INTRODUCTION

There are three major bonding types, chemical bonding / thermal bonding/ mechanical
bonding (needle punching). The development of the past few years has shown that the share of
thermally bonded webs is growing steadily. Thermal bonding is the most popular method of
bonding used in nonwovens manufacture. It offers high production rates because bonding is
accomplished at high speed with heated calendar rolls or ovens. Thermal bonding process has
been used successfully with a number of thermoplastic fibers. Among the various types of
thermal bonding, point bonding is the most widely used technique.

The first thermally bonded nonwovens were produced in 1940s. The viability of the
thermal bonding process is rooted in the price advantage obtained by lower energy costs.
However, the thermal bonding process also addresses the demanding quality requirements of the
market place. The development of new raw materials, better web formation technologies and
higher production speeds have made thermal bonding a viable process for the manufacture of
both durable and disposable nonwovens.

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 fibres was made and then heated to the melting or softening temperature of
the constituent thermoplastic fibres followed by cooling to solidify the bonding area. In the
early development of thermal bonding, rayon fibres (the base fibre component) were blended
with plasticized cellulose acetate or vinyl chloride (the binder fibre component). Typically; a
carded web from a blend of base fibre and binder fibre was produced and hot calendared
followed by cooling to solidify and bond the web structure. The resulting thin, strong and
relatively dense product was more akin to a paper product than a textile material. Production
costs for this material were very high, primarily because the available binder fibres were
expensive. Its applications were limited to products requiring a smooth surface, low porosity,
high strength and lower thickness. Given the product limitations and the high cost of such
binder fibres, nonwoven producers continued to prefer latex bonding using chemical binders.

The rising cost of energy and greater awareness of the environmental impact of latex
bonding led to a change in direction. A comparison of energy consumption by various
webbonding processes is given in Fig. 1 which shows a considerable energy saving for the
thermal bonding process. The high production rates possible with thermal bonding and the
significant energy savings as compared to chemical bonding, due to the absence of significant
water evaporation during bonding, makes the process economically attractive. In contrast to
chemical bonding, the environmental impact of the process is also significantly reduced. The
growing market demand for disposable and durable products spurred developments in new
thermoplastic and thermoset materials in the form of powder, films, webs, hot melt compounds
as well as improved production methods such as point-bonding calendars, through-air bonding
and belt bonders. This has greatly increased the diversity of products that can be manufactured
by the thermal-bonding process.

PRINCIPLE OF THERMAL BONDING

Thermal bonding requires a thermoplastic component to be present in the form of a

homofil fibre, powder, film, web, hot melt ores a sheath as part of a bicomponent fibre. In
practice, heat is applied until the thermoplastic component becomes viscous or melts. The
polymer flows by surface tension and capillary action to fibre-to fibre crossover points where
bonding regions are formed. These bonding regions are fixed by subsequent cooling. In this case,
no chemical reaction takes place between the binder and the base fibre at the bonding sites.
When binders melt and flow into and around fibre crossover points, and into the surface crevices
of fibres in the vicinity, an adhesive or mechanical bond is formed by subsequent cooling. Such
an adhesive bond is a physio-chemical bond at the interface of two dissimilar materials. In the
thermal bonding context, a mechanical bond is formed as a result of thermal shrinkage of the
bonding material, which while in the liquid state encapsulates the fibre crossover points, In
contrast, if it the binder fibre interface both components soften or melt, inter-diffusion and
interpenetration of the molecules across the interface can occur and the interface may disappear.
This arises where compatible polymers are present with nearly comparable solubility parameters.
Bonds formed in this way may be called cohesive bonds.

