Production technology

Spunlace ( Spunlace) is a technology for the production of non-woven fabric, which consists in the mechanical bonding of the fibers (threads) of the canvas into a fabric by means of hydro-weaving. The technology originated in the 60s of the last century, but was first officially introduced in 1973 by the companydupont (Sontara).Sontara is the result of activityDupont andChicopee, now the largest manufacturers of spunlace. Since 1990 this technology has been improved and made available to other manufacturers.

The hydroentangling technology is based on the interlacing of material fibers with high-speed water jets under high pressure. Usually tightly fastened on a perforated drum using high pressure water jets from the nozzle beams. Due to these jets, the fibers of the canvas are interconnected. As a result, the canvas obtained in this way has specific properties, such as: softness and drape.

In fact, spunlace technology is just one of the ways to bind the canvas. In turn, the canvas itself can be formed in various ways, including:

· Carding of staple fibers ( drylaid) . Refers to the dry method of forming the canvas. In this case, the web is formed from staple fibers and is formed as a result of carding of the original fibers on carding machines. The fibers are combed by the working bodies of the carding machine with a needle-like surface, and are placed in the canvas on the receiver. Schematically, this process is shown in Figure 2.

· Aerodynamic way of forming a canvas ( airlaid) ; This is the same dry way of forming a canvas (dry-laid ). However, with this method, the web is formed from very short staple fibers and is formed by the action of air flow on the surface of a perforated drum or mesh conveyor. The pre-opened and mixed fibers are processed by a fast rotating carding drum (or several drums), separated from the carding set by an air jet and transported.

· Hydraulic way of forming a canvas ( wetlaid).

This method is also called papermaking (borrowed from the paper industry). A feature of this method of canvas formation is that the production of non-woven fabrics occurs by pouring an aqueous suspension onto the wire part of the paper machine.

Figure 4

· Spunlade - Spunbond ( spunlaid- spunbond) ; With this technology, the canvas is formed from continuous threads (filaments) obtained from a polymer melt. The filaments are formed from the polymer by means of a spin-blown method and are laid almost simultaneously in the canvas.

Figure 5

I must say that initially all spunlace fabrics were produced mainly with the help ofdry-laid (dry) method of forming a canvas, i.e. before punching the canvas with water jets, it was formed by combing the staple fibers. However, now the situation is somewhat different. Fabric production volumes usingairlaid andwet-laid technologies are increasing. In addition, the world's leading manufacturersspunlace hardware (Rieter andFlessner) not so long ago were able to offer consumers equipment that combines two technologies -spunlaid (as a method of forming a web based on continuous filaments from a polymer melt) andspunlacing (as a way to bond canvas). This technology "spunbond-spunlace" promises to be very popular in the future, because obtained by this method of production, the product combines the properties of both technologies.

Thus, a typical spunlace production process consists of several stages, similar to most nonwoven fabric production technologies:

· Stock of fibers;

Formation of the web;

· Penetration of the fabric with jets of water;

· Drying of a cloth;

When passing through the water circulation system, the formed web (by any of the above methods) is first compressed in order to remove all possible air bubbles, and then sealed. The water pressure usually increases from the first to the last injector. The following can serve as approximate indicators for the hydroplexing process:

pressure at the level of 2 200psi (pounds per square inch);

· 10 rows of injectors;

· hole diameter in injectors - 100-120 micrometers;

distance between holes - 3-5 mm;

number of holes in one row (25 mm) - 30-80;

Tightly fastened with water jets on a perforated drum. The vacuum in the drum sucks out excess water from the web in order, firstly, to prevent waterlogging of the product, and, secondly, not to reduce the penetration force of the jet.

The perforated drum grate (conveyor grate) plays a very important role in the formation of the finished product. The pattern of the final canvas depends on the pattern of the lattice. The special design of the grid allows you to get a different surface structure of the canvas (corrugated, terry, "hole", etc.)

Figure 6 shows the modifications of the conveyor grids and the surface of the finished web, depending on them:

Figure 6. Types of lattice and finished canvas

Usually the canvas breaks through alternately from two sides. The canvas can pass through the jets of water a certain number of times (depending on the required strength of the canvas). The bonded fabric passes to the drying device, where it is well dried.

