Spunlace process: the key to improving the mechanical properties of mesh spunlace nonwovens

Principles and characteristics of spunlace process

Spunlace process is a technology that uses high-pressure micro-water flow to reinforce the fiber web. The basic principle is to use a high-pressure water pump to refine the water flow into extremely fine water needles and spray them onto the fiber web at a very high speed. These water needles penetrate the fiber web, causing the fibers to displace, entangle and interweave under the action of the water flow, and finally form a strong three-dimensional network structure.

The characteristics of the spunlace process are mainly reflected in the following aspects:

1. Environmental protection: The spunlace process does not require the use of chemical adhesives, and only relies on the physical action of the water flow to achieve fiber entanglement. Therefore, the production process is pollution-free and meets the requirements of green environmental protection.

2. Efficiency: The spunlace process has a fast production speed, can achieve continuous production, and is suitable for large-scale industrial applications.

3. Flexibility: By adjusting parameters such as spunlace pressure and water needle arrangement, the performance of the product can be flexibly controlled to meet the needs of different application scenarios.

Improvement of the mechanical properties of mesh spunlace nonwovens by spunlace process

The spunlace process forms a strong entanglement structure between fibers through the physical action of high-pressure water flow, thereby significantly improving the mechanical properties of mesh nonwovens. The following is the specific impact of the spunlace process on the mechanical properties of mesh nonwovens:

1. Excellent tensile strength
Tensile strength is a measure of the ability of a material to resist external force stretching, and is one of the important performance indicators of mesh nonwovens. The spunlace process forms a large number of entanglement points between fibers through the action of high-pressure water flow. These entanglement points are like countless "little hands" tightly clasped together, effectively resisting external force stretching.

The role of entanglement points: The entanglement points formed by the spunlace process are not only numerous, but also evenly distributed, which can evenly disperse external forces and avoid stress concentration, thereby improving the overall tensile strength of the material.

Optimization of fiber arrangement: The spunlace process makes the fibers more evenly distributed in three-dimensional space, reduces the gaps between fibers, and further enhances the material's tensile resistance.

In practical applications, mesh nonwovens with high tensile strength can withstand greater external forces without being easily deformed or broken. For example, in medical bandages, high tensile strength can ensure that the bandage is not easy to break during the dressing process, thereby better protecting the wound; in filter materials, high tensile strength can extend the service life of the material and reduce the frequency of replacement.

2. Excellent tear strength
Tear strength is a measure of the material's ability to resist crack propagation, which is crucial to the service life and reliability of mesh nonwovens. The hydroentanglement process forms a "hook-and-loop" structure by entanglement of fibers in three-dimensional space, which can effectively prevent the propagation of cracks.

Formation of "hook-and-loop" structure: During the hydroentanglement process, the fibers are displaced and interlaced under the action of water flow to form a complex entanglement structure. This structure is similar to the "hook-and-loop" mechanism in nature, which can disperse stress under the action of external force and prevent further crack propagation.

Utilization of fiber length: The hydroentanglement process can make full use of the length of the fiber, so that the fiber forms more connection points during the entanglement process, thereby enhancing the material's tear resistance.

Mesh nonwovens with high tear strength show greater durability in applications. For example, in sanitary products, high tear strength can prevent the material from being damaged by friction or pulling during use; in industrial filter materials, high tear strength can ensure that the material is not easy to break under high pressure, thereby improving the filtration efficiency.

3. Excellent bursting strength
Burst strength is a measure of the material's ability to resist local pressure, which is particularly important for the application of mesh nonwovens in high pressure environments. The hydroentanglement process improves the material's bursting strength by making the fiber distribution more uniform and the fibers more tightly bonded.

Uniformity of fiber distribution: The hydroentanglement process makes the fibers evenly distributed in three-dimensional space, reducing the weak points in the material, thereby improving the overall compressive resistance.
Tightness of fiber bonding: The hydroentanglement process forms more contact points between fibers, enhances the bonding force between fibers, and makes the material less likely to break when subjected to local pressure.

Mesh nonwovens with high bursting strength show stronger stability under high pressure environments. For example, in medical protective clothing, high bursting strength can ensure that the material is not easy to break when subjected to external impact, thereby better protecting medical staff; in industrial filter materials, high bursting strength can ensure that the material maintains stable filtering performance under high pressure environment.

The effect of spunlace process parameters on mechanical properties

The effect of spunlace process is affected by many parameters, mainly including spunlace pressure, spunlace head arrangement, fiber mesh weight, etc. The optimization of these parameters can further improve the mechanical properties of mesh non-woven fabrics.

1. Spunlace pressure: The greater the spunlace pressure, the tighter the entanglement between the fibers, and the better the mechanical properties of the material. However, excessive spunlace pressure may cause fiber damage, so it needs to be optimized according to specific needs.

2. Spunlace head arrangement: The arrangement of the spunlace head will affect the spray angle and strength of the water flow, thereby affecting the entanglement effect of the fiber. Reasonable spunlace head arrangement can improve the uniformity of entanglement and enhance the mechanical properties of the material.

3. Fiber mesh weight: The greater the fiber mesh weight, the greater the entanglement force required, and the spunlace process parameters also need to be adjusted accordingly. By optimizing the weight of the fiber mesh, a balance between material performance and cost can be achieved.

Advantages of spunlace technology in the application of mesh non-woven fabrics

The improvement of mechanical properties brought by the spunlace process provides a more reliable guarantee for the application of mesh non-woven fabrics. The following are the advantages of spunlace technology in different application fields:

1. Medical field: In medical bandages, surgical gowns, protective clothing and other products, the high tensile strength, tear strength and bursting strength given by the spunlace process can effectively protect wounds and prevent infection, providing patients with a safer and more comfortable medical experience.
2. Hygiene field: In sanitary products such as sanitary napkins and diapers, the softness, breathability and high mechanical properties brought by the spunlace process can provide consumers with a healthier and more intimate life experience.
3. Filtration field: In industrial filtration materials such as air filtration and liquid filtration, the high strength, wear resistance and stability given by the spunlace process can improve filtration efficiency, extend the service life of the material, and provide more reliable solutions for industrial production and environmental protection.