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Based on: Industry Standards and Best Practices

Languages: English

Sample Transcript

Most of the polymers used in the spun-melt process create fibers that do not wet and are inherently water-repellent or hydrophobic. Many nonwovens are used in diapers, wipes, and other hygiene-related products. For these products, liquid transfer and absorbency are essential to how they function. One of the most important finishing coatings is the addition of a rewetting compound, which converts the sheet into a hydrophilic material, which is one that wets and allows water to pass through. This is typically done by passing the bondage sheet over a roll wetted with the rewetting compound, or a surfactant. After the application, the sheet must be dried before being wound on the parent roll. Other coatings used include antistatic compounds, softeners, and additives to enhance product performance and customer satisfaction.

Nonwovens Bonding Processes

Training Time: 39 minutes

Nonwoven fabrics are broadly defined as sheet or web structures bonded together by mechanical entanglement, chemical, thermal, or other means. Unlike traditional fabrics, the fibers are not first converted to yarn and then woven or knitted into a fabric. Instead, a porous sheet or web is made directly from separate fibers. The process of manufacturing nonwovens is made up of two basic steps; 1) web forming, where loose fibers are laid out on a moving porous belt, or drums to create a uniform sheet, and 2) web bonding, where an adhesive or entanglement process is applied to bond the laid out fibers together to create a stable web, or sheet, of material. This course covers some of the different web bonding processes which are used.

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Binder can be applied by spray nozzles to staple fibers as they are made into a sheet

Binder can be applied by spray nozzles to staple fibers as they are made into a sheet

In one application of bi-component fibers, as a high melting temperature polymer is extruded it is surrounded within a layer of lower melting temperature polymer. This arrangement maintains web integrity while assuring good fiber to fiber bonding when the

In one application of bi-component fibers, as a high melting temperature polymer is extruded it is surrounded within a layer of lower melting temperature polymer. This arrangement maintains web integrity while assuring good fiber to fiber bonding when the

In through air thermal bonding, hot air blown through the web quickly penetrates and heats the web. In addition to allowing for high production rates, this technique does not compress the web as calender heating does.

In through air thermal bonding, hot air blown through the web quickly penetrates and heats the web. In addition to allowing for high production rates, this technique does not compress the web as calender heating does.

Learning Objectives

  • List the three general classifications of web bonding used to manufacture nonwovens
  • List the three different techniques for apply binder to a nonwoven web
  • Describe solvent bonding
  • Describe thermal bonding
  • List some of the techniques for heating and bonding a nonwoven web
  • List the three general types of mechanical bonding
  • Describe the two general types of finishing processes
  • List some of the benefits that can come from nonwoven finishing
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Nonwovens Bonding Processes FAQs

What are the three broad classes of bonding use to create nonwoven materials?
Nonwovens can be bonded together using chemical, thermal or mechanical processes.

What are the advantages of using foam to apply binder to nonwoven materials?
Applying binder as a foam leads to higher production rates and lower drying costs than binder application by web immersion. Foam allows low application rates without the need for a containment enclosure which is required by the spray application technique.

How does thermal bonding work?
Thermal bonding works by heating a web and partially melting polymeric fibers, allowing them to bind to each other or to other fibers in a blended material.

What are three mechanical bonding techniques?
Nonwovens can be mechanically bonded together by needlepunching or spunlacing, which are entanglement processes, or by stitchbonding which uses woven threads to help hold fibers together.

What is one advantage of spunlacing?
Spunlacing uses high pressure water to entangle fibers and can be used to create surface patterns in the final web.

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