Under standard process conditions (6 rows (distributors) of jets, pressure 1500psi, density 68 g/m2) requires 800 pounds of water per 1 pound of product. Therefore, it is very important to develop a good filtration system capable of rationally supplying clean water, otherwise the injector holes may become clogged.

The advantages of this technology are as follows:

• No damage to the fibers (mechanical impact on the internal structure of the fiber);
• The technology allows the use of different types of fibers and their lengths
• The web forming speed is huge - 300-600 m/min;
• The production process is environmentally friendly
• By its principle, the technology is sterile;

Raw materials for the production of spunlace

The starting materials for the manufacture of spunlace fabrics are most often staple fibers obtained from viscose, polyester, polypropylene, cellulose, cotton.

Viscose

Synthetic fiber derived from pure cellulose.
The advantages of viscose materials are the same as those of natural fibers:

• pleasant to the touch;
• do not cause physiological reactions;
• have a high absorption capacity;
• easy to finish.

Cellulose

Cellulose fiber is a wood fiber that is made from wood and comes in rolls or bales.

Properties:

· hydrophilicity;

fast absorption and reliable retention of water and other liquids;

a renewable resource

Possibility of biodegradation

very favorable price compared to other natural and synthetic

fibers.

Polyester (polyester, PEF, PET, PET, polyethylene terephthalate)

Produced by melt forming process. Today, PET fibers form the largest group of synthetic fibers.

Properties

density 1.38;

· especially strong;

elastic;

Resistant to abrasion

· it is light-resistant;

Not affected by organic and mineral acids;

Water absorption is only 0.2 - 0.5%;

Wet strength is the same as dry strength.

Polypropylene (PP)

Synthetic fiber produced by a melt spinning process from isotactic polypropylene.

Properties:

lower density 0.91;

melting area 165-175°C;

Softening area 150-155°C;

The fiber is resistant to aggressive chemicals;

Practically there is no moisture absorption;

Reliable resistance to abrasion;

· sensitive to ultraviolet radiation;

Cotton

Cotton is a fibrous material that is widely accepted by consumers due to its natural origin.

Positive properties of cotton:

• absorption;
• biodegradability;
• gas permeability;
• ease of sterilization;
• heat resistance;
• high wet strength;
• good insulating properties;
• lack of allergic properties;
• the possibility of regeneration;
• softness.

Due to its high absorbency, good fabric-like structure with low linting and high wet strength, cotton is the best material for medical, technical, cosmetic, personal consumption and wet wipes applications. Spunlace cotton, besides the medical industry, can be successfully used for the production of sheets, napkins and tablecloths, which can withstand 6 to 10 washing processes. Products made with this method look like linen and can be dyed and printed to achieve the desired look.

As a rule, the above fibers are used in blends. Synthetic fibers (polyester and polypropylene) are mixed with viscose or natural fibers (cotton, cellulose). Also, any of the described fibers can be used alone without impurities.

In accordance with world practice, the following spunlace compositions have become widespread on the market:

viscose/polyester;

viscose / polypropylene;

· viscose;

polyester;

· cotton;

· polypropylene;

cotton/polypropylene;

cotton/polyester;

cotton/viscose;

· cellulose/polyester;

The composition of the spunlace determines the end use of the material. For the most popular spunlace products

Dry/Wet Wipers : polypropylene/polyester + viscose;

Wet wipes : polypropylene/polyester + viscose; polypropylene / polyester + viscose + cotton;

Clothing and underwear for operating rooms : polyester/polypropylene + viscose, cellulose + polyester; polypropylene / polyester + viscose + cotton;

Spunlace Properties

Thanks to the bonding with water jets, the spunlace nonwoven material acquires the unique properties of nonwoven materials, among which, first of all, it is worth highlighting:

· High degree of absorbency (high hygroscopicity);

· High air permeability (the highest among non-bulk nonwovens);

· Softness and good tactile sensations, close to natural fabrics.

In addition, the distinctive features and advantages of this nonwoven material are:

Combination of strength and thinness;

· Tear resistance;

· Lint-free structure;

· Non-toxicity;

· Antistatic;

· Good drapeability;

Dialergenicity;

Lack of peeling;

About Spunlace

The Spunlace manufacturing method is a technology for the production of non-woven fabric by tightly connecting fibers (threads) with high-pressure water jets, without the use of adhesives.

