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Spunbond nonwoven fabric manufacturing method
In the production of non-woven fabrics, the spunbond method has demonstrated significant advantages in terms of manufacturing technology, product performance, and production efficiency. Over the past two decades, this technique has gained widespread attention and experienced rapid growth globally. Currently, approximately 40% to 50% of non-woven fabric production utilizes melt spinning methods, which include spunbond, meltblown, and hybrid techniques. In the United States, melt spinning accounts for about 50% of the market, while in Europe and Japan, it represents 37% and 41%, respectively. These figures highlight the global preference for melt spinning as the primary production method in advanced economies.
Since the late 1950s, companies like DuPont and Freudenberg in the U.S. and Europe have been conducting research on spunbond non-woven fabrics. By the late 1960s, countries around the world began producing these materials. Japan started in the 1970s, and the Asia-Pacific region introduced the technology in the mid-1980s. The key reason behind the rapid development of the spunbond method is its use of synthetic polymers as raw materials. This process involves spinning continuous filaments, forming a web, and directly bonding them into non-woven fabric—making the production extremely efficient and cost-effective compared to traditional dry processes that involve multiple cumbersome steps such as fiber curling, cutting, and carding.
This streamlined approach significantly reduces costs, improves product quality, and enhances market competitiveness. Spunbond fabrics can be used in various applications, including disposable and durable products, entering markets such as textiles, paper, and films. Additionally, the large-scale use of polypropylene as a main material offers cost advantages and supports the industry's continued growth. Spunbond non-woven fabrics also exhibit superior mechanical properties, such as higher tensile strength, elongation at break, and tear resistance, when compared to other types of non-woven fabrics.
Recent advancements in production line capacity, technology, and equipment have further expanded the application areas of spunbond non-woven fabrics. One of the main differences between spunbond production and traditional chemical fiber spinning is the use of air drafting and direct web formation. Initially, mechanical drafting was used, which resulted in thick and uneven fibers. However, modern air drafting technology is now widely adopted, with different methods such as tube drafting, wide-slit drafting, and narrow-slit drafting being used across the globe.
The ongoing focus of spunbond technology has been on improving production line efficiency and addressing issues like non-woven uniformity, coverage, texture, and comfort. Efforts have also been made to enhance the softness, strength, and hygroscopic properties of the final product. Fine denier spunbond fabrics can significantly improve softness and comfort, but achieving fine denaturation remains a technical challenge. Finer fibers increase the number of fibers per unit area, leading to more bonding points, better uniformity, and improved coverage.