Chemical Bond Nonwoven Fabrics

I. Production Process of Chemical Bond Nonwoven Fabrics

The core of producing chemical bond nonwoven fabrics is to fully integrate the base nonwoven fabric with the functional impregnation liquid. Changshu Yongdeli Spunlaced Nonwoven Fabric Co., Ltd. ensures that each batch of products meets functional standards and maintains consistent quality through standardized production processes and meticulous control. The specific process is as follows:

Selection and Pre-treatment of Base Materials: According to the performance requirements of the application scenarios, suitable base nonwoven fabrics are selected, including spunlace, thermal-bonded, and spunbonded nonwoven fabrics. The base materials can be made of pure cotton, polyester, viscose fibers, or blended fibers. To enhance the adhesion between the base material and the impregnation liquid, pre-treatment is necessary: dust and impurities on the surface of the base material are removed by dust removal equipment, and the surface is activated by plasma treatment or mild chemical treatment to increase surface adhesion, laying the foundation for uniform impregnation in the subsequent steps.

Customization and Preparation of Impregnation Liquid: This is the key step in endowing chemical bond nonwoven fabrics with functions. The company's technical team develops exclusive impregnation liquid formulas based on customer requirements (such as antibacterial, waterproof, oil-resistant, antistatic, flame-retardant, etc.). The impregnation liquid mainly consists of functional additives (such as eco-friendly antibacterial agents, high-molecular waterproof agents, antistatic agents), solvents (preferably water-based solvents for environmental protection and safety), and stabilizers (to prevent layering and sedimentation of the impregnation liquid). After the formula is tested and approved in the laboratory, it is prepared in batches in the production workshop. During the preparation process, parameters such as concentration, viscosity, and pH value are monitored in real time to ensure compliance with production standards.

Impregnation Treatment: The pre-treated base material is fed into the impregnation tank through a unwinding device and fully immersed in the customized impregnation liquid. The impregnation method is selected based on product requirements: for general functional needs, conventional immersion impregnation is used, and the impregnation time is controlled by adjusting the base material's running speed (3-15m/min) to ensure uniform penetration of the impregnation liquid; for high-functional requirements, pressure impregnation or multi-stage impregnation is adopted to increase the penetration depth of the impregnation liquid into the base material fibers, avoiding partial non-impregnation or uneven impregnation.

Liquid Control Treatment: After impregnation, the base material carries excess impregnation liquid and enters a liquid control device (consisting of a pair of adjustable pressure rubber rollers). By precisely adjusting the roller pressure (1-6MPa), the liquid-carrying amount of the base material is controlled, avoiding waste of the impregnation liquid and preventing excessive liquid-carrying from causing excessive hardness and uneven function distribution after drying, ensuring the liquid-carrying amount meets the requirements of the drying process.

Drying and Curing: The base material after liquid control enters the drying equipment. The drying method is selected based on the characteristics of the impregnation liquid and the base material, including hot air drying, infrared drying, or a combination of hot air and infrared drying. The drying temperature is set at 70-140℃ (adjusted according to the heat resistance of the base material), and the drying time is regulated by controlling the running speed of the base material to ensure complete evaporation of the solvent and the formation of a stable functional film on the surface and inside the fibers, or chemical bonding with the fibers to achieve functional curing. During the drying process, the moisture content of the base material is monitored in real time and ultimately controlled within 5% to avoid excessive moisture affecting product stability. Post-treatment and Slitting: Post-treatment processing is carried out based on customer requirements: if softness needs to be enhanced, an eco-friendly softener is sprayed and the material is dried at a low temperature for a second time; if structural stability needs to be improved, heat pressing and shaping are performed; if the appearance needs to be beautified, embossing treatment is applied. After post-treatment, the base material is slit into rolls or sheets of the preset width and length through slitting equipment to meet the usage requirements of downstream customers.

Quality Inspection and Storage: The products after slitting enter the quality inspection stage. Inspectors conduct visual inspections (checking for defects, color differences, and uneven impregnation on the fabric surface), functional tests (such as antibacterial rate tests and water resistance tests), and physical property tests (tensile strength and elongation at break) to ensure that the products meet national standards and customer requirements. Only qualified products are allowed to be stored for shipment.

