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Current web formation technologies used by the nonwovens industry do not provide positive control over fiber orientation and it is difficult to generate lightweight webs from staple fibers with these processes. The aim of this research is to develop new methods of fiberweb formation using electrostatic force, where orientation and orientation distribution of staple fibers are positively controlled. We carried out theoretical analysis and constructed computer models for this approach. Our analysis considered the effects of geometric configurations of fiber feeding and web formation zone, electrostatic and airflow field parameters, and the fiber's initial conditions at the feeding zone on fiber orientation. The theoretical analyses and computer modeling of the electrostatic web forming process provide better insights into this method and serve as a powerful tool for engineering development. Numerical results were obtained and presented for a range of processing variables.

Formation of Fiberwebs from Staple Fibers with Controlled Fiber Orientation Using Electrostatic Forces: Theoretical Analysis