Properties: soft, lint-free material with high absorbency. It is used as a wiping material in everyday life and production in the form of napkins. High barrier properties that prevent the penetration of microorganisms to anything, which makes it possible to use it in medicine and cosmetology, as a material that reduces the infection of human tissues, compared to traditional cotton and linen fabrics, is 60% higher. The material, if necessary, is well sterilized.
All of the above properties make SPANLACE the most suitable material for the production of medical and hygienic products and wiping materials, napkins, towels . In addition, if cotton is included in the composition of the spunlace, then such a non-woven material of hydro-jet bonding can withstand repeated washing, it is very amenable to dyeing.

About Production Technology

Spunlace technology appeared in the 60s of the last century, but was first officially introduced in 1973 by DuPont (Sontara). Sontara is DuPont and Chicopee, now the largest spunlace manufacturers.

The hydroentangling technology is based on the interlacing of material fibers with high-speed water jets under high pressure. Usually tightly fastened on a perforated drum with high pressure water jets from nozzle beams. Due to these jets, the fibers of the canvas are interconnected. The canvas obtained in this way has specific properties such as softness and drape.

In fact, spunlace technology is just one of the ways to bind the canvas. In turn, the canvas itself can be formed in various ways, including:
Spunbond. With this technology, the canvas is formed from continuous threads (filaments) obtained from a polymer melt. The filaments are formed from the polymer by means of a spin-blown method and are laid almost simultaneously in the canvas.

This technology is becoming very popular, because the product obtained by this method of production has unique properties for all people with its low cost and practicality.
Thus, a typical spunlace production process consists of several stages, similar to most nonwoven fabric production technologies:

• Stock of fibers;
• Formation of the web;
• Penetration of the canvas with jets of water;
• Drying the canvas.

When passing through the water circulation system, the formed web (by any of the above methods) is first compressed in order to remove all possible air bubbles, and then sealed. The water pressure usually increases from the first to the last injector. The following can serve as approximate indicators for the hydroplexing process:

• pressure at 2,200 psi (pounds per square inch);
• 10 rows of injectors;
• hole diameter in injectors - 100-120 micrometers;
• distance between holes - 3-5 mm;
• the number of holes in one row (25 mm) - 30-80;

Tightly fastened with water jets on a perforated drum. The vacuum in the drum sucks out excess water from the web in order, firstly, to prevent waterlogging of the product, and, secondly, not to reduce the penetration force of the jet.
The perforated drum grate (conveyor grate) plays a very important role in the formation of the finished product. The pattern of the final canvas depends on the pattern of the lattice. The special design of the grid allows you to get a different surface structure of the canvas (corrugated, terry, in a "hole", etc.)
Usually the canvas breaks through alternately from two sides. The canvas can pass through the jets of water a certain number of times (depending on the required strength of the fabric). The bonded fabric passes to the drying device, where it is well dried.
Under standard process conditions (6 rows (distributors) of jets, pressure 1500 psi, density 68 g / m2), 800 pounds of water per 1 pound of product are required. Therefore, it is very important to develop a good filtration system capable of rationally supplying clean water, otherwise the injector holes may become clogged.
The advantages of this technology are as follows:

• No damage to the fibers (mechanical impact on the internal structure of the fiber);
• The technology allows the use of different types of fibers and their lengths
• The web forming speed is huge - 300-600 m/min;
• The production process is environmentally friendly

By its principle, the technology is sterile;

Raw materials for the production of spunlace

The starting materials for the manufacture of spunlace fabrics are most often staple fibers obtained from viscose, polyester, polypropylene, cellulose, cotton.

Viscose
Synthetic fiber obtained from pure cellulose.
The advantages of viscose materials are the same as those of natural fibers:

• pleasant to the touch;
• do not cause physiological reactions;
• have a high absorption capacity;
• easy to finish.

Cellulose
Cellulose fiber is a wood fiber that is made from wood and comes in rolls or bales.
Properties:

• hydrophilicity;
• fast absorption and reliable retention of water and other liquids;
• renewable resource;
• the possibility of biological decomposition;
• very favorable price compared to other natural and synthetic fibers.