II. Advantages of Chemical Bond Nonwovens

High Degree of Functional Customization: The impregnation liquid formula can be flexibly adjusted according to the needs of different industries and scenarios to achieve single or combined functions such as antibacterial, waterproof, oil-resistant, antistatic, and flame retardant. For example, high antibacterial rate products can be customized for medical scenarios, and waterproof and UV-resistant products can be customized for outdoor scenarios, precisely matching customer demands.

Strong Functional Stability: By using deep impregnation technology and precise drying and curing processes, functional additives are tightly bonded with the base material fibers and are not easily lost due to washing, friction, or environmental changes. After testing, most products can maintain their core functions (such as antibacterial rate and water resistance level) within the standard range after 5 to 15 washes, ensuring a long service life.

Wide Compatibility with Base Materials: Compatible with various base materials such as spunlace, thermal bonding, and spunbond, whether natural fibers, synthetic fibers, or blended fibers, good impregnation effects can be achieved by adjusting the pretreatment process and impregnation parameters. The optimal base material can be selected based on the application scenario, expanding the product's application boundaries.

High Production Efficiency and Stable Quality: Continuous production lines are used to integrate base material unwinding, impregnation, liquid control, drying, and slitting, with a daily production capacity of tens of thousands of square meters, achieving high production efficiency. At the same time, the entire production process is equipped with an online monitoring system to monitor key parameters in real time, combined with comprehensive quality inspection before leaving the factory, effectively avoiding batch differences and ensuring stable product quality.

III. Characteristics of Chemical Bond Nonwovens

Balanced Function and Base Material Performance: While endowing the product with specialized functions, the original excellent properties of the base material are retained to the greatest extent. For example, antibacterial impregnated products made from spunlace nonwovens not only have the softness and breathability of spunlace fabric but also possess antibacterial functions, providing a dual guarantee of "basic performance + specialized function" and enhancing the user experience.

Outstanding Environmental Friendliness: Water-based solvents and eco-friendly functional additives are prioritized, and the impregnation liquid complies with environmental standards such as RoHS and REACH. The production process does not emit toxic or harmful substances, and the solvents can be recycled through a recovery system, reducing environmental pollution. If natural fiber base materials are used, the products can be naturally degraded after disposal, aligning with the green development trend.

Excellent Uniformity: By precisely controlling the base material running speed, impregnation liquid parameters, squeezing pressure, and drying temperature, the functional distribution, thickness, and weight of the product are highly uniform, with no local functional deficiencies or uneven thickness on the fabric surface. The appearance is smooth and tidy, ensuring stable product performance during downstream applications.

Good Processing Adaptability: It has excellent properties for cutting, sewing, heat sealing, and laminating. There are no frayed edges or fiber shedding during cutting; it can be firmly bonded with films, other nonwovens, and other materials during heat sealing; and it can be tightly combined with different material base materials during laminating without affecting its own functions and bonding strength, providing convenience for downstream customers' production and processing.

IV. Weight Range of Chemical Bond Nonwovens The Chemical Bond non-woven fabric produced by Changshu Yongdeli Spunlaced Non-woven Fabric Co., Ltd. can have its weight flexibly adjusted according to the base material and impregnation process, covering the range of 25g/㎡ to 180g/㎡. This meets the demands for product thickness, strength and functional load capacity in various scenarios. The characteristics and applicable scenarios of each weight range are as follows:

Low-weight products (25g/㎡ - 50g/㎡): They are light and thin, with good softness and moderate functional load capacity. They are mainly used in scenarios sensitive to product thickness and weight, such as hygiene products (like antibacterial wet wipes base material, antibacterial layer of disposable underpants), medical dressings (lightweight wound dressings base material), and the electronics industry (anti-static packaging cloth for small components).

Medium-weight products (51g/㎡ - 100g/㎡): They combine lightness and thinness with certain strength and sufficient functional load capacity. They are widely used in scenarios such as medical protection (antibacterial medical bed sheets, flame-retardant medical curtains), household products (waterproof and oil-proof tablecloths, antibacterial sofa cover fabrics), and outdoor products (lightweight sun-protective clothing fabrics), balancing functionality, strength and comfort of use.

