The spunbond method is a comprehensive technology involving many disciplines. The spunbond technology is developing at a rapid speed. At present, several process production modes with characteristics are formed. We should strengthen our development efforts, innovate, and form our own proprietary technology and intellectual property rights, which is the fundamental way for enterprises to remain invincible.
1 large plate narrow
Due to the Uniform surface of the products produced by the large plate mode, it is suitable for medical and health products. Since most of these products are colored, due to the low production volume of narrow production lines, several narrow and small lines are installed, and each line produces one color. To minimize the transition color products and improve economic efficiency.
2 small board width
The small plate mode has a small difference in vertical and horizontal strength, and the product is suitable for waterproof base fabrics and packaging materials. Most of these products are colorless, and the processing cost of the wide large plate spinneret is doubled. The 5.lm production line has been put into production. At present, the domestic high-volume extruder has been industrialized, and the wide-width hot rolling mill manufacturing technology has matured. Production lines with a width of 6.4m and an output of tens of thousands of tons per 9.6m are also possible. It is estimated that the output of the single-die with a width of 6.4m is 20,000t/a, and the power consumption of the production line reaches 450Kwh; the large-plate mode double-die width 3.2m yields 15,000 t/a electricity consumption reaches 434Kwh.
With the rapid development of the nonwovens industry in recent years, the number of spunbond lines has rapidly expanded, and the production capacity of stand-alone equipment has become the focus. Despite some difficulties in the design and manufacture of wide-format high-speed production lines, high-yield production lines have played an active role in reducing the processing costs and large-scale management of the entire industry, and have brought considerable economic benefits to the market competition. For example, in the 1970s, the output of small fertilizers was 3,000 t/a, and later it was developed to 300,000 t/a of synthetic ammonia. The output of the original small paper was several thousand tons. In recent years, 400,000 t/a paper machines have appeared. This is the trend of social development and the inevitable result of market competition and technological progress.
3 spunbond and meltblown composite
Spunbond and meltblown composites (SMS) for the production of nonwovens are suitable for all uses from filter materials to sanitary facing materials. This method fully utilizes the advantages of both to overcome the shortcomings of both. The non-woven fabric produced has both fine denier of meltblown fibers, good filterability, soft hand feeling, and strong doubleness of spunbond continuous filaments. Features.
4 polyester tube drafting
Due to the high requirement of polyester spinning speed, the polyester spunbonded air requires higher pressure and more flow, and the drafting power consumption accounts for a larger proportion of the total power consumption, because the tubular drafting consumes less air. From the perspective of energy saving, most of the polyester spunbonds use tubular drafters.
5 orange flap fiber spunlace spunlace
The microfiber nonwoven fabric obtained by spunbonding the orange-gloss fiber filaments is used for the base fabric of the wipes, medical and hygienic articles and high-grade synthetic leathers due to its good properties. Such as Freudenberg's Evolon belongs to this product, the fiber fineness of this product is between 0.05 ~ 0.13dtex, such microfiber can not be directly spun from the spinneret, they are the orange flap fiber through the hydroentanglement process The ultrafine short fibers in the past combed web are obtained by dissolving a component of the island or the orange-shaped fiber. When the orange short fiber is combed by hydroentanglement, when the adhesion is low, the fiber is easily cracked and easily formed during the carding process, and the fiber combing performance can be improved when the degree of adhesion is high, but the fiber is not easily split during the spunlace process. The two-stage process of carding and spunlace has conflicting requirements on the adhesion of the orange short fibers.
The spunlace product has good flatness and uniform product density, and does not damage the fiber like the needle punching process. The spunbond is much stronger than the carded nonwoven fabric. The combination of spunbond and spunlace produces a microfiber nonwoven fabric, which is a continuous production process from polymer slicing to final product. When the spunbond web made of lightly bonded orange flap fiber is spunlaced, it is not only used. To entangle the fiber, also used to split the orange fiber. The consolidation of the fiber web and the fiber splitting are completed at one time, minimizing the processing cost of the product, avoiding environmental problems caused by the use of chemicals for processing, and solving the difficulty in processing the microfiber on the carding machine.
Split-type microfibers, also known as orange-striped fibers or split-fibers, are named after their cross-section like a transversely-cut orange. The same spinning assembly is used to separate two different properties of the fiber-forming polymer from the same spinning hole. When spouted, due to differences in modulus, elongation and shrinkage, the two fiber-forming polymers are easily separated at the interface when subjected to an external force. The surface of the orange petal should have pleats and embossments, and the two thermoplastic polymers adhere to each other in the pleats of the pleats rather than at the ridges. The energy of the high pressure spun can be concentrated and effectively applied to the concave of the orange petal fiber, so that the fiber is easy to split. In order to make the cracking effect better, hollow orange flap fibers can also be made.
The orange flap fiber is currently more common for 16 or 32 flaps. Low-density products with a density of less than 120g/m2 are usually produced by a spunlace process, and products with an areal density of more than 250g/m2 are generally subjected to a needle punching process.
Good web entanglement of high performance nonwovens depends on the fineness, strength and elongation of the spunbond process filaments, web uniformity and longitudinal and lateral strength, water pressure in hydroentangled processes, water needles Plate aperture, hole density, hole shape, number of spunlace heads.
To produce a high-quality microfiber spunbonded spunlace nonwoven fabric, the fiber opening rate should be 60% or higher, so that the nonwoven fabric has a high strength and a large amount of both coarse fibers. Fine fibers provide the desired hand and other characteristics. The combination of spunbond and spunlace technology to produce microfiber nonwoven fabrics can be said to be a combination of "one stone and two birds", which is the most appropriate and economical process. When the two leading processes have the same high productivity and combined, the production of spunbonded spunlace nonwovens will become efficient and low cost, resulting in a new generation of high quality nonwoven products.
Ultra-fine spunbonded spunlace is an innovative technology. The forming and entanglement of the web is fast, the width is large, the output is high, the production cost is low, and the productivity is low.
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