Polyester (polyester, PEF, PET, PET, polyethylene terephthalate)
Produced by melt forming process. Today, PET fibers form the largest group of synthetic fibers.
Properties

• density 1.38;
• especially durable;
• elastic;
• resistant to abrasion;
• lightfast;
• not affected by organic and mineral acids;
• water absorption is only 0.2 - 0.5%;
• wet strength is the same as dry strength.

Polypropylene (PP)
Synthetic fiber produced by a melt spinning process from isotactic polypropylene.
Properties:

• lower density 0.91;
• melting range 165-175°C;
• softening area 150-155°C;
• the fiber is resistant to aggressive chemicals;
• practically no moisture absorption;
• reliable resistance to abrasion;
• sensitive to ultraviolet radiation.

Cotton
Cotton is a fibrous material that is widely accepted by consumers due to its natural origin.
Positive properties of cotton:

• absorption;
• biodegradable;
• gas permeability;
• ease of sterilization;
• heat resistance;
• high wet strength;
• good insulating properties;
• lack of allergic properties;
• the possibility of regeneration;
• softness.

Due to its high absorbency, good fabric-like structure with low lint release and high wet strength, cotton is the best material for medical, technical, cosmetic, personal use and wet wipes applications. Spunlace cotton, besides the medical industry, can be successfully used for the production of sheets, napkins and tablecloths, which can withstand 6 to 10 washing processes. Products made with this method look like linen and can be dyed and printed to achieve the desired look.
As a rule, the above fibers are used in blends. Synthetic fibers (polyester and polypropylene) are mixed with viscose or natural fibers (cotton, cellulose). Also, any of the described fibers can be used alone without impurities.
In accordance with world practice, the following spunlace compositions have become widespread on the market:

• viscose/polyester;
• viscose/polypropylene;
• viscose;
• polyester;
• cotton;
• polypropylene;
• cotton/polypropylene;
• cotton/polyester;
• cotton/viscose;
• cellulose/polyester.

The composition of the spunlace determines the scope of the material.
For the most popular spunlace products, you can note:
Dry or wet wiping materials : polypropylene or polyester + viscose;
Wet wipes : polypropylene or polyester + viscose; polypropylene / polyester + viscose + cotton;
Clothing and underwear for operating rooms: polyester or polypropylene + viscose, cellulose + polyester; polypropylene or polyester + viscose + cotton.

Spunlace Properties

Thanks to the bonding with water jets, the spunlace nonwoven material acquires the unique properties of nonwoven materials, among which, first of all, it should be noted:

• High degree of moisture absorption (high hygroscopicity);
• High breathability (highest among bulk nonwovens);
• Softness and good tactile sensations, close to natural fabrics.

It can be added that the distinctive features and advantages of this nonwoven material are:

• Combination of strength and thinness;
• tear resistance;
• Lint-free structure;
• Not toxicity;
• Antistatic;
• Good drape;
• dialergenicity;
• No peeling.

Material characteristic

• Lint-free structure - the material does not delaminate (does not loosen to threads) and does not leave lint, for example, when wiping
  The lint-free structure of the material allows the production of any shape and size of products from tampons to surgical gowns, linen sets, sets for surgeons, etc.
• High absorbency
  Modern technologies for processing natural cellulose make it possible to obtain products that replace gauze and cotton wool in medicine and surpass them, for example, in terms of absorbency (hygroscopicity)
• Antistatic
• Easily breathable
• Does not cause local irritating and allergic reactions upon contact with skin and mucous membranes
• Non-toxicity
• Does not lose its properties after sterilization
• Chemically pure and safe in medical use material
• white material
• different density.

At the moment, Spunlace non-woven material is used: 70% viscose + 30% polyester (polyester) of various densities.

There is a laminated spunlace:

Laminate is a thin moisture-proof film (polyethylene) applied to one side of the material (spunlace products).

The application of a laminated coating on the material significantly increases its functionality and expands the scope:
Laminated spunlace products on the one hand absorb liquids, and on the other hand they do not let them through.

Products have high moisture resistance, dry and wet strength and are used as oilcloth, surgical sheets, as well as for sewing protective overalls.

In 2014, our company made a huge leap in its development - the latest TRUTZSCHLER equipment for the production of non-woven fabric was purchased and launched in Germany spunlace .