High-weight products (101g/㎡ - 180g/㎡): They are thicker and stronger, capable of carrying higher doses of functional additives, and have more significant functional effects. They are suitable for scenarios with high requirements for product strength and functional effects, such as the industrial field (flame-retardant protective cloth, oil-proof industrial wiping cloth), construction field (waterproof and moisture-proof covering cloth), and agricultural field (anti-aging agricultural covering cloth).

V. Application Market Scope of Chemical Bond Non-woven Fabric

Medical and health market: It is one of the core application fields of chemical bond non-woven fabric. The company has launched antibacterial, breathable, and cross-infection-preventing chemical bond non-woven fabric for this field. It can be used to make medical bed sheets, pillowcases, and duvet covers (antibacterial treatment to reduce bacterial growth), inner layers of medical protective suits (moisture-absorbing, breathable, and antibacterial), medical dressings (such as antibacterial wound dressings, burn care pads to promote wound healing), and base materials for disinfection wet wipes (resistant to disinfection solution corrosion and antibacterial). For example, the antibacterial medical bed sheet uses medium-weight products with an antibacterial rate of over 99%, reducing the risk of cross-infection in hospitals while maintaining good breathability and enhancing patient comfort.

Sanitary products market: With customized functions, it meets consumers' demands for hygiene and comfort. It can be used to make antibacterial sanitary napkin surface layers (reducing bacterial growth and preventing gynecological problems), antibacterial and leak-proof edges of baby diapers (soft and skin-friendly, protecting baby skin from irritation), waterproof layers of adult incontinence products (improving leak-proof effect), and base materials for makeup removal wet wipes (with mild cleaning additives, combining cleaning and moisturizing). For instance, the leak-proof edge of baby diapers uses low-weight products, which are soft and non-irritating, effectively preventing urine leakage and skin redness.

Household and daily products market: With the increasing demands for living quality, the application requirements continue to grow. It can be used to make waterproof and oil-proof tablecloths (easy to wipe off stains and prevent penetration), antibacterial sofa covers / curtains (reducing bacteria in dust and improving indoor environment), moisture-absorbing and sweat-wicking towels (improving water absorption and drying speed), and dust-proof cloths (anti-static treatment to reduce dust adhesion). For example, the waterproof and oil-proof tablecloth uses medium-weight products, which are soft and easy to fold and store, suitable for home and restaurant use.

Industrial and protective market: Relying on high strength and specialized functions, it plays an important role. It can be used to make industrial flame-retardant protective cloth (meeting fire protection standards for workshop and warehouse protection), oil-proof industrial wiping cloth (quickly absorbing oil, not easily damaged, and reusable), anti-static packaging cloth (protecting electronic components and precision instruments from static damage), and base materials for wear-resistant conveyor belts (extending service life). For instance, the oil-proof industrial wiping cloth uses high-weight products, which have strong oil absorption capacity and no fiber residue when wiping mechanical parts, reducing enterprise production costs.

Agricultural and outdoor market: The application scenarios are constantly expanding. In the agricultural sector, it can be used to produce anti-aging agricultural covering cloth (UV-resistant and anti-aging, suitable for seedling raising and weed prevention, with a service life of 2-3 years) and anti-insect agricultural cloth (reducing pest damage to crops). In the outdoor field, it can be used to make outdoor tent fabric (waterproof and UV-resistant, suitable for harsh environments) and outdoor backpack fabric (wear-resistant and waterproof, enhancing durability), providing guarantees for agricultural production and outdoor activities 

Changshu Yongdeli Spunlaced Nonwoven Fabric Co., Ltd. has always been customer demand-oriented, continuously optimizing the production process and formula research and development of chemical bond nonwoven fabrics, and is committed to providing high-quality and customized product solutions for various industries. In the future, the company will continue to invest in R&D resources, explore new environmentally friendly functional additives and efficient impregnation processes, further expand the application boundaries of products, and work hand in hand with customers to achieve win-win development.