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In the web formed on the spun-melt nonwoven production line, the fibers mainly overlap each other in the plane, and the bonding force in the vertical direction is very low, and it can hardly withstand the external force from any direction, and does not have Practical application value. Therefore, an appropriate web consolidation process must be employed to strengthen the bond between the fibers, making the web a nonwoven having a certain vertical (MD) cross direction (CD) direction.
Consolidation method of fiber web
There are many ways to consolidate the fiber web, except that the web of the melt-blown nonwoven fabric is bonded by its own residual heat. The common consolidation methods of the spunbonded fiber web are hot rolling, needle punching and hydroentangling. Wait.
Hot rolling and needle-punching consolidation are two of the most common conventional reinforcement processes used in spunbond lines. Most lightweight and non-woven products are produced by hot rolling. The PET production line for producing medium-thick products mostly uses acupuncture method. When the product is more than 200g/m2, it is basically acupuncture reinforcement.
In practical applications, a production line can be equipped with a variety of consolidation equipment to select different consolidation processes as needed. In addition, it is also possible to use a consolidation process combining acupuncture reinforcement and hot rolling reinforcement in the spunbond production line. For example, in the production of medium-thick PET products, a consolidation process of hot rolling and post-needle is adopted.
In the PP spunbond line, in addition to the traditional hot-rolling method for consolidating the web, the hydroentangled system can be used to fix the web with water pricking, or two different consolidation methods can be used at the same time. Hot-rolled, post-spun two-step consolidation process.
Melt-blown nonwovens rely on the residual heat of the fibers to bond to each other, usually without the need to separately configure the fiber consolidation equipment in the production line. However, in the production of some special-purpose products, such as to increase the strength of the product or to avoid fiber shedding, melt-blown nonwovens are sometimes reinforced by hot rolling.
Effect of consolidation method on product performance
Different consolidation methods have a major impact on product performance, especially mechanical properties. Quantitatively the same spunbonded nonwoven fabric, when consolidated by needle punching, because some of the fibers are pierced by the needle during the needling process, the breaking strength is low; when using hydroentanglement, due to the fiber Keeping intact and continuous water flow, the entanglement point of the fiber web will be much more than that of the needle punching method, so the breaking strength will be much higher; when using hot rolling consolidation, the fiber concentrates around the pressure point due to stress concentration. Moreover, due to the high temperature, the fiber also has a certain degree of embrittlement, so the breaking strength of the hot-rolled spunbonded fabric is lower than that of the spunlace, but the elongation at break is smaller than that of the spunlace.
In the process of consolidation of acupuncture or hydroentanglement, since the web is not subjected to high-strength rolling, the product is relatively bulky, and the hand feeling and gas permeability are also better than the hot rolling method.
When the two processes are used to consolidate the web, the product combines the advantages of both processes with distinctive properties. If the two-step consolidation process of hot-rolling and post-spunging is used, the product can be made to have higher strength, and the hot-rolling point can be pierced by hydroentanglement, so that the product has an ultra-soft hand.
Effect of consolidation method on product cost
Due to different consolidation methods, the process is different, and the equipment purchase cost, installation cost and operation management cost are also greatly different, which will have a greater impact on the cost of the product.
When the production line adopts the hot rolling consolidation process, the equipment configuration is simple, the process is mature, and the operation management cost is also small, which is a consolidation process widely used.
When the acupuncture consolidation process is adopted, the speed of the production line is limited, the movement mechanism of the needle-punching machine is more, and the wearing parts are also more, which takes more workshop space than the hot-rolling process, and the operation management cost is large.
When the hydroentanglement consolidation process is adopted, the equipment is complicated, the system is complicated, the installation capacity is large, the purchase cost is high, and the production line needs to occupy a large number of sites. Among them, the water treatment device also has environmental protection problems and more consumable parts. Operation management costs are large.
Dongyang Laichi Environmental Protection Technology Co., Ltd. is based on the concept of “Seiko Quality, Fine Service”. The main production and operation: spunbond non-woven fabric, elastic non-woven fabric, medical non-woven fabric, SSS non-woven fabric, SMS non-woven fabric, etc. , is a professional non-woven fabric manufacturer.