Views: 0 Author: Site Editor Publish Time: 2023-02-27 Origin: Site
Nowadays, the application of non-woven products covers almost all aspects of our lives, and you can find non-woven fabrics anywhere, such as wipes, curtains, car cushions, carpets, etc. Non-woven fabrics are also widely used in medical and health care, such as masks, doctor's caps, surgical gowns, surgery drapes, etc. So, for these dazzling non-woven products, do you know what the manufacturing process is? Read this article, and you might learn something.
Classifications of Non-woven Fabric Production Process
A. Production process of spunlace non-woven fabric
B. The advantages of spunlace non-woven fabric
C. Application of spun lace non-woven fabric
2. Heat-bonded Non-woven Fabric
A. The process flow of hot air non-woven fabric
B. Process flow of hot rolled non-woven fabric
C. Production process of ultrasonic hot bonded non-woven fabric
A. The advantages of Pulp air-laid non-woven fabric
B. Application of Pulp air-laid non-woven fabric
A. Characteristics of wet-laid non-woven fabric
B. Application of wet-laid non-woven fabric
A. Classification of spun-bond non-woven fabrics
6. Melt-blown non-woven fabric
A. Process flow of melt-blown non-woven fabric
B. The characteristics and use of melt-blown non-woven fabrics
7. Acupuncture non-woven fabric
The production of non-woven fabrics has three stages. In some cases, these three phases can be simultaneity.
The three stages are:
Comb the fibers into a network structure by various means
The methods of comb fibers are Drylaid - Carded, Drylaid - High loft, (Short Fiber) Airlaid, Wetlaid, Spunlaid, Meltblown, and Submicron spinning.
After forme the fiber network, various bonding mechanisms are used to glue these network structures together.
The adhesion mechanisms are Thermal (Calendering / Air through), Mechanical (Needle punching / Hydro-entanglement / Stichbonding), and Chemical.
The combination of different raw materials and various technologies enhances the diversity of non-woven products.
Finishing processing methods are Mechanical treatment, Surface modification, and Coating.
The final product of non-woven fabrics is the coil, which is transformed into consumer goods by different factories in various ways.
These methods are Splay, cut, fold, sew, or heat seal.
The production process of non-woven fabrics is mainly dry forming, spinning melting forming, and wet forming. Wet forming is usually based on conventional papermaking process techniques.
Among them, dry non-woven fabrics include heat (hot air, hot rolling), needling method, spunlace method, air flow netting method, sewing methods;
Spunmelt non-woven fabrics include the spun-bond method and the melt-blown method.
Spunlace technology is to lay the fiber on the patterned metal curtain with porous water infiltration or holes and tangle the bulk fibers with each other in the effect of multiple rows of high-pressure fine water, thus forming a sheet structure.
Spunlace technology can give products better softness, durability, and wear resistance than other non-woven technologies. It is suitable for making wet wipes and sanitary and medical products.
The production process suitable for spunlaced sanitary materials isFiber raw materials → opening and mixing → carding disorderly into the net → fiber net pre-wetting → forward and reverse spiny → surface finishing → drying → winding → inspection → packaging into the warehouse
There is no extrusion of the fiber mesh in the spun lace process, thus improving the final product swelling degree;
No resin or adhesive was added, and the fibrous mesh remained soft;
The high integrity of the product avoids the fluffy phenomenon;
Fiber mesh has high mechanical strength, up to the textile strength of 80%~90%;
In particular, You can compound a water-spiced fiber mesh with any substrate;
According to different uses to produce a variety of functional products.
Spunlace non-woven fabric can be used to make medical curtains, surgical gowns, surgical cover cloth, medical dressing material, wound dressing, medical gauze, Band-aid, cosmetic cotton, wet wipes, mask covering material, etc.
Heat-bonded non-woven fabric is added to the fiber mesh fiber or powder of hot melt adhesive reinforcement materials after heating and melting the cooling cloth. It includes hot air, hot rolling, and ultrasonic bonding.
According to the process requirements, batching → unpacking feeding → cotton box mixing → carding - oven hot air shaping → ironing → metal detection → defect detection → coiling → squaring → finished product packaging
Hot rolled non-woven using polyester as raw material through high-temperature melting, spinneret mesh, hot rolling bonding, winding slitting, and other continuous production processes.