BONDING PROCESS

Thermal bonding can be performed in several ways. In through-air bonding, a hot fluid,
air, is forced through a preformed web. If the temperature of the fluid is high enough, the fibers
may partially melt. In this case, they form bonds where two or more fibers come into contact. In
infrared bonding (IR-bonding), infrared light provides the heat required to partially melt the
fibers. In ultrasonic bonding, friction between contacting fibers due to the application of
ultrasound causes partial melting of the fibers. In thermal point bonding, the preformed fiber web
is passed between heated calendar rolls. The rolls may be smooth or embossed with a bonding
pattern. A uniform fabric requires uniform pressure, uniform temperature, and uniform input
web. Bonding occurs only where the fibers contact the heated rolls. Therefore, on a smooth
calendar roll, bonding occurs wherever fibers cross each other, while on an embossed calendar
roll, bonding occurs primarily between the raised areas. This results in bonding points or spots.
In each of these processes, the underlying physics is the same, the fibers are heated, they form a
bond, and they are subsequently cooled. To keep the discussion tractable, the remainder of this
discussion will be restricted to the formation of bond-points or spots via thermal point bonding,
and the effect of the formation process on the resulting fabric properties.
RAW MATERIALS

Thermally bonded fabrics are produced both from entirely thermoplastic materials and
from blends containing fibres that are not intended to soften or flow on heating. The non binder
component may be referred to as the base fibre component and commercially, a variety
of base fibre types are used. The binder fibre component normally ranges from 5-50% on
weight of' fibre depending on the physical property requirements of' the final product.

Base Fibres Types

The base fibre contributes to key physical, chemical and mechanical properties of the
fabric derived from the polymer from which it is constituted. This influences dyeing
characteristics, flame resistance, tensile and attritional properties, hydrolytic resistance, and
biodegradability amongst many other properties. The commonly used base fibres include
natural fibres (regenerated cellulosic fibres, bast, vegetable and protein fibres such as wool),
synthetic fibres (polyester, polypropylene, acrylic, nylon, aramid and many others), mineral
fibres (e.g., glass and silica) and metallic fibres. Sometimes the base fibre (carrier fibre) is the
core of a bicomponent fibre, with the sheath component being the binder portion.

Binder Materials

Binder components are produced in many different forms including fibre or filament
(homogeneous or bicomponent sheath/core or side-by-side type melt-bonding fibres), powder,
film, low melt webs, and hot melts. The physical form of the binder affects its distribution
throughout tile fibre matrix which has significant impact oil fabric properties. The amount of
binder also plays an important role in determining the properties of the resultant nonwoven
fabric. If the binder content is more than 50% of the total blend the fabric behaves like a
reinforced plastic. At a binder content of 10 % the fabric is a bulky, porous and flexible
structure with relatively low strength. To minimise energy costs it is desirable that binder
fibres have a high melting speed, a low melting shrinkage and a narrow melting point range.
The most widely used thermoplastic binder polymers are given in Table 1.

Table 1: Thermal transition point in common thermoplastic binder material

Glass transition Melting temperature

S.No. Fibre type
temperature CQ (IC)
 Polyvinyl chloride
1 91 200-215
(PVC)
2 Polyamide (PA) 50 210-230
3 Polyester (PET) 69 245-265
4 Polypropylene (PP) -18 160-175
Polyethylene (PE)
5 -110 115
( low density)

Decreasing the melt temperature of polymers, for instance PET, from 260 °C to 135-190
°C, requires the use of copolymers produced by polycondensation. The melting speed of these
copolymers is very high; hence the thermal shrinkage is reasonably low. When thermoplastic
fibres or powder, are used as binders, their melting temperature is significantly lower than the
base fibres in the web, which helps to prevent thermal degradation. In low melting temperature
homopolymers, or copolymer binder fibres or powders, complete melting can occur and the
polymer becomes a fluid. If the viscosity of the molten polymer is sufficiently low, it flows along
the surface of the base fibres and is collected at the fibre crossover points to form bonding points
in the shape of beads by subsequent cooling. In webs composed of bicomponent fibres (of the
sheath/core type) the sheath polymer does not need to completely melt but softens enough to
form a bond. However, if it does melt and flow, the bonding mechanism becomes similar to that
of homopolymer binder fibres. The advantage of bicomponent fibres is that every crossover can
be potentially bonded and also since the physical structure of the core component is not
degraded, thermal shrinkage is minimised, web structure remains essentially intact and fabric
strength is usually higher. Binder fibres are selected by their suitability for the different thermal
bonding processes.

