无纺布应用和制造工艺

NonwovenApplications&Processes无纺布应用和制造工艺ProductComponentsTechnologyMicrographsLinerFlap/SpacerStretchEarSurgeFasteningOutcoverSpunbondSMSNBLTABCWPUBSFLSidepanel(WaistElastics)SBLGowns&DrapesSMSSFLTextilesvsNonwovens纺织品与无纺布TRADITIONALTEXTILES:1)FIBERSTWISTED(SPUN)INTOYARNS2)YARNSAREMECHANICALLYINTERTWINEDTOPRODUCEASHEETWITHINHERENTSTRENGTHNONWOVENS:1)FIBERSAREFORMEDDIRECTLYINTOSHEETS2)SHEETSAREBONDEDTOPROVIDESTRENGTHA.MECHANICALLYFORMED-CARDING(COMBINGSTAPLEFIBERS)B.WET-FORMED-USESPAPERMAKINGTECHNOLOGYC.AIR-FORMED-FILTERINGSHOURTFIBERSFROMAIRDISPERSIOND.DIRECTLYSPUN-SINGLESTEPFIBER&WEBFORMING-CONTINUOUSFILAMENTSFOTHERMOPLASTICPOLYMERSWEBFORMATIONA.NEEDLEPUNCHING-ENTANGLEFIBERSTOGETHERC.SPUNLACED(HYDRO-ENTANGLING)-WATERJETSD.LATEXORRESINBONDINGE.THERMALBONDING-REQUIRESTHERMALPLASTICCOMPONENTWEBBONDINGNONWOVENPROCESSESWhyPolyolefin?1-Density(0.9g/cc)2-HygieneandDryness3-Cost($1.6/kg,￥10/kg)1.FiberOpening,Blending2.WebFormation(carding)3.WebStabilization(bonding)4.WebFinishingBONDEDCARDEDWEB(BCW)粘合梳理网,(热轧,热风)opening,blendingcoarseopeningfineopeningBCWPROCESScardingrawmaterialsbondingfinishingRAWMATERIALSSYNTHETIC•Homofiliament–polyester,polypropylene–polyethylene,rayon–nylon,acrylic•Bicomponent–PE/PP–PE/PET–PET/PETSheath/CoreSidebySideHomofiliamentRAWMATERIALPROPERTIESStapleLength25,50,75mmDeniergrams/9000meters0.5to16normalmicrodenier1macrodenier16Decitexgrams/10000meters3.0denier=3.3decitexBLENDINGThemostpowerfulcapabilityofBCWprocess+=BondedCardedWeb(BCW)ProcessSteps1.FiberPreparation2.WebFormation(carding)3.WebStabilization(bonding)4.WebFinishingCARDINGCardingtransformsafiberbattintoacontinuousweb.ThecarddoesthisbyworkingandstrippingthefibersworkingstrippingTypicalCardingActionSTEP3WEBSTABILIZATIONMechanicalHydroentangle,ultrasonic,needlepunch,stitchbondChemicalSaturation,spray,print,foam,powderThermalcalender,(TBCW)throughair(TABCW)STEP4WEBFINISHINGWindingSlittingSpoolingAirlaidProcess(空气铺网,无塵纸)PulpFiberThermalBinderFiberBondingOvenFormingHeadsCalenderRollFormingwire/VacuumOvenwireTypesofAirlaidMultibond-Latex/ThermalThermalbondcorewithlatexbondexteriorPositives•AllowsforhighBWlatexbondmaterial•Reduceslintingofthermalbondmaterials•PreventsSAPfalloutCrossSectionMaterialPropertiesUniformityHighabsorbencyHighmechanicalintegrity-x,y,zStructuralstability-porelevelHighwettabilityHighwetintegrityHighabrasionresistance-LatexbondedTechnologyOptionsFlexibilitytomakelayeredabsorbentcomponents32PulpBinderSAFPulpBinderSyntheticPulpBinder1PulpRichLayerSyntheticRichLayerSAPRichLayerSpunbondProcess(纺粘)DryerBlendingStationReceiverMixerHopperExtruderSpinBeamSlitter/WinderFinishingCalenderWebformerBank1Bank2PolymerPelletsExtruderFilterSpinPumpSpinPackPolymerProcessingHeating/CoolingHopper/DryerTPSpunbondSpinningQuenchAirSystemFiberDrawUnit(FDU)FumeExhaustLurgiProcess(Traditional)SpreadersGuideTubesGunsQuenchAirFumeExhaustWebformerSpinBeamLDS(LinearDrawSystem)Process(KCC,Reifenhauser)FumeExhaustSpinBeamDeflectorWebformerQuenchAirBondingDefinitionsTypesofThermalBondingCalenderPatternBondUltrasonicBondingThrough-Hot-AirBondingBONDPICTUREDBONDINGPATTERNSDesignedWithEndProductInMindNumber,Arrangement,AndSizeOfPinsDeterminesProductAttributesTrendIsTowardLower%BondedArea10-20%RangeBrandIdentificationHasBecomeImportantHANSENPENNINGPATTERNPUBPATTERNSurfacepropertiesofPParenotoptimumforanumberofnonwovenapplicationsPoorwettabilityforurine,menses,etc..PoordissipationofstaticchargeSurfactantareusedtoimpartfabrichydrophilicityIntakespeedDurabilitySurfaceTreatmentHighloftfiberSplitablefiberNewSpinningTechnologiesMELTBLOWNPROCESS(熔喷)Definition:Themeltblownprocessisaonestepprocessusedtoconvertthermoplasticresinsintofibrousnonwovenmaterialsandiscapableofproducingmicrofiberswithdiametersintheonetofivemicronrange.MBPROCESSPolymerisextrudedthroughalineararrayoforificesTwoconverginghighvelocityairjetsattenuatetheindividualpolymerstreamsintofibersFibersrandomlymixforminganonwovenwebMBEXTRUDERPOLYMERHOPPERDIEBODYPRIMARYAIRFILTERSPINPUMPDIETIPFORMINGWIRESingleBankMeltblownFormationMELTBLOWNPROCESSMBHeadMBCHARACTERISTICSMicrofiberstructuresarepossibleêFineporestructureêHighsurfaceareaêTortuouspathInitialintegritybutlowfinalstrengthLowabrasionresistanceMBMATERIALATTRIBUTESLiquidBarrierParticulateBarrier(FiltrationEfficiency)BreathabilityOpacitySMSLAMINATESAPPLICATIONSMedicalGownandDrapesSterileWrapIndustrialWorkwearLabCoatsCarCoversFilterMediaFaceMaskSMSMaterial(TopView)SMSMaterial(CrossSection)SMSLAMINATESProperties:Providesprotectionfromfluids,particles,dirt,andcontaminants,yetisbreathableandpermeabletoairorsterilantsinapplicationssuchashealthcaregowns,apparelanddrapes,andincarcovers,diaperoutercoversanddiapercontainmentflapsSMSLAMINATESKEYATTRIBUTES•Hydrohead-resistancetowater,urine•BloodStrikethrough-resistancetobloodpenetration•AbrasionResistance-propensitytolintordelaminateSMSLAMINATESPRODUCTAPPLICATIONS•InfantCare-DiaperContainmentFlaps(0.70osy20%MB)-Outercover(0.8osy)FacingPreventsBM/UrineleakageBreatha