The production process of ultrasonic bonding is to transmit the welding head from the sound wave to the non-woven welding surface, instantly causing the non-woven fabric to produce friction, and reach the plastic melting point, to complete the rapid dissolution of solid materials and complete the welding.
Hot air and hot rolling are commonly used in personal hygiene care products. You can use it to manufacture disposable products, such as baby diapers, adult incontinence pads, fabrics for women's hygiene products, as well as napkins, bath towels, and disposable tablecloths.
Pulp air-laid non-woven fabric is also called dry papermaking non-woven fabric. It is the use of airflow into the net technology to open the wood pulp fiber board into a single fiber state and then use the air flow method to make the fiber condensate on the net curtain and then strengthen it into cloth. Using wood pulp fiber as the raw material has the advantage of being biodegradable.
Air flow into the net non-woven fabric has good fluffiness. It is a soft feel, the wet strength is better than paper, and the moisture absorption performance is super strong.
It is mainly used in medical and health materials, such as disposable surgical gowns, face masks, bouffant caps, medical bed sheets, etc.
Wet-laid non-woven fabric is to open the fiber raw material in the water into a single fiber. At the same time, the different fiber raw materials are mixed to make a fiber suspension slurry, the suspension slurry is transported to the network mechanism, and the fiber is reinforced into a cloth in the wet state.
Wet-laid non-woven fabrics have strong adaptability to raw materials because of their technical characteristics of weaving. According to the final use of the product requirements for design, the wide selection of fiber raw materials. In addition to plant fibers, polyester, polypropylene, nylon, viscose, and glass fibers can also be used as raw materials. These ingredients can be used alone or mixed in proportion.
The application field is extensive. In medical and health care, they can be made into surgical gowns, bed sheets, pillowcases for patients, bandages, plasters, etc.
Spunbond non-woven fabric in the polymer has been extracted, stretched, and formed a continuous filament, filament laying into a network, fiber network and then through self-adhesive, thermal bonding, chemical bonding, or mechanical reinforcement method so that the fiber network into a non-woven fabric.
The materials of spunbond non-woven fabrics are polyester and polypropylene.
Polypropylene spunbonded non-woven fabric can produce S, SS, SSS, SMS, etc., with a soft feel, chemical resistance, and hydrophobicity. Its hydrophilicity and UV resistance can be changed by processing and adding additives. It can be used to produce disposable masks, protective coveralls, isolation gowns, laboratory clothes, nurses' caps, doctors' caps, maternity bags, first aid kits, diapers, pillowcases, sheets, quilt covers, shoe covers, and other disposable medical consumables series.
Polyester spunbond non-woven fabrics have higher heat resistance than polypropylene non-woven fabrics used for filtration, lamination, etc.
Melt-blown non-woven fabrics use high-speed hot air to pull the polymer melt stream extruded by the spinneret, thus forming microfiber and condensing in the coagulation curtain roller and relying on their adhesion and becoming a non-woven fabric.
Polymer preparation → melt extrusion → metering pump → melt-blown die head assembly → melt flow stretching → cooling → receiving device
Melt-blown non-woven fabric has fine fiber, good air permeability, high filtration efficiency, bacteria isolation, heat insulation, non-toxic, no stimulation, etc.
You can use it as a gas filter material, such as a medical mask, and its middle layer is a composite material made of melt-blown material.
Acupuncture non-woven fabric is a kind of dry non-woven fabric. It uses the puncture effect of the needle to reinforce the fluffy fiber net into a cloth.
The process flow of needle non-woven fabric is the textile's short fibers that are oriented or randomly arranged to form a fiber network structure, and then the fiber network is reinforced into a cloth through a needle. The needle has a hook, which can puncture the fiber network repeatedly, and then strengthen it with the hook belt fiber, and finally, be sent to the high-temperature box for heating and strengthening to form a needle non-woven fabric.
Stitch non-woven fabric is a kind of dry non-woven fabric. The knitted method is to use warp knitted coil structure to reinforce fiber mesh, yarn layer, non-textile materials (such as plastic sheet, plastic thin metal foil, etc.), or their combination to make non-woven fabric.
Through the above introduction, I believe you have a general understanding of the production process of non-woven fabrics. The raw materials of non-woven fabrics are different, the production process is different, and the characteristics of the final product are also distinct. Of course, these production processes do not exist in isolation, and you can mix these processes according to the characteristics of the product you need to make. For example, if we need to produce materials for surgical gowns, we will use spun-bond and melt-blown to manufacture non-woven fabrics.
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