How is spunbond non-woven fabric manufactured?

Spunbond non-woven fabric is manufactured through a process called spunbonding, which is a method of producing continuous filaments from thermoplastic polymers and then bonding them together to form a fabric. Here's a general overview of the manufacturing process:

Polymer Extrusion:

The process begins with the extrusion of thermoplastic polymers, such as polypropylene or polyester, into fine filaments. This is typically done using a process called melt spinning, where the polymer is melted and then extruded through spinnerets to create continuous filaments.

Filament Formation:

The extruded filaments are drawn out and cooled to solidify them. This results in the formation of long, continuous filaments that are collected onto a conveyor belt.

Web Formation:

The collected filaments are laid down randomly or in a specific pattern to form a web. This web of filaments is still in a loose, non-woven state.

Bonding:

The loose web of filaments then undergoes a bonding process to give the fabric strength and stability. There are different methods for bonding, with heat and pressure being commonly used. The two main bonding techniques are:

Thermal Bonding: Involves passing the fabric through heated rollers or calenders, which melt and fuse the filaments together at contact points.

Chemical Bonding: In this method, chemical binders are applied to the filaments, and then the fabric is cured or heated to set the bonds.

Finishing:

The bonded fabric may undergo additional processes for finishing, such as calendaring (smoothing the surface), printing, or treatment to enhance properties like water repellency or flame resistance.

Cutting and Packaging:

Finally, the manufactured spunbond non-woven fabric is cut into rolls or sheets, depending on the application, and packaged for distribution.

Spunbond non-woven fabrics are widely used in various industries due to their characteristics such as strength, durability, and breathability. They find applications in products like disposable medical gowns, surgical masks, filters, agricultural covers, and more.