunoco30. TTIR

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NCRC’s Mission

Education Training students Technology transfer

Short Courses In-plant Training

Research Core – Creating Knowledge – Fundamental & Applied Non-core – Outreach – Applied & Fundamental

Economic Development (Extension/Engagement) Analytical services Product innovation/development

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Why an ERC?To Sustain and Support a Rapidly Growing Industry

Initially, focused on single-use disposable products, today this $50 billion industry, with as much as $11 billion in roll goods, produces a wide-ranging array of products – These are not apparel textiles.

Presently, the major markets include medical and hygiene, filtration, personal care and industrial and automotive.

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Innovation & The Industry

Are we doing enough to ensure our future?

It is unlikely, that growth in these markets can be sustained, or that new markets can be generated, in the absence of significant innovations in materials or process technologies that can enable the development of new and innovative products.

Roll Goods

Machinery

Products

Materials

Innovation

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TAPEBACKINGS

LOWDENSITY

ABRASIVES

MEDICALPRODUCTS

INSULATION AND

FILTERS

Liquid FiltersBags

1980

ThinsulateThermal Insulation

RemovableHighway

Marking Tapes

RescueSoap Pads

Surface Conditioning Pads,Brushes, Disks, Belts and Wheels

Steri-Strip Closureand Surgical Tapes

DoodledusterMeltblown

Webs

1940 1950

Oil Sorbent

19701960

FiltreteElectrets

TM

BreathableTapes

Face Masks andRespirators

TMCOBAN

Masks andDrapes

NomadEntry Mats

TM

Surgical Masks

TM

Membranes

Clean 'N StripPads

TM

TM

SasheenDecorativeRibbons

TM

Scotch-BritePads

FilamentTape

FloorPads

ScrubbingPads

Tapesand

Ribbons

Food ServiceCleaning Pads

TMBuf-PufPads

DampeningSleeves

InteramMats

TM

ProPore FabricsTM

HoldFast and TriplexConsumer Gauze

Ultra ComformablePremium First Aid Tape

Attest BiologicalIndicators

AcousticalInsulation

TM

Furnace Filters

Cabin Air Filters

1990

Chemical Spill Sorbents

Liquid FiltersCartridges

AirFilters

2000

FlexInsulation

FiltreteHEPA Filters

TM

Vacuum Bags

First AidDressings

LiteLoftInsulation

Surgical Gowns

TM

TM

MedicalElectrodeBackings

TMEntrap Mats

TM

Flat FoldRespirators

TM

WristRest

NexcareComfort Strips

TM

Cast Paddingand Stockinets

TM

TM

TM

Nomad 9000

Hookit IIAbrasive DisksInsulation

TapeHookit

Abrasive Disks

Never ScratchWool Soap Pads

Never RustWool Soap Pads

RK Mill Rolls

ConformableNVH Tape

TM

MillRolls

3M FloppyDisk Liners

Film BackedBelts

TM

Non-ScratchCleaning PadsTM

TM

AntifatigueMats

TM

Floor Brushes

LoopFasteners

Summit Hand Pads

TM Multi-FlexSheets

Nextel FlameStopping Dot Paper

FireBarrier

TM TM

TM

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The Vision

to become a global research, educational, and training resource for the Fibrous Materials Industry by developing innovative fibrous materials and systems that sustain and improve the economic well being of the nation and contribute to the quality of the environment and public health.

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Mission

to develop new scientific and engineering knowledge through world-class scholarship.

to transfer that knowledge to the Industry to spawn commercialization of next-generation product technologies to drive the innovations required to realize new classes of uniquely robust and responsive products.

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Our Model …

Creating Knowledge

Adding ValueTransferring Knowledge

University, Industry, GovernmentIndustry, University & Government

Fundamental Research

New Product Development

Core Research Non-Core, Applied Research

Extension, Engagement and Economic Development

Graduate & Undergraduate

Education

NSF’s Missio

n

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Goals

1. Undertake research in the areas of materials synthesis, surface engineering, and structure/process modeling to aid in the development of new and innovative products related, but not restricted, to medical, surgical and drug delivery applications, biospecific biological separations processes, drug and toxin detection and removal, national defense, energy conversion, reinforced materials for construction and aeronautical applications, and energy conservation.

