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1、Nonwoven Applications&Processes 无纺布应用和制造工艺无纺布应用和制造工艺 Product Components Technology Micrographs Liner Flap/Spacer Stretch Ear Surge Fastening Outcover Spunbond SMS NBL TABCW PUB SFL Side panel(Waist Elastics)SBL Gowns&Drapes SMS SFL 产品组分内衬垫片拉伸耳冲击紧固外罩侧幅（腰部松紧带）手术服&消毒被单纺粘法纺粘-熔喷-纺粘 复合工艺熔喷法气流成网粘结梳理纤维网PUB粘
2、合剂丁苯胶乳固体膜润滑剂工艺微观图纺粘-熔喷-纺粘 复合工艺固体膜润滑剂Textiles vs Nonwovens 纺织品与纺织品与无纺布无纺布 TRADITIONAL TEXTILES:1)FIBERS TWISTED(SPUN)INTO YARNS 2)YARNS ARE MECHANICALLY INTERTWINED TO PRODUCE A SHEET WITH INHERENT STRENGTH NONWOVENS:1)FIBERS ARE FORMED DIRECTLY INTO SHEETS 2)SHEETS ARE BONDED TO PROVIDE STRENGTH 传统纺
3、织品1）纤维缠绕成纱2）纱线机械性的交织在一起，产生富有内在力的网无纺布1）纤维直接形成纤维片材2）片材粘合形成一定强度的网A.MECHANICALLY FORMED -CARDING(COMBING STAPLE FIBERS)B.WET-FORMED -USES PAPER MAKING TECHNOLOGY C.AIR-FORMED -FILTERING SHOURT FIBERS FROM AIR DISPERSION D.DIRECTLY SPUN -SINGLE STEP FIBER&WEB FORMING -CONTINUOUS FILAMENTS FO THERMOPLASTI
4、C POLYMERS WEB FORMATION 成网A.机械成型-梳棉（精梳短纤维）B.湿法成型-使用造纸技术C.气流成型-空气分布系统过滤超短纤维 D.直接纺纱-纤网一步成型-连续纤维热塑性聚合物A.NEEDLE PUNCHING -ENTANGLE FIBERS TOGETHER C.SPUNLACED(HYDRO-ENTANGLING)-WATER JETS D.LATEX OR RESIN BONDING E.THERMAL BONDING -REQUIRES THERMALPLASTIC COMPONENT WEB BONDING 粘合A.针刺法-将纤维缠绕在一起C.水刺法-水刺头
5、（水射流）D.橡胶或树脂粘合E.热粘合-需要热塑性组件NONWOVEN PROCESSES Why Polyolefin?1-Density (0.9 g/cc)2-Hygiene and Dryness 3-Cost ($1.6/kg,￥10/kg)无纺布工艺为何选择高聚物聚烯烃？1-密度（0.9g/cc）2-卫生 干燥3 -成本（1.6 美元/k g，1 0 元/k g）1.Fiber Opening,Blending 2.Web Formation (carding)3.Web Stabilization (bonding)4.Web Finishing BONDED CARDED WE
6、B(BCW)粘合梳理网粘合梳理网,(热轧热轧,热风热风)1.开棉，混棉2.成网（梳理）3.网加固（粘合）4.后整理opening,blending coarse opening fine opening BCW PROCESS carding raw materials bonding finishing BCW（粘合梳理纤网法）制程开棉，混棉粗开棉精开棉粘合后整理原材料梳理RAW MATERIALS SYNTHETIC Homofiliament polyester,polypropylene polyethylene,rayon nylon,acrylic Bicomponent PE/P
7、P PE/PET PET/PET Sheath/Core Side by Side Homofiliament 原材料合成物单组份纤维-聚酯，聚丙烯-聚乙烯，人造纤维-尼龙，丙烯酸双组分纤维-PE:高聚物聚乙烯-PP:高聚物聚丙烯-PET:聚对苯二甲酸乙二醇酯外壳/核心并排单组份纤维RAW MATERIAL PROPERTIES Staple Length 25,50,75 mm Denier grams/9000 meters 0.5 to 16 normal microdenier 16 Decitex grams/10000 meters 3.0 denier =3.3 decitex
8、原材料性质纤维长度纤度分特（纤维纤度国际单位）g/9000m正差值：0.5-16细旦1粗旦16g/10000m3.0旦尼尔=3.3分特BLENDING The most powerful capability of BCW process+=混棉BCW（粘合梳理纤网法）制程的最大能力Bonded Carded Web(BCW)Process Steps 1.Fiber Preparation 2.Web Formation(carding)3.Web Stabilization (bonding)4.Web Finishing BCW制程步骤1.纤维准备过程2.成网（梳理）3.网加固（粘合）4
