Nonwoven machines are used in the production of nonwoven fabrics, which are materials made from fibers that are bonded together through various methods, including mechanical, chemical, or thermal processes. The production process for nonwoven fabrics typically involves several stages, including fiber preparation, web formation, bonding, and finishing. Here’s a brief overview of each stage:
Fiber preparation
In this stage, raw materials, such as natural fibers (e.g., cotton, wool) or synthetic fibers (e.g., polyester, polypropylene), are opened, cleaned, and blended to achieve the desired properties. This can be done using machines like bale openers, mixers, and carding machines.
Web formation
The prepared fibers are then formed into a web or mat-like structure. This can be achieved through several methods, including:
Drylaid: The fibers are carded or airlaid to form a web. Carding machines use a series of rollers and wire teeth to separate and align fibers, while airlaid machines use air to disperse and deposit fibers onto a moving conveyor belt.
Wetlaid: Fibers are suspended in water, and the resulting slurry is deposited onto a moving screen where the water drains away, leaving a web of fibers.
Spunbond: In this method, molten polymer is extruded through spinnerets, forming continuous filaments that are cooled and deposited onto a conveyor belt to form a web.
Meltblown: Similar to spunbond, but the extruded filaments are much finer and are dispersed by high-velocity air, forming a web of microfibers.
Bonding: The web produced in the previous step is bonded to create a cohesive fabric. Common bonding methods include:
Mechanical bonding
Involves entangling fibers using needle punching or hydroentangling (water jets).
Thermal bonding: Fibers with a low melting point are heated and pressed to create a bond. This can be done using machines like calendar rollers or through-air bonding ovens.
Chemical bonding: A binder or adhesive is applied to the web, which is then cured to create a bond.
Finishing: Once the nonwoven fabric is bonded, it may undergo additional finishing processes, such as:
Cutting and slitting the fabric to the desired width and length.
Adding treatments for specific properties, such as fire resistance, water repellency, or UV resistance.
Laminating the fabric with other materials, such as films or foams, for added strength or functionality.
Nonwoven machines are often customized to suit specific production requirements, and the process may vary depending on the type of nonwoven fabric being produced.