This nonwoven material is obtained by interlacing the fibers of the canvas with high pressure water jets. The advantage of this method is the absence of adhesive chemicals, which ensures a high environmental friendliness of the process. The resulting soft, lint-free material is highly absorbent and is most suitable for use in the manufacture of wet wipes and in many areas of cosmetology, as well as medicine.

Our equipment, thanks to advanced carding and hydroweaving technologies, allows us to achieve a high degree of web uniformity and stable linear density.

Spunlace Wholesale

Looking for a reliable supplier? We offer non-woven fabric in rolls with delivery across Russia. Spunlace high density, non-stretching, hygroscopic can be used as disposable bed linen, towels, tampons and dressings. It is also suitable for the production of hospital gowns and caps, impregnated cosmetic wipes and other products.

We offer flexible prices for wholesale, uninterrupted supply, stable product quality. Contact the Grand AV manager to get the terms of cooperation and buy spunlace in bulk at the best price!

Production of non-woven fabric

The Spunlace manufacturing method is a technology for the production of non-woven fabric by tightly connecting fibers (threads) with high-pressure water jets, without the use of adhesives.

Properties: soft, lint-free material with high absorbency. It is used as a wiping material in everyday life and production in the form of napkins. High barrier properties that prevent the penetration of microorganisms to anything make it possible to use it in medicine and cosmetology, as a material that reduces the infection of human tissues, compared to traditional cotton and linen fabrics, this ability is 60% higher. The material, if necessary, is well sterilized.

Production technology.

Spunlace technology appeared in the 60s of the last century, but was first officially introduced in 1973 by DuPont (Sontara), now the largest manufacturer of spunlace.

The technology of hydroentanglement (Fig. 3.30) is based on the interlacing of material fibers with high-speed high-pressure water jets. Typically, the web is bonded to a perforated drum using high-pressure water jets from nozzle beams. Due to these jets, the fibers of the canvas are interconnected. The fabric obtained in this way has specific properties such as softness and drape.

In fact, spunlace technology is just one of the ways to bind the canvas. In turn, the canvas itself can be formed in various ways.

This technology is becoming very popular, because the product obtained by this method of production has unique properties and has a low cost and practicality.

Rice. 3.30. Spunlace technology

Thus, a typical spunlace production process consists of several stages, similar to most nonwoven fabric production technologies:

fiber feed;

Formation of the web;

Penetration of the canvas with jets of water;

Drying the canvas.

When passing through the water circulation system, the formed web is first compressed in order to remove all possible air bubbles, and then sealed. The water pressure usually increases from the first to the last injector. The following can serve as approximate indicators for the hydroplexing process:

Pressure at 2,200 psi (pounds per square inch);

10 rows of injectors;

Hole diameter in injectors: 100-120 micrometers;

Hole spacing: 3-5mm;

Number of holes in one row (25 mm): 30-80;

Tightly fastened with water jets on a perforated drum.

The vacuum in the drum sucks out excess water from the web in order, firstly, to prevent waterlogging of the product, and, secondly, not to reduce the penetration force of the jet. The grid of the perforated drum (conveyor grid) plays a very important role in the formation of the finished product. The pattern of the final canvas depends on the pattern of the lattice. The special design of the grid allows you to get a different surface structure of the canvas (corrugated, terry, in a "hole", etc.)
Usually the canvas breaks through alternately from two sides. The canvas can pass through the jets of water a certain number of times (depending on the required strength of the fabric). The bonded web is fed to a drying device, where it is well dried.

Under standard process conditions (6 rows of sprayers, 1500 psi, 68 gsm), 800 pounds of water per pound of product is required. Therefore, it is very important to develop a good filtration system capable of rationally supplying clean water, otherwise the injector holes may become clogged.

The advantages of this technology are as follows:

No damage to the fibers (mechanical impact on the internal structure of the fiber);

The technology allows the use of different types of fibers and their lengths;

High web forming speed - 300-600 m/min;

The production process is environmentally friendly

By its principle, the technology is sterile.

Raw materials for the production of spunlace.

The starting materials for the manufacture of spunlace fabrics are most often staple fibers obtained from viscose, polyester, polypropylene, cellulose, cotton.