9、.后整理CARDING Carding transforms a fiber batt into a continuous web.The card does this by working and stripping the fibers working stripping Typical Carding Action 梳理梳理过程将零散的纤维絮整合为连续的网，该过程由梳棉机不断工作和剥取来实现。工作剥取典型梳棉行为STEP 3 WEB STABILIZATION Mechanical Hydroentangle,ultrasonic,needlepunch,stitchbond Chemi
10、cal Saturation,spray,print,foam,powder Thermal calender,(TBCW)through air(TABCW)第3步 网加固机械性过程水刺，超声波针刺，针脚式接合化学性过程饱和度，喷雾印刷，起泡，撒粉热力学过程压延成型热风法STEP 4 WEB FINISHING Winding Slitting Spooling 第4步 后整理缠绕切割络筒Airlaid Process (空气铺网,无塵纸)Pulp Fiber Thermal Binder Fiber Bonding Oven Forming Heads Calender Roll Form
11、ing wire/Vacuum Oven wire 纸浆纤维热粘合纤维成型封头焊炉压辊线料成型/真空烤箱线束Types of Airlaid Multibond-Latex/Thermal Thermal bond core with latex bond exterior Positives Allows for high BW latex bond material Reduces linting of thermal bond materials Prevents SAP fallout Cross Section 气流类型横截面有胶乳结合外层的热粘合核心多重粘合-胶乳/热粘合高对接焊胶
12、乳粘合材料适用减少热粘合材料的纤维脱落优点防止超级吸水聚合物沉降Material Properties Uniformity High absorbency High mechanical integrity-x,y,z Structural stability-pore level High wettability High wet integrity High abrasion resistance-Latex bonded 材料性能均一性高吸收能力优良的力学性能-x,y,z结构稳定-孔隙级高润湿性高润湿完全性高抗磨损性-胶乳粘合Technology Options Flexibility
13、 to make layered absorbent components 3 2 Pulp Binder SAF Pulp Binder Synthetic Pulp Binder 1 Pulp Rich Layer Synthetic Rich Layer SAP Rich Layer 技术选择利用其柔顺性制造分层吸水组件纸浆粘合剂纸浆粘合剂高分子吸水纤维合成纸浆粘合剂纸浆富裕层合成富裕层超级吸水聚合物富裕层Spunbond Process(纺粘纺粘)Dryer Blending Station Receiver Mixer Hopper Extruder Spin Beam Slitte
14、r/Winder Finishing Calender Webformer Bank 1 Bank 2 干燥后整理混棉区接收器混合器料斗纺丝箱挤压机经纱架1经纱架2纵断器/络筒机热轧机成网机Polymer Pellets Extruder Filter Spin Pump Spin Pack Polymer Processing Heating/Cooling Hopper/Dryer T P 料斗/干燥机加热/冷却过滤器纺纱泵聚合物颗粒机挤压机纺纱组件聚合物制程Spunbond Spinning Quench Air System Fiber Draw Unit(FDU)Fume Exhau
15、st 纺粘法纺丝排烟装置淬火空气系统拉丝台Lurgi Process(Traditional)Spreaders Guide Tubes Guns Quench Air Fume Exhaust Webformer Spin Beam 传统鲁奇(加压煤气化)法工艺纺丝箱排烟装置空气淬火成网导管分离机纤维枪LDS(Linear Draw System)Process(KCC,Reifenhauser)Fume Exhaust Spin Beam Deflector Webformer Quench Air 线性拉伸系统工艺空气淬火纺丝箱排烟装置成网导向装置Bonding Definitions
16、Types of Thermal Bonding Calender Pattern Bond Ultrasonic Bonding Through-Hot-Air Bonding 粘合定义热粘合的类型热轧粘合超声粘合 热风粘合BOND PICTURED 粘合图示BONDING PATTERNS Designed With End Product In Mind Number,Arrangement,And Size Of Pins Determines Product Attributes Trend Is Toward Lower%Bonded Area 10-20%Range Brand
17、Identification Has Become Important 粘合模式设计时需考虑最终产品数量、排列和针的尺寸决定了产品属性品牌识别已愈发重要目前趋势为低于粘合区域1020%HANSEN PENNING PATTERN 汉森粘合模式PUB PATTERN PUB粘合模式 Surface properties of PP are not optimum for a number of nonwoven applications Poor wettability for urine,menses,etc.Poor dissipation of static charge Surfacta
