On the development trend of spunbond technology

Spunbond method is a comprehensive technology involving many disciplines. Spunbond technology is developing rapidly. At present, several process production modes with distinctive characteristics have been formed. We should strengthen development efforts, constantly innovate, and form our own proprietary technology and intellectual property rights is the fundamental way for enterprises to be invincible.

1 large plate narrow

Due to the uniform surface of the product produced by the large board mode, it is suitable for medical and health products. Since most of these products are colored, due to the low output of the narrow-width production line, several narrow-width small lines are installed, and each line produces a color To minimize transitional color products and improve economic efficiency.

2 small plates wide

In the small-plate mode, the net-to-horizontal strength difference is small. The products are suitable for waterproof base fabrics and packaging materials. Most of these products are colorless. At the same time, the processing cost of wide-format large-plate spinnerets has doubled. The 5.lm width production line has been put into production. At present, domestic high-output extruders have been industrialized, and the manufacturing technology of wide-width hot rolling mills has matured. Production lines with an annual output of tens of thousands of tons with a width of 6.4m and 9.6m are also possible. It is estimated that the single-die head with a width of 6.4m has a power consumption of 450Kwh on the 20,000 t / a production line; the large-plate mode dual-die head with a width of 3.2m has a power consumption of 15,000 t / a and a consumption of 434Kwh.

With the rapid development of the nonwovens industry in recent years, the number of spunbond yarn production has expanded rapidly, and the improvement of the production capacity of stand-alone equipment has become the focus. Although there are some difficulties in the design and manufacture of wide-format high-speed production lines, the high-volume production lines play an active role in reducing the processing cost and scale management of the entire industry, and enable the production enterprises to bring considerable economic benefits in market competition. For example, in the 1970s, the output of small chemical fertilizers was 3,000 t / a, which was later developed into a large 300,000 t / a ammonia synthesis plant; the output of the original small paper mills was several thousand tons, and 400,000 t / a paper machines have appeared in recent years. This is a trend of social development and an inevitable result of market competition and technological progress.

3 Spunbond and meltblown compound

Spunbond and meltblown composite (SMS) production of nonwoven fabrics is suitable for all applications from filter materials to sanitary cladding materials. This method makes full use of the advantages of the two to overcome the shortcomings of the two. The non-woven fabrics produced have both the fine denier of melt-blown fibers, good filterability, soft feel, and the double strength of spunbond continuous filaments. Features.

4 polyester tube drafting

Due to the high requirements of polyester spinning speed, the air of polyester spunbond drafting requires higher pressure and more flow, and the power consumption of drafting accounts for a larger proportion of the total power consumption, because the tubular drafting consumes less air From the perspective of energy saving, most polyester spunbonds use tube drafters.

5 orange petal fiber spunbond spunlace

Spunbond orange petal fiber filaments obtained by spunlacing ultrafine fiber nonwoven fabrics are used for wipes, medical and sanitary products and high-grade synthetic leather base fabrics due to their good performance. For example, Evolon of Freudenberg Company belongs to this product. The fiber fineness of this product is between 0.05 and 0.13 dtex. Such ultrafine fibers cannot be directly spun from the spinneret. They are orange petal fibers through the spunlace process. It is formed by splitting. In the past, the ultra-fine short fibers in the carded web were obtained by dissolving a component of the sea island or orange petal fibers. When the orange petal short fibers are combed and spunlaced, when the adhesion is low, the fibers are likely to crack and form knots. Although the adhesion is high, the fiber combing performance can be improved, but the fibers are not easy to split during the spunlace process. The two-stage process of carding and spunlacing have contradictory requirements for the adhesion of orange petal short fibers.

Spunlaced products have good flatness and uniform product density, and will not damage fibers like the needle punching process. Spunbond is much stronger than carded nonwoven fabrics. The combination of spunbond and spunlace produces ultrafine fiber nonwoven fabrics. It is a continuous production process from polymer chips to final products. When the spunbond web made of lightly bonded orange petal fibers passes through spunlace, it is not only used It is used to twist the fiber and also used to split the orange petal fiber. The web consolidation and fiber splitting are completed at one time, which minimizes the processing cost of the product, avoids the environmental protection problems of using chemicals for processing, and also solves the difficulty of processing ultrafine fibers on the carding machine.

Split-type ultrafine fiber, also known as orange petal fiber or split fiber, is named because its cross section resembles a transversely cut orange, and uses the same spinning component to remove two different fiber-forming polymers from the same spinning hole After being ejected, due to differences in modulus, elongation, and shrinkage, the two fiber-forming polymers are likely to separate at the interface when subjected to external forces. The surface of the orange petal fibers should have wrinkles and bumps. The two thermoplastic polymers are bonded to each other at the wrinkles and not at the ridges. The energy of high-pressure spunlace can be concentrated and effectively act on the concave of the orange petal fiber, making the fiber easy to split. In order to make the cracking effect better, hollow orange petal fibers can also be made.

Orange petal fibers are currently 16 or 32 petals. Generally, the low areal density products less than 120g / m2 are produced by the spunlace process, and the products with areal density above 250g / m2 generally adopt the acupuncture process.

The good web entanglement effect of obtaining high-performance nonwoven fabrics depends on the fineness, strength and elongation of the filaments in the spunbond process, the uniformity and the vertical and horizontal strength of the web, the water pressure and water needles in the spunlace process The hole diameter, hole density, hole shape and number of spunlace heads of the board.

To produce high-quality ultra-fine fiber spunbond spunlace nonwoven fabrics, the fiber opening rate should be 60% or higher, so that this nonwoven fabric has some crude fibers with high strength and a large number of Fine fibers can obtain the required hand and other characteristics. The combination of spunbond and spunlace technology to produce ultra-fine fiber nonwoven fabrics can be described as a perfect combination, or "two birds with one stone" is the most appropriate and economical process. When the two leading processes have the same high production capacity and are combined together, the production of spunbond spunlace nonwovens will become efficient and low-cost, and a new generation of high-quality nonwoven products will be produced.

Superfine spunbond spunlace is an innovative technology. The forming and entanglement speed of the web is fast, the width is large, the output is high, the production cost is low, and the productivity

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