Many materials that are used as a binder for thermally bonded nonwovens can be apply
by following methods in production.
• Binding fibers
• Binding powder
• Binding web

Binding Fibers

Single-component and bi-component fibers, as binder fibers, are most widely used in
thermal bonding of nonwovens. Single-component fibers are the least sophisticated and most
economical because the fibers are often already in existence and low in cost. The type bond that
is formed is dependent on several factors including fiber chemistry, morphology, linear density,
staple length, crimp, and processing conditions. The major disadvantage encountered when using
100 percent single-component fibers is the narrow temperature range that is necessary when
thermal bonding. If the temperature is too low, there is inadequate bond strength. If the
temperature is too high, the web will melt excessively and lose its identity as a web.
When bi-component fibers are used to produce thermal bonded nonwoven, the acceptable
temperature range for bonding may be as great as 25°C. When thermal bonding, the high melting
portion of the fiber maintains the integrity of the web, while the low melting point portion melts
and will bond with other fibers at the fiber crossover points. The product produced tends to have
bulk and exceptional softness.

Binding Powder

Powdered polymers are sometimes used in thermal bonding of nonwovens. The most
prevalent use is powdered polyethylene. Powdered polymeric binders can be applied during
web or batt formation or following web formation and pre-bonding. A thermoplastic polymer
with a low softening temperature is desirable that requires a short exposure to heat to melt and
fuse the powder. For ease of operation the thermoplastic powder should have a low melt
viscosity and the transition from melt to solid should occur over the shortest possible
temperature range. Polymers such as polyethylene, low molecular weight polyamide and
copolymers of vinyl chloride and vinyl acetate, are generally used. This method of thermal
bonding is limited by difficulties in obtaining polymers with a suitable range of particle sizes
to suit the base web. Obtaining a uniform powder distribution throughout the web is also
problematic. Powder bonding is suited to lightweight webs where an open structure is required
with a soft handle or in the production of reinforced, moulded products. Applications include
feminine hygiene, adult incontinence, medical and automotive products, wipes, computer
disks, apparel and shoe composites.

Binding Web

A very open-structured, low-melting-point thermoplastic fabric is placed between the

webs and, during thermal bonding between the calendar rolls, the fabric melts completely
bonding the webs together. The nonwoven produced by this technique is soft and bulky.
Thermoplastic coatings and hot melt print bonding have been used to a limited extent in
controlled porosity filters, impermeable membranes and other items. However, the use of this
method of bonding is not expected to achieve a high level of importance.

METHODS OF THERMAL BONDING

• Hot calendaring
• Belt calendaring
• Through-air thermal bonding
• Ultrasonic bonding
• Radiant-heat bonding, etc.

Hot Calendaring
Thermal bonding relies on the use of heat energy to melt or soften one or more
components of a web to achieve bonding. There are different methods of applying heat energy
to the web and the heal transfer mechanism can take different forms; conduction, convection
and heat radiation. The widely used methods are discussed in this section. Thermal calendar
bonding is a process in which a fibrous web containing thermoplastic components (fibres,
powders or webs) is passed continuously through a heated calendar nip that is created by two
rolls pressed against each other. Multi-nip calendars are also employed depending on the web
weight and degree of bonding required. Both rolls are internally heated to a temperature that
usually exceeds the melting point of the binder components in the web to ensure there is
sufficient heat transfer to induce softening at the prevailing line speed. As the web passes
between the at lender nip, fibres are both heated and compressed. This causes the binder
components of the web to become soft and tacky and induces polymer flow in and around the
base fibres. The fluid polymer tends to collect at fibre crossover or contact points and bonding
sites are formed. Cooling leads to solidification of the polymer and bonding.

