Thermal and Adhesive Bonding AFMT

1. INTRODUCTION

After web formation bonding process is done. It plays an important role when manufacturing
nonwovens, the loose cohesion of the fibers is treated in one or more steps to form a more
[1]
solid type of web, the nonwoven. Bonding may be carried out as a separate operation, but
is generally done at the same time as the web formation.
The degree of bonding is also a factor in determining fabric mechanical properties including
strength, porosity, flexibility, softness and density. More than one type of bonding process
can be used for some fabric constructions. [2]

2. THERMAL BONDING

The first thermally bonded nonwovens were produced in the 1940s. It offers high production
rates because bonding is accomplished at high speed with heated calendar rolls or ovens.
Thermal bonding is successfully employed in bonding dry-laid, polymer laid and wet-laid
webs as well as multi-layer materials. The basic concept of thermal bonding was introduced
by Reed. He described a process in which a web consisting of thermoplastic and non-
thermoplastic fibers was made and then heated to the melting or softening temperature of the
constituent thermoplastic fibers followed by cooling to solidify the bonding area. [3]

2.1. FIBERS SUITABLE FOR THERMAL BONDING

The thermal bonding processes utilize either thermoplastic fibers alone or blends containing
fibers that are not intended to soften or flow on heating. The base fibers can be of natural or
synthetic or mineral or metallic origin. The binder fibers can be mono-component (homofil)
like polyester (PET), polypropylene (PP), polyamide (PA), and polyethylene (PE) and
bicomponent (sheath-core) like PE/PET, PE/PP, and CoPET/PET. Looking at the thermal
bonding process, it is important to note down the melting temperature of these fibers. [4]

2.2. PRINCIPLE OF THERMAL BONDING

The formation of a bond during thermal bonding follows in sequence through three critical
steps:
i. Heating the web to partially melt the crystalline region,
ii. Repetition of the newly released chain segments across the fibre-fibre interface, and
iii. Subsequent cooling of the web to re-solidify it and to trap the chain segments that

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 Thermal and Adhesive Bonding AFMT

diffused across the fibre-fibre interface. [5]

2.3. METHODS OF THERMAL BONDING

Basically carding, airlaying and crosslapping techniques are used to form a batt. Then webs
are heated by following methods in thermal bonding:

2.3.1. HOT CALENDARING

The batt is passed through the nip of a pair of calendar rollers (Figure 1). One or both
calender rollers are heated to a temperature above the melting point of binder fibre. The low
melt fibre softens or melts to form. Heating is done usually by oil which is heated in a
separate unit by gas burner or electric heater circulated through the calender rollers by a
centrifugal pump.[6]

Figure 1: thermal bonding

2.3.2. BELT CALENDARING

Belt calendering is a modified form of hot roll calendering. The two main differences are the
time in the nip and the degree of pressure applied. In belt calendering, time in the nip is 1-10
seconds. The pressure applied is about 1/10th of the pressure applied in the hot calendering
process. The belt bonder consists of a heated roll and a rubber blanket. The nonwoven
fabric is heat bonded by running it between the roll and the blanket. (Figure 4) [7]

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Figure 2: belt calendaring

2.3.3. THROUGH AIR BONDING

Through-air thermal bonding involves the application of hot air to the surface of the
nonwoven fabric. The hot air flows through holes in a plenum positioned just above the
nonwoven. Pulling the air through the nonwoven fabric (as shown in figure 5) allows much
more rapid and even transmission of heat and minimizes fabric distortion. [8]

Figure 3: through air bonding

2.3.4. ULTRASONIC BONDING

This process involves the application of rapidly alternating compressive forces to localized
areas of fibers in the web (figure 6). The stress created by these compressive forces is
converted to thermal energy, which softens the fibers as they are pressed against each other.
Upon removal from the source of ultrasonic vibration, the softened fibers cool, solidifying the
bond points. [9]

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Figure 4: schematic diagram of an ultrasonic bonding machine

2.3.5. RADIANT HEAT BONDING

Radiant heat bonding takes place by exposing the web to a source of radiant energy in the
infrared range. The electromagnetic energy radiated from the source is absorbed by the web,
increasing its temperature. Bonding occurs when the binder resolidifies upon removal of the
source of radiant heat. [10]

Figure 5: schematic diagram of an infrared bonding machine

2.4. APPLICATIONS

Upholstery, Cushion pads, Heat insulation, Sound insulation, Medical Products, Automotive
heat insulation, Protective wrapping material etc. [11]

3. ADHESIVE BONDING
3.1. DEFINITION

In adhesive bonding, the fibers in the web are bound together. The fibers are interlock by the
application of a chemical binder. The most frequently used chemical binder to consolidate
fiber webs is water-borne latex. Most latex binders are made from vinyl materials, such as
polyvinyl acetate, polyvinylchloride, styrene/butadiene resin, and polyacrylic.

