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Spunbond nonwoven fabric manufacturing method
In the production of non-woven fabrics, the spunbond method stands out for its advanced technology, superior product performance, and high efficiency, which have led to its rapid global development over the past two decades. Today, approximately 40% to 50% of non-woven fabric production relies on melt spinning techniques, including spunbond, meltblown, and hybrid methods. In the U.S., melt spinning accounts for about 50% of the market, while in Europe it's around 37%, and in Japan, it's 41%. This clearly shows that developed nations favor melt spinning as their primary production method.
Since the late 1950s, companies like DuPont and Freudenberg in the U.S. and Europe have been researching spunbond non-wovens. By the late 1960s, countries worldwide began producing these materials. Japan started in the 1970s, and the Asia-Pacific region followed in the mid-1980s through technology transfers.
The key to the rapid growth of the spunbond method lies in its use of synthetic polymers, particularly polypropylene, which is cost-effective and easy to process. The process involves extruding molten polymer into continuous filaments, forming a web, and then bonding it directly—eliminating many time-consuming steps such as fiber cutting, carding, and mixing. This simplification leads to lower costs, better quality control, and strong market competitiveness. Spunbond non-wovens are now widely used in both disposable and durable applications across textile, paper, and film industries.
Another major advantage is the excellent mechanical properties of spunbond fabrics, including higher tensile strength, elongation, and tear resistance compared to dry, wet, or meltblown non-wovens. With advancements in production line capacity, technology, and equipment, the application fields of spunbond have expanded significantly in recent years.
One of the main differences between spunbond and traditional chemical fiber spinning is the use of air drafting and direct web formation. Earlier methods relied on mechanical drafting, resulting in thick and uneven fibers. Now, most countries use air drafting technology, leading to three types of spunbond lines: tube drafting, wide slit drafting, and narrow slit drafting.
Researchers continue to focus on improving production line efficiency and addressing issues like uniformity, coverage, and texture. Enhancing softness, comfort, and hygroscopicity remains a priority. Fine denier spunbond can improve softness, but achieving finer fibers presents technical challenges. Finer fibers increase the number of fibers per unit area, leading to more bonding points, better uniformity, and improved coverage.