What are the two major types of making non woven fabric?

Introduction

Non-woven fabric is a versatile material that is used in various industries due to its unique properties and advantages. It is made by bonding fibers together without weaving or knitting them, resulting in a fabric that is lightweight, durable, and has excellent breathability. There are two major types of making non-woven fabric, each with its own distinctive manufacturing process. In this article, we will explore these two types in detail, highlighting their differences and applications.

Spunbond Non-Woven Fabric

Spunbond non-woven fabric is produced using a continuous extrusion process. It involves the extrusion of thermoplastic polymers, such as polypropylene or polyester, through spinnerets to form fibers. These fibers are then laid down in a random arrangement onto a conveyor belt or a drum, where they are bonded together.

The first step in the spunbond process is polymer extrusion. The polymer is melted and forced through the spinneret, which contains numerous small holes. This causes the polymer to emerge as continuous filaments. These filaments are then solidified by cooling, usually through a cooling chamber or air quenching. The solidified filaments are collected on a moving belt or drum, forming a web of randomly-oriented fibers.

The next step is bonding. There are several methods for bonding spunbond non-woven fabric, including thermal bonding, chemical bonding, and mechanical bonding. Thermal bonding involves applying heat and pressure to the web, causing the fibers to melt and fuse together. Chemical bonding utilizes adhesive substances that are applied to the web, creating a bond between the fibers. Mechanical bonding involves the use of needles or barbed rollers to entangle the fibers, in a process known as needle punching.

Spunbond non-woven fabrics have many applications due to their excellent strength, stability, and uniformity. They are commonly used in industries such as healthcare and medical, agriculture, automotive, construction, and geotextiles. In healthcare, spunbond non-wovens are used for surgical gowns, masks, and drapes, providing a protective barrier against bacteria and viruses. In agriculture, they are used for crop covers, greenhouse shading, and groundcovers, offering protection and moisture control.

Meltblown Non-Woven Fabric

Meltblown non-woven fabric is manufactured through a unique and specialized process called meltblowing. It involves the extrusion of thermoplastic polymers at high temperatures to produce extremely fine fibers. These fibers are then laid down on a conveyer belt or drum, forming a non-woven web.

The process of meltblowing starts with polymer extrusion, similar to spunbond non-woven fabric. However, the extruded polymer is fed through a high-velocity air stream, which stretches and attenuates the fibers. The air blows the molten polymer into a fine fiber mesh, which is then rapidly cooled and solidified. The resulting fibers have micro-sized diameters, typically in the range of 1 to 5 microns.

After the fibers are formed, they are collected on a conveyer belt or drum. To enhance the strength and integrity of the fabric, the meltblown non-woven web is subjected to thermal bonding. Heat and pressure are applied, causing the fibers to melt and fuse together, forming a stable fabric structure.

Meltblown non-woven fabrics have exceptional filtration properties due to their fine fiber diameter and high surface area. They are widely used in applications that require efficient particle filtration, such as surgical masks, respirators, air filters, and oil absorbents. These fabrics can effectively capture and retain particles, including bacteria, viruses, and fine dust particles.

Comparison between Spunbond and Meltblown Non-Woven Fabrics

Spunbond and meltblown non-woven fabrics have distinct characteristics that make them suitable for different applications. Let's compare these two types:

1. Fiber Diameter: In terms of fiber diameter, meltblown non-woven fabrics have much finer fibers compared to spunbond fabrics. The fibers in meltblown fabrics are micro-sized, while spunbond fabrics have larger fibers. The fine fiber diameter of meltblown fabrics provides excellent filtration efficiency, whereas the larger fibers of spunbond fabrics offer enhanced strength and stability.

2. Filtration Properties: Meltblown fabrics are well-known for their superior filtration properties. The fine fiber diameter and high surface area allow meltblown fabrics to effectively capture and retain particles, making them ideal for applications requiring particle filtration. On the other hand, spunbond fabrics have lower filtration efficiency but offer better breathability and liquid resistance.

3. Manufacturing Process: The manufacturing processes for spunbond and meltblown fabrics are different. Spunbond fabrics are produced by extruding continuous filaments, whereas meltblown fabrics are formed by extruding and stretching fine fibers. Additionally, the bonding methods used in these fabrics vary. Spunbond fabrics can be thermally, chemically, or mechanically bonded, whereas meltblown fabrics are primarily thermally bonded.

4. Strength and Stability: Spunbond fabrics have better strength and stability due to their larger fiber diameter and random fiber orientation. They are highly resistant to tearing and stretching, making them suitable for applications that require durability. Meltblown fabrics have lower strength but possess excellent filtration efficiency. They are more delicate and may tear easily, requiring additional support in certain applications.

5. Applications: Both spunbond and meltblown non-woven fabrics find applications in various industries. Spunbond fabrics are commonly used in healthcare, agriculture, automotive, construction, and geotextiles, offering strength, stability, and protective qualities. Meltblown fabrics are predominantly used in filtration applications, including surgical masks, respirators, air filters, and oil absorbents, providing exceptional particle capture and retention.

Conclusion

In conclusion, non-woven fabrics are manufactured through two major types: spunbond and meltblown. Spunbond non-woven fabrics are produced by extruding continuous filaments and bonding them thermally, chemically, or mechanically. They offer excellent strength, stability, and uniformity, making them suitable for various applications. Meltblown non-woven fabrics, on the other hand, are manufactured by extruding and stretching fine fibers, followed by thermal bonding. They have finer fibers and exceptional filtration properties, making them ideal for particle filtration applications. Both types have their own unique characteristics and find extensive use in different industries. Understanding the differences between these two major types of non-woven fabric is crucial in selecting the most appropriate material for specific applications.

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