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3.2. PRINCIPLE OF ADHESIVE BONDING

In Adhesive bonding fabric formation is materialized by the application of resin or latex to
the structure. A general objective of each method is to apply the binder material in a manner
sufficient to interlock the fibers and provide fabric properties required of the intended fabric
usage.
As the viscosity of these resin or latex is close to that of water so they can easily penetrate
into nonwoven structure by emulsion. After application of binder, they are dried and the
water evaporates. The binder then forms an adhesive film across or between fiber
intersections and fiber bonding takes place.
3.3. FIBER SSUITABLE FOR ADHESIVE BONDING
Mostly cotton, polyester and viscose fibers and their blends are use in adhesive bonding. [12]

3.4. ADHESIVE BONDING OR CHEMICAL BONDING METHODS

Mostly wet-laid method is used in adhesive bonding. Following are the various adhesive
bonding methods:

3.4.1. SATURATION ADHESIVE BONDING

Fabrics can be produced by total saturation of the dry laid web of fibers in suitable adhesive.
The webs are immersed in a bath containing adhesives, where the amount take-up by the web
is controlled by the concentration of adhesive in the bath and by the degree of squeezing
applied to the impregnated material (figure 1). When it passes between two pressure and
emerge from the liquor. The saturation technique of adhesive bonding is only suitable for
producing stiff highly compressed fabrics for very open and bulky products.

Guiding To drying
Web screen Nip

Bath

Figure 6: principle of saturation adhesive bonding process

3.4.2. SPRAY ADHESIVE BONDING

The bonding by means of spraying the binders into or onto the textile structure by means of

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sprayers arranged above the moving web. The binder is saturated on the surface layers and
does not penetrate far in the structure.

Figure 7: principle of spray adhesive bonding process

3.4.3. FOAM BONDING

Foam-impregnation process is used for light weight webs. This high speed process is carried
out by the Fleisher static foaming box, where foam is produced directly at the foam padded
with the binder and compressed air being supplied in metered quantities. The foam is applied
over the full width of the fabric by means of an adjustable slot in the foam box (figure 3).

Figure 8: principle of foam bonding process

3.4.4. PRINT BONDING

In print bonding, the binders turned into the paste are transferred to the web by the surface of
the rollers. This bonding process is suitable for use at high production speeds the web has to
be wetted beforehand to prevent the fibers from sticking to the screen roller or matting roller
or web for splitting. In this bonding process the binders are only applied in places as dictated
by the pattern of the screen roller (figure 4).

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 Thermal and Adhesive Bonding AFMT

Figure 9: principle of print bonding process

3.5. APPLICATIONS
Automotive industry, upholstery, bedding applications, insulations, pre-filters, roofing membrane, wipes
towels, medical nonwovens, apparel interlinings etc. [13]

4. CONCLUSION:
It is clearly understood from the description of both the bonding methods that
contribution of each bonding method to the final nonwoven products may differ. The
functionality and performance characteristics of the products such as strength drape
ability, durability, application field, and some others can be classified among these
differences. Thus, the selection of proper bonding method and material is pretty important
in defining final properties and quality of nonwoven products.

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REFRENCES

[1] https://www.freudenberg-pm.com/Materials/Webbonding

[2] http://www.nonwovenexperts.com/bonding

[3]https://www.researchgate.net/publication/326669036_THERMAL_BONDED_NONWOV
EN-AN_OVERVIEW

[4] [5] https://nptel.ac.in/courses/116102014/7

[6][7][8]https://www.researchgate.net/publication/326669036_THERMAL_BONDED_NO
NWOVEN-AN_OVERVIEW

[9][10]http://textilelearner.blogspot.com/2012/01/thermal-bonding-process-of-
nonwoven.html

[11] https://www.slideshare.net/rajeshkumar572/nonwovens-its-applications

[12] http://www.textilevaluechain.com/index.php/article/item/276-overview-of-nonwovens-bonding-
technologies

[13] https://textlnfo.files.wordpress.com/2011/10/nonwoven-fabrics1.pdf

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