Mesh Spunlace Nonwoven Fabric Products

I. Process Flow of Mesh Spunlace Nonwoven Fabric

The core of mesh spunlace nonwoven fabric is to form controllable nets during the spunlace reinforcement process. Changshu Yongdeli Spunlaced Nonwoven Fabric Co., Ltd. ensures the stability of net shape, distribution, and product performance through refined process control. The specific process is as follows:

Raw material selection and blending: According to the strength and softness requirements of the net product, high-quality fiber raw materials are selected, including common types such as polyester, viscose fiber, pure cotton fiber, or blended fibers (such as polyester-viscose blends). The technical team will adjust the fiber ratio according to the application scenarios. For example, in the medical field, viscose fibers with good skin friendliness are preferred, while in the industrial field, the proportion of polyester is increased to enhance strength, ensuring the basic performance of the product from the source.

Opening and blending: The baled fibers are dispersed by opening equipment to remove impurities and short fibers, making the fibers fluffy; then they are fed into the blending equipment according to the preset ratio and mixed evenly through mechanical stirring to avoid fiber agglomeration, laying the foundation for the uniformity of the subsequent carding and web formation.

Carding and web formation: The mixed fibers enter a high-precision carding machine, where they are combed and straightened by needle rollers and laid into a continuous, uniform web in terms of thickness. Compared with ordinary spunlace nonwoven fabrics, the net product has higher requirements for web uniformity. Technicians will monitor the thickness deviation of the web in real time (within ±2%), ensuring the consistency of subsequent net formation.

Mesh formation and spunlace reinforcement (core process): This is the key process of mesh spunlace nonwoven fabric, which differs from the "full reinforcement" of ordinary spunlace. This process achieves mesh through two methods:

Template spunlace: A metal template with specific hole diameters (0.1-5mm) and specific patterns (such as circular, rhombic, or square) is placed under the web. High-pressure water (8-15MPa) is sprayed from above. The fibers in the areas not covered by the template (corresponding to the mesh positions) are impacted by the water and penetrate with the water flow, forming "open nets", while the areas covered by the template are reinforced by fiber entanglement through water flow, ultimately forming a stable structure of "reinforced area + net area".

Special support mesh spunlace: A polyester support net with raised patterns (pattern spacing corresponding to the net size) is used. The web is laid on the support net, and when high-pressure water is sprayed, the raised parts of the support net support the web to form "support points", while the fibers in the depressed parts are more easily entangled and contracted due to water impact, naturally forming nets. The company will choose the process based on the precision requirements of the nets. The template method is suitable for scenarios requiring precise hole diameters (such as medical filtration), while the support net method is suitable for large-area net products (such as the surface layer of hygiene products).

Dewatering and drying: The wet mesh spunlace nonwoven fabric first enters a vacuum dewatering device to remove 70%-80% of the water, reducing drying energy consumption; then it enters a hot air drying device and is dried at 80-120°C, controlling the moisture content within 5%. During the drying process, the temperature and air speed must be precisely controlled to prevent the nets from deforming due to thermal shrinkage and ensure the stability of the net size. Post-treatment and Slitting: Post-treatment is carried out based on customer requirements, with common processes including hydrophilic treatment (to enhance the liquid absorption speed of hygiene products), antibacterial treatment (for medical applications), and antistatic treatment (for use in the electronics industry). After post-treatment, the material is slit into rolls or sheets of preset widths (1-3m) and lengths using slitting equipment to meet the needs of downstream processing.

Quality Inspection and Storage: In addition to routine appearance and strength checks, the quality inspection process focuses on adding "mesh parameter inspection". The mesh hole diameter deviation (controlled within ±0.05mm) and mesh distribution density (such as the number of mesh holes per square centimeter) are inspected using an image measuring instrument to ensure compliance with customer requirements. At the same time, air permeability (measured by an air permeability tester, controlled within 500-3000L/m²・s) is also inspected. Only qualified products can be stored in the warehouse.