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Goals

2. Build strategic alliances with industrial partners and facilitate technology transfer and commercialization, and meet the education, research, and engagement needs of the industry.

3. Educate and train students and researchers through targeted educational programs, short courses, online and distance education programs, internships, sabbaticals, direct in-plant training, and one-on-one consulting.

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Research FocusResponsive Polymer Structures - Examples

Electrically conducting fibers – Use in adsorptive filters – detection and removal

Thermally responsible fibers – Drug delivery, sensors, energy conversion

Impregnation of drugs into fibers – Drug delivery, wound healing, surgical applications

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Research FocusSurface Modification Technologies - Examples

1. Atomic Layer Deposition (ALD) approaches for organic, inorganic and metallic coatings

2. Plasma treatment for ligand attachment – Biospecific separations, detection, removal

3. Controlling of surface-modified fiber properties

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Research FocusComposites & Hybrid Materials - Examples

1. Particle – nano fiber composites, nano tubes – Uses in energy storage, conversion, catalysis

2. Nano- and micro- particle impregnated membranes – energy conversion, medical devices

3. Composite/mixed-mode/gradient materials (combination of nano and micro fibers)

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Outreach

1. Involve undergraduate and graduate students in research projects, publications, and presentations,  

2. Develop an interdisciplinary Graduate Certificate and MS programs in Engineered Fabrics at NC State.

3. Collaborate with The Science House and the Kenan Fellows Program at NC State to implement teacher institutes to train secondary school teachers on ways to teach engineering and scientific concepts.

4. Work closely with North Carolina and US Department of Commerce, Wake County and other Economic Development groups to recruit small and mid-sized companies to North Carolina and provide in-plant training and technical assistance to those in need.

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Fundamental Knowledge

Enabling Technology

Engineered System

New Products & Processes

Models for Product/Process Development

Material Synthesis and

Surface Engineering

1 532 4 6 1087 9

Year

Fiber and polymer materials synthesis Fiber and polymer materials synthesis Engineering of surfaces Engineering of surfaces

Creation of multi-component and responsive fibers, nano fibers, and nano materials

Creation of multi-component and responsive fibers, nano fibers, and nano materials

Expedient processes for the large-scale production Expedient processes for the large-scale production

Performance models Performance models

Integrative fibrous material tesbeds Integrative fibrous material tesbeds

Engineered Innovative Fibrous MaterialsEngineered Innovative Fibrous Materials

Process models Process models Structure models Structure models

Structure-propertyrelationships Structure-propertyrelationships

Filtration, Separation, Automotive, Medical, Hygiene

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Thrust Areas & Leaders

Fiber and Polymer Materials Synthesis Saad Khan; Richard Spontak; Alan Tonelli, Sam Hudson

Surface Engineering Greg Parsons; Jan Genzer; Peter Hauser; Ruben Carbonell

Process Engineering, and Structure modeling Jon Rust; Behnam Pourdeyhimi

Structure modeling Hooman Tafreshi; Jeffrey W. Eischen; George Chase, Dr.

Alexander Yarin

Entrepreneurship – Systems

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Status to date…

First draft will be ready by 3/26 Over 50 responses from NCSU and

Partner universities NCSU Georgia Tech Maryland Akron U.I.C Loughborough Liberec

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AOCCouncil of

Deans:NCSU and

Partner Universities

DeputyDirector

University Policy CommitteeNCSU and

Partner Universities

Associate DirectorResearch

Associate Director

Education

Associate Director

Tech. Transfer

CenterAnalyst

Industrial Advisory Board

DirectorCo-Director

Communications Director

National Science

Foundation