Calendar bonding is mainly applicable to light and medium-weight webs because the
fibres in a thick web insulate heat from the interior of the structure leading to a temperature
gradient and variation in the degree of bonding through the cross-section. To increase the
efficiency of the process, the web may be pre-heated immediately prior to calendar bonding
sometimes by infra-red heaters. Commercially, light-weight webs of 25-30 g/m2 for medical
and hygiene applications and medium-weight webs of l00 g/m2 for interlining and filtration
applications are thermally bonded using calendar bonding. The degree of bonding depends on
temperature, pressure and speed, which determines the contact or dwell time.

There are three main types of hot calendaring.

• Area bonding
• Point bonding
• Embossing.

The properties of the fabric are influenced by the total bond area, which is normally
expressed in percentage terms. In practice, area bonding (100%) or point bonding (embossing)
is possible (<100%).

Area Bonding

This process involves the use of a calendar with a hot metal roll opposed by a wool felt,
cotton or special composition roll. Two, three or four roll calendars can be used, depending on
the weight of the web to be bonded and the degree of bonding desired. The three-roll calendar
has the heated roll in the middle while the four-roll configuration has the heated rolls on the top
and bottom, with the two composition roll in the middle. The amorphous or co-polymeric binder
fibers used in this process provide bonding at all cross-over points between the carrier and binder
fibers. The resultant product - commonly used in electrical insulation and coating substrates - is
smooth, thin and stiff. The material is always two sided, but this effect is most apparent in
material processed through two and three roll calendars. Four roll calendars minimize this effect.

The application of heat from the outside produces a material whose inner area is less bonded than
its outer surface. This becomes more pronounced as the product weight increases beyond 35
g/m2 and can become detrimental unless corrective measures are taken. These include increasing
heat, slowing speed, or increasing the binder/carrier fiber ratio. The two-roll calendar is used for
low-to-medium weight products with light-to- medium bonding. The three-roll calendar is used
for special bonding and finish effects on a single surface. The four roll calendar produces the
widest weight range of materials because it provides more flexibility in the application of heat.

Area-bond hot calendaring is influenced by five factors:

• Heat
Bonding occurs at the surface of the metal roll, which obtains its heat by conduction from
heated oil circulated through its center or from restrictive heating. The composition rolls
obtain their heat from contact with the heated metal roll. Before the start of a production
run, the roll stacks are operated until the composition rolls achieve dynamic heat
equilibrium.

• Pressure
Bonding occurs through simultaneous application of heat and pressure. The heat causes
the fiber binder to become thermoplastic. The pressure enhances mechanical bonding by
forcing the binder polymer to flow in and around the carrier fibers.
• Speed
The speed at which the nonwoven passes through the calendar, combined with heat and
pressure conditions, determines the degree of bonding in the nonwoven. It also
determines the throughput rate of the entire nonwoven line and is a critical factor in
product cost. The faster the rate, the lower is the cost. This is the primary reason for the
recent development of lower melting binders.
• Roll combination.
The only practical roll combination for area bonding is a metal roll-felt roll. The metal
roll applies the heat. The surface resilience of the felt roll enables uniform application of
pressure to all the minute surface thickness variations throughout the product.
• Cooling rolls
The product is warm and thermoplastic as it leaves the calendar nip. If the product were
to be wound while it was still hot, the tension applied to eliminate wrinkles would stretch
the web and introduce unrelieved stresses. This would lead to shrinkage whenever postheat
treatments were used. A set of two cooling rolls placed immediately after the
calendaring stage eliminates these unwanted side effects.