18、nt are used to impart fabric hydrophilicity Intake speed Durability Surface Treatment 表面处理PP材料的表面属性致使它不是一系列无纺布应用的最佳选择润湿性欠佳（对于尿液、经期分泌物）静电损耗欠佳利用表面活性剂来赋予织物亲水性摄入速度耐用度Highloft fiber Splitable fiber New Spinning Technologies 新型纺织技术高蓬松纤维可剥离纤维MELTBLOWN PROCESS(熔喷)Definition:The meltblown process is a one st
19、ep process used to convert thermoplastic resins into fibrous nonwoven materials and is capable of producing microfibers with diameters in the one to five micron range.定义熔喷过程是将热塑性树脂转化为纤维无纺布材料的一段式制程，它能生产直径在1至5微米的范围内的超细纤维。MB PROCESS Polymer is extruded through a linear array of orifices Two converging
20、high velocity air jets attenuate the individual polymer streams into fibers Fibers randomly mix forming a nonwoven web 熔喷制程聚合物通过线性阵列孔挤压两个合流高速空气喷气机将聚合物流吹成超细段纤维纤维随机混合、粘合加固形成无纺布网MB EXTRUDER POLYMER HOPPER DIE BODY PRIMARY AIR FILTER SPIN PUMP DIE TIP FORMING WIRE Single Bank Meltblown Formation MELTBLO
21、WN PROCESS 熔喷制程冲压方偏转模体过滤器聚合物料斗熔喷挤压机纺纱泵单一经纱架熔喷形成成型网一次风MB Head 熔喷头MB CHARACTERISTICS Microfiber structures are possible Fine pore structure High surface area Tortuous path Initial integrity but low final strength Low abrasion resistance 熔喷特性超细纤维结构是可能的微孔结构高比表面道路曲折最初有完整性但是最终强度较低低耐磨性MB MATERIAL ATTRIBUTE
22、S Liquid Barrier Particulate Barrier(Filtration Efficiency)Breathability Opacity 熔喷材料的属性特征液体阻隔性微粒阻隔性（过滤效率）透气性阻光性SMS LAMINATES APPLICATIONS Medical Gown and Drapes Sterile Wrap Industrial Workwear Lab Coats Car Covers Filter Media Face Mask SMS工艺层压制品应用手术服&消毒被单消毒封装工业工作服实验服汽车罩滤料面罩SMS Material(Top View)
23、SMS 材料（俯视图）SMS Material(Cross Section)S MS 材料（横截面）SMS LAMINATES Properties:Provides protection from fluids,particles,dirt,and contaminants,yet is breathable and permeable to air or sterilants in applications such as healthcare gowns,apparel and drapes,and in car covers,diaper outer covers and diaper
24、 containment flaps S MS 层压材料性能：提供保护，隔离液体、颗粒、灰尘和污染物，但在手术服、医用服饰、消毒被单、汽车罩、尿布外罩和尿布吸收翼的应用上，它对空气或杀菌剂有良好的透气性、透水性。SMS LAMINATES KEY ATTRIBUTES Hydrohead-resistance to water,urine Blood Strikethrough-resistance to blood penetration Abrasion Resistance-propensity to lint or delaminate SMS层压材料关键属性静水压-抗水、尿液血液渗透
25、-抗血液渗透耐磨性-脱棉或分层的倾向SMS LAMINATES PRODUCT APPLICATIONS Infant Care -Diaper Containment Flaps(0.70 osy 20%MB)-Outercover(0.8 osy)Facing Prevents BM/Urine leakage Breathable for skin health SMS层压材料产品应用婴幼儿护理-尿布吸收翼（0.70盎司每平方码，20%熔喷无纺布）-外罩贴边（0.8盎司每平方码）防止排泄物/尿液泄露 保持透气性，呵护肌肤Elastomeric Laminates Body Conform
