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Non-woven fabric is manufactured by putting small fibers together in the form of a sheet and then binding them either with an adhesive or by interlocking them with serrated needles such that the inter-fiber friction results in a strong fabric.

1 Raw material

Non-woven materials are nowadays mainly produced from man-made fibers. Two synthetic polymers dominate the market: polypropylene and polyesters (mainly PET).

2 Applications

Non-woven materials are used in numerous applications, including:

• Hygiene
  • Baby diapers
  • Feminine hygiene
  • Adult incontinence products
• Wipes
  • Domestic
  • Technical
• FilterThe term filter may refer to: Filter (chemistry) — a device to separate mixtures Electrostatic Dust Filter Filter (mathematics) — a certain kind of subset of a partially ordered set Filter program — in Unix, any program with standard I/O streams. Any softs
• Geotextile s
• CarpetCarpet is a general term given to any loom-woven or felted textile and to grass floor coverings. Historically, the term was also used for table and wall coverings. Some distinguish between carpet and rug based on size (the former being larger) or use (car backing
• CompositesComposites are materials formed by a continuous phase and a dispersed phase which have properties different of the constituent materials. An example are reinforced plastics. While developments in metals have had an impact on engine design, there is a grow

3 Manufacturing processes

3.1 Staple non-wovens

Staple non-wovens are made in two steps. Fibers are first spun, cut to a few centimeters length, and put into baleBale can mean several things: French for Basel Bale, a town in Croatia Bale province in Burkina Faso A large package of material tightly bound with twine or wire, typically hay or straw, often after being compressed by a baler. Actor Christian Bale.s. These bales are then dispersed on a conveyor beltA conveyor belt is a continuous loop of material that rotates about the pulleys. The pulleys are powered, moving the belt in a clockwise (or counter-clockwise direction), and moving the material on the belt forward. Conveyor belts are extensively used to, and the fibers are spread in a uniform web by a wetlaid process or by cardingCarding is the processing of raw or fibres brushing it. It is used for cotton, wool and bast fibres. Hand carders are like dog brushes and are used two at a time, brushing the wool between the two until all the fibers in a bunch are going in the same dire.

3.2 Spunlaid non-wovens

Spunlaid non-wovens are made in one continuous process. Fibers are spun and directly dispersed in a web by deflectors. This technique leads to faster belt speeds, and cheaper costs. Several variants of this concept are available, but the leading technology is the Reicofil machinery, manufactured by Reifenhaüser ( GermanyThe Federal Republic of Germany ( German: Bundesrepublik Deutschland is one of the world's leading industrialized countries, located in the middle of the European Union. It is bordered to the north by the North Sea, Denmark and the Baltic Sea, to the east).

3.3 Bonding

Both staple and spunlaid non-wovens would have no mechanical resistance per se without the bonding step. Several methods can be used:

• thermal bonding: calendering through heated rollers (called spunbond when combined with spunlaid)
• hydro-entanglement: mechanical intertwining of fibers by water jets
• needlefelt: mechanical intertwining of fibers by needles

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Topics: Non-woven Fibers Non-wovens Spunlaid Mechanical Staple Bonding...

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