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difference between spunbond and meltblown
Spun-bonded non-woven fabrics are laid after the polymer has been extruded and stretched to form continuous filaments. The filaments are laid into a web, and the web is then subjected to self-adhesion, thermal bonding, chemical bonding, or mechanical reinforcement. The web becomes a non-woven fabric.
Melt-blown nonwoven fabric
The process of meltblown nonwoven fabrics: polymer feed - melt extrusion - fiber formation - fiber cooling - web formation - reinforcement into cloth.
The spun-bonded filaments do not have the fineness of the melt-blown method, and the reason is the production process.
difference between spunbond and meltblown
Meltblown is known as ultra-fine fibers.
There are many manufacturing processes for the manufacture of nonwoven fabrics, of which the spunbond process is one of the non-woven fabric manufacturing processes spun-bonded nonwoven fabrics (including spunbonded, melt-blown, hot-rolled, and ladle processes). Most of the nonwovens in the market are spun-bonded non-woven fabrics, which are mainly polypropylene (PP), polyester (PET), nylon (PA), viscose, acrylic, and B. Polyester (HDPE), Polyester (PVC).Spun-bonded non-woven fabrics: Spun-bonded non-woven fabrics are formed by continuous filaments after the polymer has been extruded and stretched. Self-adhesive, thermal-bonding, chemical-bonding or mechanically reinforcing methods make the web a non-woven fabric.
Development Status and Trends of Spunbond, Meltblown Technology and Equipment
Spunbond
difference between spunbond and meltblown
Through the analysis of mature and advanced spunbond technologies abroad, spunbond equipment should be developed to high quality, high efficiency, fine denier, differential, dual component, and multi-functionality, and at the same time, the flexibility of the equipment structure must be increased and the equipment structure must be raised and lowered. Features.
(1) High-efficiency, high-quality production technology
Rieter Perfojet's PERFObondTM spunbond nonwovens line produces high-quality products in a low-energy, flexible process configuration, with filament diameters of 10 to 40 μm and MD/CD close to 1. In PET spunlaid webs, spinning speeds range from 5 000 to 6 000 m/min, and the broken filaments must not exceed one time per 24 h. Under the conditions of high quality and low energy consumption, improving production efficiency is an important aspect that people are concerned about. For example, Oerlikon Neumag's AST production line can provide up to 3 sets of boxes when spinning PET products, with a drawing speed of 8 000 m/min, a line speed of 600 m/min, and a spinneret hole density of 8,000 holes/m. Its spunbonded nonwovens production line, which is supplied to Albis, Italy, is the world's largest spunbond production line, reaching 7 m. Table 5 shows the performance of several representative spunbond equipment.
(2) Composite Technology
difference between spunbond and meltblown
Composite technologies include the compounding of raw materials and the combination of processes. From the point of view of changes in spunbond technology and market demand that have arisen at home and abroad, spunbond production will enter the stage of two-component or multi-component, multi-functional, ultra-fine spunbond nonwovens. There are five major types of bicomponent fibers currently in use, including skin core type, side-by-side type, sea-island type, segmented pie type, and mixed fiber type.
Since the 1980s, bicomponent spunbonded nonwovens have received attention. At present, two-component products account for approximately 12% to 15% of spunbonded nonwovens and are expected to increase at a rate of 15% to 20% per year in the future. According to Chisso Polypro Fiber Co., Ltd. of Japan, the current global production of bicomponent fibers is approximately 236,000 t. Of which, 80,000 t are produced in Japan, 40,000 t are produced in the United States, 35,000 t are produced in Europe, and the entire Asian production About 2/3 of the world's total production.
Hills (USA) has accumulated rich experience in the development of bicomponent spunbonded nonwovens and completed the construction of more than 30 bicomponent spunbonded nonwovens production plant projects. Recently, Hills has developed an industrial-scale island-type spunbonded two-component production line with a diameter of up to 2 μm. The two-component Reicofil spunbond line meets the needs of developing thin and ultra-thin products.
In the aspect of compounding between processes, Reifenhauser's multi-cassette compound product for spunbonded nonwoven fabrics can reach 7 layers; Italian Fare's multi-cassette composite product can achieve 6 layers; USA Alex Jemas & Associate provides 3 sets of boxes and 3 types of polymer processing lines with a processing speed of 300 m/min. The 4-cassette composite spinning non-woven equipment from Italy's Meccaniche-Moderne company has a width of 1 to 4 m. Up to 150 to 1 000 kg/h, equipped with 4 extruders, can simultaneously spin 4 different polymers.