Viscose
Synthetic fiber obtained from pure cellulose.
The advantages of viscose materials are the same as those of natural fibers:

Pleasant to the touch;

Do not cause physiological reactions;

Have a high absorption capacity;

Easy to finish.

Cellulose
Cellulose fiber is a wood fiber that is made from wood and comes in rolls or bales.

Properties:

hydrophilicity;

Rapid absorption and reliable retention of water and other liquids;

Renewable resource;

Possibility of biodegradation;

Very favorable price compared to other natural and synthetic fibers.

Polyester (polyester, PEF, PET, PET, polyethylene terephthalate)

Produced by melt forming process. Today, PET fibers form the largest group of synthetic fibers.

Properties:

Density 1.38;

Particularly durable;

Elastic;

Abrasion resistant;

Lightfast;

Resistant to organic and mineral acids;

Water absorption is only 0.2 - 0.5%;

Wet strength is the same as dry strength.

Polypropylene (PP)

Synthetic fiber produced by a melt spinning process from isotactic polypropylene.

Properties:

Lower density 0.91;

Melting range 165-175°C;

Softening area 150-155°C;

The fiber is resistant to aggressive chemicals;

Virtually no moisture absorption;

Reliable resistance to abrasion;

Sensitive to ultraviolet radiation.

Cotton
It is a fibrous material that is widely accepted by consumers due to its natural origin.
Positive properties of cotton:

Absorption;

Biodegradable;

Gas permeability;

Ease of sterilization;

Heat resistance;

High wet strength;

Good insulating properties;

No allergic properties;

Possibility of regeneration;

Softness.

Due to its high absorbency, good fabric-like structure with low linting and high wet strength, cotton is the best material for medical, technical, cosmetic, personal consumption and wet wipes applications. Spunlace cotton, besides the medical industry, can be successfully used for the production of sheets, napkins and tablecloths, which can withstand 6 to 10 washing processes. Products made with this method look like linen and can be dyed and printed to achieve the desired look.

As a rule, the above fibers are used in blends. Synthetic fibers (polyester and polypropylene) are mixed with viscose or natural fibers (cotton, cellulose). Also, any of the described fibers can be used alone without impurities.
In accordance with world practice, the following spunlace compositions have become widespread on the market:

Viscose / polyester;

Viscose / polypropylene;

Viscose;

polyester;

Polypropylene;

Cotton/polypropylene;

Cotton/polyester;

Cotton/viscose;

Cellulose/polyester.

Spunbond

Spunbond (eng. spunbond) - the name of the technology for the production of non-woven material from a polymer melt using a spunbond method. Often in a professional environment, the term "spunbond" also refers to material produced using the "spunbond" technology (Fig. 3.33).

The essence of the spunbond method is as follows: the polymer melt is released through the dies in the form of thin continuous filaments, which are then drawn in the air stream and, laid on a moving conveyor, form a web. The threads on the formed web are subsequently fastened together.

Rice. 3.33. Spunbond

The threads in the canvas can be fastened in several ways:

acupuncture;

Chemical impregnation of threads with binders;

Thermal bonding on the calender;

Water jet bonding;

Thermal bonding with hot air.

The most common bonding methods are calender thermal bonding and needle punching. The method of fastening the threads on the canvas determines the characteristics of the resulting material, and, consequently, the scope.

Production technology.

Fiber-forming polymers with a wide molecular weight distribution, such as polypropylene (PP), polyethylene terephthalate (PET), polyamide (PA), etc. are used as raw materials for the production of spunbond material. Polypropylene is most often used for the production of spunbond, since it allows you to get the most dense distribution of fibers in the canvas and provides a high production of fibers in terms of kilograms of raw materials.

The canvas formation process includes the following main steps:

Preparation and supply of polymer raw materials to the melting device.

Polymer melting and melt filtration.

Melt supply to the spinneret set.

fiber formation.

Aerodynamic drawing and air cooling of the fibers.

Laying the fiber on the conveyor to form the web.

Calendering and winding material.

Meltblown

In contrast to the technology for producing spunbond nonwoven materials based on drawing elementary fibers in an aerodynamic way with their simultaneous cooling, the meltblown technology involves the formation of fibers by blowing the molten polymer (spunbond technology) with hot air directly onto the layout conveyor table.