II. Advantages of Mesh Spunlace Nonwoven Fabric

Superior Air and Moisture Permeability: The uniform mesh structure on the fabric surface significantly improves the efficiency of air and water vapor circulation. Compared to ordinary spunlace nonwoven fabrics, the air permeability is increased by 30% to 80%, making it suitable for applications where "non-stuffy" is highly demanded, such as the surface layer of baby diapers and the breathable layer of medical protective clothing, effectively reducing the feeling of stuffiness and moisture retention.

Precise Filtration and Drainage Performance: The mesh size is controllable (0.1-5mm), allowing for the design of specific hole diameters to achieve "specific particle interception" or "rapid liquid drainage". For example, a product with a 0.5mm hole diameter can be used for air filtration (to intercept dust particles), while a product with a 2mm hole diameter can be used for the drainage layer of hygiene products (to quickly disperse liquids and prevent local accumulation).

Lightweight and Material-saving Advantage: Under the same strength requirements, the mesh structure replaces "full reinforcement" with "local reinforcement", reducing fiber usage by 15% to 30%, making the product thinner (low weight can reach 20g/㎡), and simultaneously lowering raw material costs, meeting the "lightweight and cost reduction" demands of downstream customers.

Softness and Skin-friendly Advantage: Retaining the fiber entanglement structure of spunlace nonwoven fabric, the mesh edges are smooth without burrs, providing a soft touch when in contact with the skin and no friction irritation. According to ISO 12826 standards, the skin feel score of the product is superior to that of ordinary hot-rolled mesh materials, making it suitable for hygiene products used by infants and people with sensitive skin.

III. Characteristics of Mesh Spunlace Nonwoven Fabric

Stable and Controllable Mesh Structure: Through the use of templates or special mesh processes, the hole diameter, shape, and distribution density of the mesh can be precisely designed. During the drying process, temperature control is used to prevent mesh deformation, ensuring that the mesh parameters of different batches of products have a deviation of less than 5%, maintaining stable performance in downstream applications (such as consistent filtration efficiency and drainage speed).

Balance of Strength and Air Permeability: Although the mesh area is a "lattice structure", the reinforced areas achieve tight fiber entanglement through high-pressure waterjet, allowing the product's longitudinal and transverse tensile strength to reach 10-30N/5cm (adjusted according to weight), meeting the tensile and friction requirements in daily use and avoiding insufficient strength due to the presence of mesh holes.

Environmental Friendliness and Biodegradability: If natural fibers such as cotton and viscose are used, the product can be naturally degraded after disposal (with a degradation rate of over 90%, meeting GB/T 28018-2011 standards). The production process does not involve the addition of chemical adhesives, only physical waterjet reinforcement is used, with no harmful substances remaining, aligning with environmental trends.

Strong Processing Adaptability: The mesh structure does not affect the cutting, sewing, and heat sealing performance of the product. It can be combined with films and other nonwoven fabrics for processing, and the mesh area can serve as a "composite bonding point" to enhance the composite strength. For example, when combined with PE film, the adhesive can penetrate through the mesh holes, increasing the composite strength by more than 20%.

IV. Weight Range of Mesh Spunlace Nonwoven Fabric The mesh spunlace nonwoven fabric produced by Changshu Yongdeli Spunlaced Nonwoven Fabric Co., Ltd. has a weight range of 20g/㎡ to 100g/㎡. It can be flexibly adjusted according to the size and strength requirements of the net holes. The characteristics and application scenarios of each weight range are as follows:

Low weight products (20g/㎡ - 40g/㎡): Light, soft, and with a high proportion of net holes (30% - 50%), they have excellent breathability and are mainly used in the surface layer of hygiene products (such as the surface layer of baby diapers and feminine hygiene products), the inner layer of medical masks (to enhance breathability and comfort), and light filtering materials (such as the primary filter screen of air conditioners).

Medium weight products (41g/㎡ - 70g/㎡): They combine breathability and strength, with a net hole proportion of 20% - 30%, and are suitable for the breathable layer of medical protective clothing (to balance protection and breathability), wet wipe base materials (net holes accelerate liquid penetration and improve wiping efficiency), and agricultural seedling covering cloth (to maintain moisture and promote seed germination).