The composite technology of spunbond + spunlace is a new combination of strength and strength. It is used to dry PA, PP, or PET slices, and the extruder melts and filters them. Two different melts are injected into the segment. Spinning in the module, and then air-drawing, lapping into the spunlace machine, using high-pressure water to disperse the fiber segment of the fiber to make ultra-fine fibers, dried into a roll and become ultra-fine fibers Weaving cloth.
Spunlace fiber nonwoven fabric is a high-grade material, mainly used in high-grade fabrics, high synthetic leather fabrics, high-precision filter materials, clothing and other aspects. Since the production of cloth is done once from the beginning of the slicing, the production cost of this emerging non-woven fabric is much lower than that of other microfiber fabrics. The international price is approximately 10,000 Euro/t, and it is more environmentally friendly. The economic benefits are considerable. The economic benefits of a spunbond/spunlace nonwoven fabric production line are even stronger than those of 10 ordinary spunbonded nonwovens production lines.
difference between spunbond and meltblown
In early 2007, Oerlikon Neumag's first non-woven composite production line began industrial production. The introduction of the production line is the German company Ascania Vliesstoffe, which uses a production line width of 4 m and uses three different molding processes: one is Oerlikon Neumag's two-component spunbond die, and the other is M&J's airlaid. The forming head and a carding machine form a three-layer web (SPC) reinforced with Fleissner's AquaJet spunlace equipment. Compared with the traditional production process, this composite process not only optimizes the product quality and characteristics, but also improves the cost structure.
The S PU Nj e t ? technology developed by R i e t e r P e r f o j e t is a spunbond nonwoven fabric production line of PERFObondTM 3000.
JETlace? 3000 spunlace equipment complex production line. In April 2007, RKW expanded its non-woven fabric production capacity at its Gronau plant in Germany by purchasing a SPUNjetTM production line. Recently, the production line has produced the first non-woven fabric products, and can enter the mass production stage within a few months. Excellent product quality, more fluffy, softer, high tensile strength, MD/CD close to 1, its product weight is 20 ~ 300 g/m2, mainly used in medical, health, roofing materials, geotextiles and other fields.
Meltblowing
In terms of meltblown equipment, Oerlikon Neumag's J & M meltblown equipment has an excellent price/performance ratio after being upgraded. It can be used as part of a spunlace production line or as a stand-alone solution. The company plans to add a set of meltblown equipment on top of the original equipment and transform it into a double box. It is expected that the new production line will be open to customers in mid-2009.
difference between spunbond and meltblown
PGI recently developed a patented technology for the production of microfibers that utilizes a one-step melt film fibrillation process to produce nonwoven webs, where more than 99% of the fibers are submicron in size. The technology is highly efficient and cost-effective, and its core lies in the design of multi-stage nozzles, in which the polymer film is fibrillated and detached from the hot zone using compressed air. The resulting web is uniform and of high quality. The technology is suitable for processing a variety of polymer raw materials, the diameter of loose fibers obtained is 0.3-0.6 μm, and the weight of the fiber web is 0.1-200 g/m2. In addition, such microfibrils or meltblown fibers can exhibit a one-component or multi-component structure, and their non-woven fabric products have excellent barrier properties, liquid absorption and opacity, and are soft and comfortable to handle.
Biax-Fiberfilm also successfully introduced melt-blown technology that can produce PP fibers with a diameter of less than 1 μm. With this technology, non-woven fabric manufacturers can produce products with better filtration and shielding properties. At the same time, the company also introduced a proprietary process for the production of meltblown cellulose fibers, a process that will provide a new approach to the application of cellulose fibers in the melt blowing field. At INDEX08, Biax and Recofil announced that they will jointly develop a "turnkey" production line for the production of meltblown Lyocell nonwovens. According to the plan, the test line width is 1 m, and the fiber has a wide range of fineness, from ultra-fine fibers to fibers with larger deniers, and its products can be 100% degraded and applied in many fields. Both parties plan to introduce the industrial production line to the market in early 2009.
difference between spunbond and meltblown
The use of patented "thin metal plate" extrusion dies by Hills, USA has made a new leap in the fineness of meltblown nonwoven fibers. The company uses high melt index PP and special dies to produce meltblown fibers with average denier up to 250 nm, with fiber deniers ranging from 25 to 400 nm. In order to produce such microfibers at a reasonable production rate, the special die employs spinneret orifices of up to 100 holes/inch or more, and also has a large aspect ratio. These process conditions allow the meltblown fibers to reach a fineness that can only be achieved by electrospinning.
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