Module 3: Web bonding processes
3.2 Thermal Bonding Processes
Introduction
It is known that the fibres in the webs can be bonded thermally in order to have sufficient resistance to mechanical deformation. The basic concept of thermal bonding was introduced by Reed in 1942. He described a process in which a web consisting of thermoplastic and non-thermoplastic fibres was made and then heated to the melting or softening temperature of the constituent thermoplastic fibres followed by cooling or solidify the bonding area. Since then many developments have been made in thermal bonding processes. Today the thermal bonding processes include calender bonding, through-air bonding, infrared bonding, and ultrasonic bonding. Thermal bonding requires a thermoplastic component to be present in the web in the form of homofil fibre, powder, film, hot melt or as a part (sheath) of bicomponent fibre. The thermoplastic component becomes viscous under the application of thermal energy. The polymer flows to fibre-to-fibre crossover points where bonding regions are formed. The bonding regions are fixed by subsequent cooling. The thermal bonding process is environmental-friendly, as no latex binder is required. The thermal bonding process consumes less energy compared to foam bonding or hydroentanglement bonding.
Module 3: Web bonding processes3.2 Thermal Bonding ProcessesIntroductionIt is known that the fibres in the webs can be bonded thermally in order to have sufficient resistance to mechanical deformation. The basic concept of thermal bonding was introduced by Reed in 1942. He described a process in which a web consisting of thermoplastic and non-thermoplastic fibres was made and then heated to the melting or softening temperature of the constituent thermoplastic fibres followed by cooling or solidify the bonding area. Since then many developments have been made in thermal bonding processes. Today the thermal bonding processes include calender bonding, through-air bonding, infrared bonding, and ultrasonic bonding. Thermal bonding requires a thermoplastic component to be present in the web in the form of homofil fibre, powder, film, hot melt or as a part (sheath) of bicomponent fibre. The thermoplastic component becomes viscous under the application of thermal energy. The polymer flows to fibre-to-fibre crossover points where bonding regions are formed. The bonding regions are fixed by subsequent cooling. The thermal bonding process is environmental-friendly, as no latex binder is required. The thermal bonding process consumes less energy compared to foam bonding or hydroentanglement bonding.
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