How is the manufacturing process of Spunbonded No-woven Fabric?

The manufacturing process of spunbonded non-woven fabric involves several steps that transform synthetic polymer fibers into a cohesive and continuous sheet of fabric. Here's an overview of the typical process:

1. Polymer Extrusion:

The process begins with the extrusion of synthetic polymer pellets, such as polypropylene (PP) or polyester (PET), into a molten state. The molten polymer is then forced through spinnerets, which are small holes arranged in a pattern. These spinnerets are similar to a showerhead, allowing the molten polymer to exit in multiple fine streams.

2. Filament Spinning:

As the molten polymer streams exit the spinnerets, they are rapidly cooled, solidifying into continuous filaments. These filaments are collected onto a moving conveyor belt or forming surface.

3. Web Formation:

The collected filaments are laid down in a random or controlled arrangement on the conveyor belt, forming a loose web of fibers. The web's density and uniformity can be controlled by adjusting the speed of the conveyor belt and the rate of filament deposition.

4. Bonding:

The loose fiber web passes through a bonding process, where the individual filaments are bonded together to create a cohesive fabric structure. Bonding can be achieved through various methods:

Thermal Bonding: Heat is applied to the fiber web, causing the polymer filaments to partially melt and fuse together at their contact points.

Chemical Bonding: A bonding agent or adhesive is applied to the fiber web, which reacts with the polymer and creates bonds as it cures.

Mechanical Bonding: Needles or other mechanical means are used to physically entangle and interlock the fibers, creating a bonded structure.

5. Cooling and Finishing:

After bonding, the fabric may pass through a cooling section to solidify the bonds and set the fabric's structure. Additional finishing processes, such as calendaring (pressing between heated rollers) or coating, may be applied to enhance properties like smoothness, texture, water resistance, or other functionalities.

6. Winding and Cutting:

The final bonded fabric is wound onto rolls for storage or further processing. It can then be cut into desired widths and lengths for various applications.

The spunbonded non-woven fabric manufacturing process is known for producing fabrics with high strength, durability, and uniformity, making them suitable for a wide range of applications, including medical, hygiene, geotextiles, automotive, and more.