High weight products (71g/㎡ - 100g/㎡): They have high strength, with more tightly reinforced mesh edges and a mesh proportion of 10% - 20%. They are suitable for industrial filter cloth (such as machine tool oil mist filter cloth), household cleaning cloth (meshes absorb dust and oil stains, leaving no residue after wiping), and the surface layer of pet care pads (durable and quickly divert pet urine to the absorption layer).

V. Application Market Scope of Mesh Spunlace Nonwoven Fabric

Sanitary Products Market: This is the core application field of mesh spunlace nonwoven fabric. With the advantages of breathability and fluid drainage, it is widely used in the surface layer of baby diapers (low weight 25g/㎡ product, net hole diameter 1-2mm, quickly drains urine and keeps the skin dry), the surface layer of feminine hygiene products (30g/㎡ product, breathable and anti-stuffy), and the drainage layer of adult incontinence products (40g/㎡ product, disperses liquid and avoids local dampness). For example, after a well-known diaper brand adopted the company's 25g/㎡ circular net hole product, users reported a 30% reduction in the incidence of "red buttocks", and the product repurchase rate increased.

Medical and Health Market: Relying on its environmental friendliness, breathability, and controllable filtration characteristics, it is used in the breathable layer of medical protective clothing (medium weight 50g/㎡ product, hole diameter 0.5mm, enhancing breathability while ensuring protection, reducing the discomfort of medical staff due to heat), the inner layer of medical masks (20g/㎡ product, soft and skin-friendly, enhancing wearing comfort), and medical filtering materials (45g/㎡ product, hole diameter 0.3mm, used for air filtration in operating rooms to intercept bacterial particles). The products comply with standards such as YY/T 0334-2022 "Medical Absorbent Cotton" and GB 19083-2010 "Technical Requirements for Medical Protective Masks", and can pass third-party authoritative testing.

Household and Cleaning Market: With the increasing demand for "efficient cleaning and breathable comfort", the products are used in household cleaning cloth (high weight 80g/㎡ product, net holes absorb dust and oil stains, no residue after wiping), disposable tablecloths (60g/㎡ product, breathable and not stuffy, and the net holes facilitate folding and storage), and the surface layer of pet care pads (70g/㎡ product, durable and tear-resistant, quickly diverting pet urine to the absorption layer). For example, the household cleaning cloth with a diamond-shaped net hole design has a 40% higher cleaning efficiency than ordinary nonwoven fabric and is easy to clean and reuse.

Industrial Filtration Market: To meet the demand for "dust and oil mist filtration" in the industrial field, it is used in machine tool oil mist filter cloth (high weight 90g/㎡ product, mesh diameter 0.8mm, intercepting oil mist particles and ensuring equipment accuracy), air purifier filters (40g/㎡ product, hole diameter 0.3mm, primary filtration of dust, improving overall filtration efficiency when combined with HEPA filters), and car air conditioning filters (50g/㎡ product, breathable and intercepting pollen and dust, improving indoor air quality). The products have a temperature resistance of up to 80℃, meeting the usage requirements of industrial environments. Agriculture and Outdoor Markets: Application scenarios continue to expand. In the agricultural sector, it is used for seedling covering fabric (45g/㎡ medium weight product, with 1mm mesh aperture, breathable and moisture-retaining, promoting seed germination and preventing pest damage), and for weed control fabric (100g/㎡ high weight product, allowing water to pass through the mesh to inhibit weed growth). In the outdoor sector, it is used for the breathable layer of outdoor tents (55g/㎡ product, breathable and sweat-wicking, preventing condensation inside the tent), and as the inner lining of sun-protective clothing (35g/㎡ product, lightweight and breathable, enhancing wearing comfort).

Changshu Yongdeli Spunlaced Nonwoven Fabric Co., Ltd. always takes customer needs as the guide, continuously optimizing the process of mesh spunlace nonwoven fabric. It can customize the mesh shape (round, rhombic, square), mesh size (0.1-5mm), and functional characteristics (antibacterial, hydrophilic, antistatic) according to customer requirements. In the future, the company will further develop new products such as "ultra-fine mesh" and "composite mesh", expand applications in high-end medical and precision filtration fields, provide customers with more high-quality and demand-oriented solutions, and achieve win-win development.