Point Bonding

Point-bond hot calendaring is the main method of thermally bonding in disposables as diaper,
sanitary products, and medical products. This method involves the use of a two-roll nip
consisting of a heated patterned metal roll and a smooth or patterned metal roll. This second roll
may or may not be heated, depending on the application. In a typical production line, the web is
fed by an apron leading to a calendar nip and the fiber temperature is raised to the point at which
tackiness and melting cause fiber segments caught between the tips of engraved points and the
smooth roll to adhere together. The heating time is typically of the order of milliseconds. The
fabric properties are dependent on the process temperature and pressure and other parameters
like the contact time, quench rate and calendar pattern. Experimental results show that for a
given nip line pressure and calendaring speed, the breaking strength reaches a maximum at a
critical bonding temperature; on keeping the nip line pressure constant, the critical temperature
was found to be a function of the calendaring speed.

Embossing or Novonette System

This method is a figured or sculptured area-bond hot calendaring. In this case, though, the area
bonding is three-dimensional. A "bulky but thin" product can be made in any pleasing or
functional construction, depending on the faces of the embossing rolls. The calendar roll
combination has a male patterned heatable metal roll and a matching female patterned felt roll.

In point bonding, webs are embossed by passing between an engraved calendar roller
and a solid smooth roller. This produces a fabric with an impression on one side only, while
the other side remains smooth. Both calendar rollers may be engraved with an identical pattern
of raised and depressed areas, so that a raised area on one roller matches a raised area on the
other roller to create a highly compressed area. However, two engraved rollers may be
designed in such a way that the raised area of one registers with the depressed area of the other.
The main problem in this case is that exact positioning of both rollers is essential to achieve
proper pattern definition which is difficult and expensive. The Novonette pattern is a patented
calendar system developed by the Kendall Co. Two identical helically engraved steel rollers
are used with lands and grooved areas. Owing to this helical pattern on each calendar roller, a
multiplicity of lands on one roller is constantly engaged with a multiplicity of lands on the
other roller. The pressure distribution is therefore even, and there is no need for exact
positioning of the roller.

The width of the lands and grooves can be varied, as well as the angle of the rollers, to
alter the physical and aesthetic properties of the nonwoven fabric. As the web passes through the
heated rollers under pressure, a repeating pattern is formed as shown in Figure. Three defined
areas are shown; (i) the dark section represents the area where the land of one roller crosses the
land of the other roller and maximum pressure is applied to produce a high degree of bonding,
(ii) the grey block represents the area where the land of one roller passes over a groove of
another roller and (iii) the white block is where the groove of one roller passes over the groove of
the second roller. Various factors influence the effect of the calendar associated with mechanical
process conditions and web structure.
BELT CALENDERING

Belt calendaring is a modified form of roller calendaring with two main differences i.e.
time in the nip and the degree of applied pressure. In roller calendaring the heating time is
measured in milliseconds whereas in belt bonding, time in the nip is extended to 1-10 seconds.
Pressure in a calendar roll nip is in the range 35-260 N/mm while in belt bonding the pressure
does not normally exceed 9 N/mm. The belt bonder consists of a heated roller and a rubber
blanket. The roller diameter ranges from 40-250 cm and is usually coated with PTFE to
increase its life. The resilient, heat-resistant (up to a temperature of 250 °C), silicone rubber
blanket wraps around the heated roller, covering up to 90% of the roller surface. The
nonwoven fabric is bonded by running in between the roller and the blanket when the heat and
pressure are applied simultaneously. Pressure is applied by varying

(i) The tension of the blanket against the heated roller and
(ii) The pressure on the exit guide roller
The resultant product is much less dense and papery compared to roller calendared
products. This method also facilitates the use of binders with sharp melting point and flow
properties which present difficulties in roller calendars. Both area bonding and point bonding
can be achieved using different types of blanket. The embossing can be done in line using an
embossing roller positioned after the web exits the belt section. A double drum belt bonder
suitable for thick fabrics is also available. Working widths up to 6 m and production speeds of
up to 100 m/min are claimed for belt bonding.