26、ance Fit:Contour-takes shape of body Contact-snug&gentle Enduring-retains fit Dynamic-wears well Gasket sealing-prevents leaks Closure-provides adjustment 弹性层压材料形体一致性舒适外形-根据人体形状成形触感-舒适&温和持续-保持舒适动态-耐穿密封垫-防止泄露门襟-提供调整Attributes of Elastomeric Laminates Stretch and Recovery Resistant to:Creep Stress Rel
27、axation Hysteresis Converting Compatibility Cost Effective 弹性层压材料的属性弹性及回复力防止：1.蠕变 2.应力松弛 3.滞后现象 转换的兼容性性价比高NBL Stretch Ear Application in Diaper Products 纸尿裤产品中的应用拉伸带FILM TECHNOLOGIES Blown Film(吹膜)-Mono and multi-layer extrusion capability-Biaxially oriented films-Typically higher gauge(1.0 mil)薄膜工艺
28、-单层和多层抗压能力-双轴取向薄膜-更高的线径（1.0mil）BLOWN FILM PROCESS 吹膜工艺FILM TECHNOLOGIES Cast Film(流埏膜)Mono and multi-layer extrusion capability MD oriented films Capable of fractional gauges(1.0 mil)Compatible with in-line nonwovens manufacturing 薄膜工艺单层和多层抗压能力纵向取向薄膜可以实现极小的线径（1.0mil）与无纺布在线生产相兼容CHILL CAST PROCESS 冷铸薄
29、膜工艺Microporous Film (透气膜)Highly Breathable Stretch Thermal Laminate FOR Diaper Outercover Objective:Clothlike aesthetics,and vapor permeable liquid barrier to outercovers.Product:Facing:0.6 OSY PP SB;2.0 dpf Film:.55 OSY Cast highly filled polyethylene film.尿布外罩用 高度拉伸透气热层压材料目的：布样美学，针对尿布外罩的蒸汽液体渗透屏障产品
30、：贴边：PP SB，0.6盎司每平方码；旦数为2.0薄膜：高填充聚乙烯薄膜，0.5 5 盎司每平方码HYDROENTANGLING(水刺)DEFINITION:Hydroentangling is a PROCESS for BONDING fibrous webs through fiber entanglement achieved with fine,high pressure,columnar water jets.定义：水刺法又称射流喷网成布法，它是一个采用精确的高压、水射流柱产生的多股微细水射流喷射纤网、纤网中纤维在不同方向高速水射流穿插的水力作用下，产生位移、穿插、缠结和抱合，从
31、而使纤网得到加固的过程。HYDROENTANGLING Fabric Attributes Cloth-like Hand Cloth-like Appearance Strength/Durability Absorbency Launderability Residue free 水刺面料的属性手感似布，柔软外观比其它非织造材料更接近传 统纺织品强度高/耐用 吸水性 耐洗性 水溶性高及不留残渍HYDROENTANGLING Process Overview Vacuum Boxes Porous Belt Substrate Water Jets Manifolds Entangled F
32、abric to dryers 水刺制程综述水射流基材集合管真空箱网眼传送带无纺布送至干燥器Water Jet 水射流HYDROENTANGLING Materials-Fibers Polyester Rayon Cotton Polypropylene Wood Pulp Elastomers 水刺材料-纤维聚酯 人造丝 棉花 聚丙烯 木浆 弹性合成橡胶材料类HYDROENTANGLING Materials-Substrates Carded Webs Meltblown Airlaid Wetlaid Spunbond 水刺材料-基材粗纺纤维网 熔喷法 干法 湿法 纺粘法HYDROEN
33、TANGLING Commercial Applications Medical fabrics:surgical gowns,sponges,wipes Durable fabrics:Mattress pad covers,interlacing,lining,coated/saturated fabrics Consumer wipes High performance fabrics:Kevlar/Nomex Personal Care Components Disposable garments 水刺布的商业应用医用织物：一次性手术服，吸血海绵制品，外科清洁用品耐用布料：软床垫，床垫罩，交织面料，内衬，涂层布普通湿巾高性能纤维织物：凯芙拉（聚对苯二甲酰对苯二胺）/诺梅克斯（聚间苯二甲酰间 苯二胺）个人护理一次性服装