The melt blowing process is a one-step process in which high-velocity air blows a molten thermoplastic resin from an extruder die tip onto a conveyor or takeup screen to form a fine fibrous and self-bonding web. In other words it is a nonwoven web forming process that extrudes and draws molten polymer resins with heated, high velocity air to form fine filaments. The filaments are cooled and collected as a web onto a moving screen. In some ways the process is similar to the spunbond process, but meltblown fibers are much finer and generally measured in microns. Meltblowing is a spunlaid process. The term is also spelled “melt blowing.”
Needlepunched nonwovens are created by mechanically orienting and interlocking the fibers of a spunbonded or carded web. This mechanical interlocking is achieved with thousands of barbed felting needles repeatedly passing into and out of the web with the help of a needle loom. It is a kind of dry non woven, nonwoven fabrics of acupuncture is the use of the needle puncture effect, fluffy fiber net reinforcement into cloth.
The needle loom is made up of needle board with thousands of needles is fitted into a needle beam which passes up and down through two perforated plates—the bottom web plate moves the fabric and the top stripper plate which removes the fibers from the needles. The exit rolls wind the needlepunched fabric at the end of the loom. Four types of nonwovens for mattresses namely medium soft, hard with plain surface, one side hard and one side soft and nonwoven poly pet are used as intermediate product by home furnishing manufacturers and mattress manufacturers. They are also used as spring insulators that hold staples that fasten the upholstery to the wood frame, insulators in mattress construction to cover springs and as flanges are the panels of material that surrounds the edge of the mattress and join the mattress top and bottom together.
Airlaid paper is a textile-like material categorized as a nonwoven fabric made from wood pulp. Unlike the normal papermaking process, air-laid paper does not use water as the carrying medium for the fibre. Fibres are carried and formed to the structure of paper by air.The characteristics of airlaid paper nonwovens are outstanding absorbency for wipes and towels, multi-layered materials that gather dust, microbes, and other household irritants efficiently and economically, tabletop and table napkin with excellent printability, versatile fabrics for every task from dusting to heavy scrubbing, improved strength in wet or dry wiping, specialty fabrics available for pre-moistened wipes, low lint-gathering properties and embossed wipe surface for antimicrobial qualities. The applications include napkins and tablecloths, pre-moistened cleaning wipes, dry wipes, kitchen towels, vacuum cleaner bags and kitchen and fan filters.
Engineered nonwoven fabrics
A major benefit of a nonwoven is the ease of engineering physical property requirements into the fabric that may be necessary for specific conversion operations or performance issues. Nonwovens that go into the home furnishing market are relatively easy for manufacturers to produce as opposed to more technical applications. Household furnishings must withstand high wear and tear, stains, spills and dirt which brings in the necessity of engineering nonwovens to ensure a longer lifespan. Thermal bonded spunlaid polyester nonwovens made from bicomponent filaments, with a polyester core and a polyamide skin, are used as a primary backing in applications such as tiles and broadloom carpeting for dimensional stability. Spunbonded nonwovens are ideal for the furniture, bed coverings, spring insulation, quilting and cushioning markets. High loft needlepunch and spunbond technologies are used to produce indoor and outdoor bedding products, quilts, comforter tops and pads. High loft provides the bulk and resilience and needle punching the strength and stability to the products.
• Heat and flame resistance: Engineered nonwoven fabrics can be designed to have an extremely high melting point as well as dimensional stability at high temperatures.
• Durability: Relative to their weight, engineered nonwoven fabrics can be designed to wear better than comparable weights of woven or knitted materials. When used as backing material, engineered nonwoven fabrics can increase the longevity of upholstery by reducing internal abrasion (up to five times more durable than other traditional materials).
• Anti- allergy and antimicrobial properties: Engineered nonwoven composites can be laminated to bedding and mattress materials to protect allergy sufferers from dust and mites - without any chemical additives.
• Strength and uniformity: Many engineered nonwoven fabrics have higher tensile, tear, and burst strength than their traditional textile counterparts and can resist repeated load bearing. Home furnishings can thus retain their form and appearance over longer periods of time, making them very cost-effective.
• Fluid resistance and retention: Engineered nonwoven fabrics can be designed to retain fluids and to resist staining. Engineered nonwoven fabrics can also be designed to resist attack by many solvents, alkalies, and other chemicals.