The process of forming a web of meltblown nonwoven materials can be divided into several stages (Fig. 3.36):

1. Supply of polymer raw materials in the form of granules ( 1 ) to the melting device (melting head or extruder 2 );

2. Melting of the polymer and filtration of the melt ( 2 );

3. distribution and dosed supply of the melt to the spinneret set ( 3 );

4. Blowing out filaments in a high-speed hot air stream ( 4, 5 );

5. Deposition of fibers on the receiving surface ( 6 );

6. Material winding ( 7 ).

Meltblown technology makes it possible to obtain non-woven materials with the thinnest fibers and their uniform arrangement in the canvas. These characteristics give the material high filtration and absorption characteristics.

Another distinctive feature of the "spunbond" technology is that the fibers in the spunbond method for producing nonwoven materials, after deposition on the receiving and transporting surface, do not need additional bonding. The fibers in the canvas are held together naturally by the stickiness of the hot polymer.

Rice. 3.36. Meltblown nonwoven web forming process

The material obtained by the meltblown technology is characterized by the following indicators:

a wide range of densities;

· high degree of distribution of elementary fibers in a cloth;

· isotropy of material properties in longitudinal and transverse directions;

· high filtering properties;

absorbent properties, etc.

It is worth noting that this material is widely used in such areas as the production of hygiene products, the production of sterile and non-sterile medical devices, the production of booms and means for collecting pollutants.

But more often, Meltblown nonwoven material is used as one or more layers in the composition of composite materials SMS, SMMS, which also include layers of spunbond nonwoven material.

The production of nonwoven materials is one of the most promising areas of the textile industry. Over the past 10 years, it has grown in volume by almost 3 times. Such high growth rates of production are explained by the use of cheap and fast methods for producing textile fabrics:

• Spandbond (from polymer melt);
• Spunlace (fixing fibers with water jets);
• SMS (blown polymer).

Being environmentally friendly, sterile and chemically inert products, non-woven materials are widely used in the medical industry (obstetrics, gynecology, surgery). They have acquired high protective properties due to the coating with polymeric compositions, which is especially important when used under sterile conditions. Today, disposable clothing, sheets, napkins, towels, masks and much more are produced from nonwovens.

Spunbond

This non-woven thermally bonded material, consisting of the finest polypropylene threads, is the main one in the production of disposable clothing and underwear. Its advantages include bioinertness, strength and affordable cost. The most popular in Russia is spandbond based on polypropylene. Mandatory steps in its production are antistatic and bactericidal treatment.

At a density reaching 42 gr./m2, spunbond is characterized by high moisture and air permeability, ease of sewing. Spunbond can be welded, it is also possible to print on its surface. Non-toxicity and hypoallergenicity, the possibility of sterilization and a wide color palette perfectly explain its prevalence.

Spunlace

The material is produced by interlacing fibers of polyester, viscose, polypropylene, cellulose with high-pressure water flows. The most popular in Russia is spunlace based on viscose. The main characteristics of the material are:

• Elasticity,
• Strength,
• Ease,
• environmental friendliness,
• hygroscopicity,
• volume,
• barrier properties;
• Lack of lint.

Distinctive characteristics of spunlace can be called the optimal ratio of thinness and strength, non-toxicity and antistatic properties. According to the degree of moisture absorption, spunlace is not inferior to cotton wool and gauze. Disposable napkins and towels made of this material are pleasant to the touch, do not cause allergic reactions and irritations. The density of spunlace used in the production of disposable medical clothing and consumables varies in the range of 30-80 g/m2.

SMS

SMS is a spunbond composite. For all 100% it consists of polypropylene fibers. A distinctive feature of this material is that between the 2 layers of spunbond there is a layer of meltblown. SMS is distinguished by high absorbent properties, while it does not allow biologically active liquids, chemical compositions, and fats to pass through. In its pure form, it is used to collect oil slicks from the surface of the water.

SMS is widely used in the production of disposable medical clothing. In comparison with the traditional spunbond, the antibacterial properties of SMS are 7-10 times higher. Also, this material perfectly copes with the role of a filter element in protective masks. It is used to make headrests in trains and planes, sets of disposable bed linen for hotels, and much more.