Methods of Laminated Nonwoven Fabric with PE Film

With the increasing maturity of the primary processing technology of nonwoven fabric, more and more enterprises are turning their attention to the deep processing of nonwoven fabric in order to enhance the added value of products and the profits of enterprises.

In China, the application field of hot-melt adhesive coating equipment is constantly expanding. The medical and sanitary material production sector is the industry where such equipment is most widely used. The rapid development of the automotive industry in China has also driven the demand of auto parts manufacturers for hot-melt adhesive coating equipment. Relevant data shows that the disposable nonwoven geotextile industry in China has recently introduced its first hot-melt adhesive production line. As a mature and continuously developing technology, the prospect of hot-melt adhesive coating technology in the deep processing industry of nonwoven fabric is very broad.

Disposable medical supplies (such as surgical gowns, surgical drapes, fenestration drapes, gloves, shoes, hats, etc.), industrial protective products, and personal care products are mainly based on nonwoven composite film products. The requirements of these industries for products are almost the same, that is, waterproof, breathable and comfortable. Laminated nonwoven fabric with PE film also called Clothlike PE film.

Based on the analysis and comparison of the characteristics of several main laminated processes currently used in medical and sanitary materials, this article introduces a new type of nonwoven and PE film laminated technology.

Existing Technologies of Laminated Nonwoven fabric with PE Film 

Extrusion Coating

This is the most widely used method by domestic enterprises. Its advantages are simple, mature process and relatively fast production speed, about 100 meters per minute. The disadvantages are that it cannot produce products with breathability requirements; the hand feel is hard and the comfort is poor; the requirements for nonwoven fabric are high. Nonwoven fabric with a basis weight lower than 18 grams per square meter and a coating amount lower than 15 grams per square meter has an unsatisfactory extrusion coating effect, because the uneven surface of the roll material makes it easy for the extrusion coating process to produce leakage points.

Thermal Calendering

This is the standard process for manufacturing composite nonwoven fabric by the two-step method, and some domestic enterprises use this process for film and fabric laminated. The advantage is that it can use existing equipment and processes. The disadvantages are that the film is made of PE and the nonwoven fabric is made of polypropylene, and the different melting points of the two make it difficult for the thermal calendering roll temperature to take both into account; the heat capacity of the thermal calendering roll makes the uniformity of the composite strength of the products at different production speeds under the same temperature relatively poor; the processing accuracy of the thermal calendering engraved roll is also a factor that affects product quality; the breathability loss rate of breathable film materials in the thermal calendering process is relatively high, between 30% and 40%; the production speed is relatively slow.

Powder Spreading laminated

Hot-melt Adhesive Breathable Coating laminated

New Process of laminated Nonwoven Fabric with PE Film

The fiber spray gluing process adopts high-tech and high-precision airflow high-frequency oscillation technology and laminated nozzle structure design, which makes the liquid distribution more uniform and the fiber diameter of the glue silk well controlled. The fiber is uniform and continuous in thickness, and the defects caused by broken silk and granular glue points are eliminated. Within a certain range, the frequency and amplitude of the glue silk swing can be controlled. The industrial original internal filtration function design effectively solves the problem of nozzle blockage. In addition to the above, this process also has the following advantages:

• Adhesive-saving: Under the same laminated strength, it can save more than 40% of adhesive compared with traditional laminated methods.

• Uniform spraying: The unique patent design improves the control of liquid pressure and fiber glue silk, making the adhesive amount of the composite nonwoven fabric more uniform and accurate in all directions, and maintaining the excellent breathability and softness of the composite nonwoven fabric.

• Maintenance-free nozzle: The unique gasket-type nozzle structure design and filtration function mean that the nozzle does not need to be disassembled and cleaned, greatly reducing the production of substandard products caused by nozzle blockage and reducing maintenance costs.

• High hardness special stainless steel design: It greatly improves the service life and maintenance cycle.

• Non-contact spraying: It eliminates the impact of factors such as equipment and material flatness, tension, heat resistance, and production speed on the quality of composite products in traditional coating, and reduces the breathability loss rate of breathable film to the lowest level.

• Easy installation and adjustment: The operation is simple, there is no need to adjust each nozzle, and the air consumption is very low.

• Spraying width: It can be adjusted between 4 mm and 7000 mm.

• Production line laminated speed: Up to 900 meters per minute.

• Hot-melt adhesive fiber diameter controllable: The range is between 2 - 50 microns.