A brief discussion on the development trend of spunbond technology
The spunbond method is a comprehensive technology involving many disciplines. Spunbond technology is developing rapidly, and several unique process production models have been formed. We should strengthen development efforts, continue to innovate, and form our own proprietary technology and intellectual property rights as the fundamental way for enterprises to remain invincible.
1 Large plate and narrow width
Because the surface of the products produced by the large plate mode is uniform, it is suitable for medical and sanitary products. Since most of these products are colored, due to the narrow-width production line output Low, install several narrow and small lines, each line produces one color, minimize transition color products and improve economic benefits.
2 Small board width
The small board mode has a small difference in vertical and horizontal strength of the web. The product is suitable for waterproof base fabrics and packaging materials. Most of these supplies are colorless. The processing cost of wide-width large-plate spinnerets has doubled. The production line with a width of 5.lm has been put into operation. At present, domestic high-output extruders have been industrialized, and the manufacturing technology of wide-width hot rolling mills has matured. It is also possible to manufacture production lines with a width of 6.4m and 9.6m and an annual output of tens of thousands of tons. It is estimated that the electricity consumption of a production line with a single die head with a width of 6.4m and an output of 20,000 t/a reaches 450Kwh; the electricity consumption of a production line with a double die head with a width of 3.2m and an output of 15,000 t/a in the large plate mode reaches 434Kwh.
With the rapid development of the nonwovens industry in recent years, the number of spunbond line production has expanded rapidly, and improving the production capacity of stand-alone equipment has become a focus. Although there are some difficulties in the design and manufacturing of wide-width high-speed production lines, high-output production lines play a positive role in reducing processing costs and large-scale management of the entire industry, and enable production companies to bring considerable economic benefits in market competition. For example, in the 1970s, the output of small-scale chemical fertilizers was 3,000 t/a, and later developed into a large-scale ammonia synthesis device of 300,000 t/a; the output of small-scale papermaking was originally several thousand tons, but in recent years, 400,000 t/a paper machines have appeared. This is the trend of social development and the inevitable result of market competition and technological progress.
3 Spunbond and Meltblown Lamination
Spunbond and Meltblown Lamination (SMS) produces nonwovens that are suitable for all uses from filter materials to sanitary covering materials. This method makes full use of the advantages of both and overcomes their shortcomings. The nonwoven fabric produced has the fine denier, good filterability, and soft feel of melt-blown fibers, as well as the high strength of spunbond continuous filaments. Features.
4 Polyester tubular drafting
Due to the high requirements for polyester spinning speed, the air for polyester spunbond drafting requires higher pressure and more flow, and the drafting power consumption accounts for The proportion of total power consumption is relatively large. Since tubular drafting consumes less air, most polyester spunbonds use tubular drafters from the perspective of energy saving.
5 Orange petal fiber spunbond spunlace
The superfine fiber nonwoven fabric obtained by spunbond orange petal fiber filament through spunlace is used in wipes, medical and health care due to its good performance. products and base fabrics for high-grade synthetic leather. For example, Freudenberg’s Evolon belongs to this product. The fiber fineness of this product is between 0.05 and 0.13 dtex. Such ultra-fine fibers cannot be directly spun from the spinneret. They are orange petal fibers through the spunlace process. Split, the ultra-fine short fibers in carded webs in the past were obtained by dissolving one component of sea island or orange petal fibers.
When orange petal short fibers are carded and spunlaced, when the adhesion is low, it is easy to cause fiber cracking and knotting during the carding process. When the adhesion is high, although the fiber carding performance can be improved, the spunlace process Fibers are less likely to split. The two stages of carding and spunlace processes have conflicting requirements for the adhesion of orange petal short fibers.
Spunlace products have good flatness and uniform product density, and will not damage the fibers like the needle punching process. Spunbond is much stronger than carded nonwovens. The combination of spunbond and spunlace produces microfiber nonwovens. It is a continuous production process from polymer slices to the final product. When the spunbond fiber web made of lightly bonded orange petal fibers is spunlace, it is not only used To wind fibers and also to split orange fibers. The fiber web consolidation and fiber splitting are completed at one time, which greatly reduces the processing cost of the product, avoids the environmental problems caused by the use of chemicals for treatment, and also solves the difficulty of processing ultrafine fibers on a carding machine.
Split microfiber is also called orange petal fiber or split fiber. It is named because its cross section is like a transversely cut orange. It uses the same spinning component to combine two fiber-forming polymers with different properties. It is ejected from the same spinning hole. Due to differences in modulus, elongation and shrinkage, the two fiber-forming polymers are prone to separation at the interface when subjected to external forces. The surface of the orange flap fiber should have wrinkles and convexities, and the two thermoplastic polymers bond to each other in the concave areas of the wrinkles rather than at the ridges. The energy of high-pressure hydroentanglement can concentrate and effectively act on the recesses of the orange petal fibers, making the fibers easy to split. In order to make the cracking effect better, hollow orange petal fibers can also be made.
Currently, the more common orange-petal fibers have 16 or 32 petals. Usually, products with low areal density less than 120g/m2 are mostly produced by hydroentanglement process, while products with areal density above 250g/m2 are generally produced by needle punching process.
Obtaining good web entanglement effect of high-performance nonwoven fabrics depends on the fineness, strength and elongation of the filaments in the spunbond process, the uniformity and longitudinal and transverse strength of the web, and the spunlace process. water pressure,�The hole diameter, hole density, hole shape, and number of spunlace heads of the needle plate.
To produce high-quality microfiber spunbond spunlace nonwovens, the fiber opening rate should be 60% or higher, so that the existing part of the thick fibers in this nonwoven fabric can have a high It is strong and has a large amount of fine fibers to obtain the desired feel and other properties.
The combination of spunbond and spunlace technology to produce microfiber nonwovens is a perfect match. It can also be said to “kill two birds with one stone”. It is an appropriate and economical process. When the two processes have the same high production capacity and are combined, the production of spunbond spunlace nonwovens will become efficient and low-cost, and will produce a new generation of high-quality nonwoven products.
Ultra-fine spunbond spunlace is an innovative technology. The fiber web can be formed and entangled quickly, with large width, high output, low production cost and high productivity. Moreover, there are no rolled spots on the cloth surface, and the product feels soft, has good breathability and high strength. Ultra-fine spunbond spunlace nonwovens are products with greater development potential in the future market.
AA
Disclaimer:
Disclaimer: Some of the texts, pictures, audios, and videos of some articles published on this site are from the Internet and do not represent the views of this site. The copyrights belong to the original authors. If you find that the information reproduced on this website infringes upon your rights, please contact us and we will change or delete it as soon as possible.
AA