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. However, the air is not pushed through the nonwoven, as in common hot air ovens,
but negative pressure or suction, pulls the air through the open conveyor apron that supports the
nonwoven as it passes thorough the oven. Pulling the air through the nonwoven fabric allows
much more rapid and even transmission of heat and minimizes fabric distortion.
Binders used in through-air thermal bonding include crystalline binder fibers, bi component
binder fibers, and powders. When using crystalline binder fibers or powders, the
binder melts entirely and forms molten droplets throughout the nonwoven's cross-section.
Bonding occurs at these points upon cooling. In the case of sheath/core binder fibers, the sheath
is the binder and the core is the carrier fiber. Products manufactured using through-air ovens tend
to be bulky, open, soft, strong, extensible, breathable and absorbent. Through-air bonding
followed by immediate cold calendaring results in thicknesses between a hot roll calendared
product and one that has been though-air bonded without compression. Even after cold
calendaring, this product is softer, more flexible and more extensible than area-bond hot
calendared material.

Through-air bonding can take two different forms:

1. The perforated drum or rotary system and
2. The perforated conveyor or flat bed system
3. Impingement bonding (air jetting system)

PERFORATED DRUM-THROUGH-AIR BONDING

In this method a web wraps around the circumference of a porous drum at an angle of 300°. The
remaining part of the drum is covered with a fixed shield positioned inside the drum. Heated air
supplied to the area adjacent to the outside of the web is drawn through the entire width of the
product by suction created using a rotary fan. The perforated drum and fan are combined in
one chamber which results in high flow efficiency. The open area depends on the shape and
size/diameter of the perforation and can be up to 48%. When using a square perforation for
special applications (e.g., sanitary products) it is possible to achieve open areas of up to 75%.
Light-weight webs of 10 g/m2 up to very heavy but permeable webs and felts of 3000 g/m2 can
be processed. The heating system is determined by the required temperature using steam,
thermal oil, direct gas, hot water or electric energy. A process speed of 300 m/min is
achievable.
The drum system has the following advantages compared with the belt method:
• Compact design (i.e., perforated drums, fans and radiators are installed in an insulated
housing).
• Reduced energy consumption (no thermal losses by conveying device, i.e. the drum remains
inside the insulated chamber).
• Through-air bonding provides automatic heat recovery from the material, unless the line is
combined with a calibrating unit.

Perforated drums are available in diameters from 1000 to 3500 mm and working widths
from 400 to 7000 mm. Generally, one-drum or two-drum units are in use; however there are
some multi drum lines. Figure 9 gives a schematic diagram of a two-drum configuration
arranged horizontally where a shield covers half the circumference of each of the cylinders.
In some through-air bonding designs, a pair of pressure rolls with adjustable roll gaps
known as a calibrating unit is placed at the end of the line sees Fig. This allows bulkier webs or
batts to be produced to a pre-specified thickness than can be achieved by calendar bonding as
well as the production of dense webs having high tensile strength and a smooth surface.

Perforated drums with a high open area of up to 96% are designed for bonding webs with low
air permeability and when high production speeds or high temperature and flow uniformities
are required. Production speeds of more than 1000 m/min and working widths of up to 10 m
are available.
PERFORATED CONVEYOR-THROUGH-AIR BONDING

In flat conveyor systems, the web is carried without the need for control by suction draught.
This enables bonding of voluminous nonwoven fabrics as used, for example, in the production
of air laid waddings. Thickness changes depend on the degree of thermal shrinkage arising
from unrestricted fibre shrinkage and therefore, bicomponent fibres with low shrinkage
properties are preferred. A uniform air flow and temperature distribution across the working
width is essential to avoid irregular thermal shrinkage and bonding in the fabric. Generally, the
perforated belt system is particularly suitable for bulky, low-density webs.

IMPINGEMENT BONDING (AIR JETTING SYSTEM)

Impingement systems are traditionally associated will the drying of paper products but they
can be adapted for thermal bonding of nonwovens. In such air jetting systems, hot air is blown
onto the web from one or both sides by means of a nozzle system at a speed of up to
approximately 40 m/s. The air flow approaches the web vertically from above and on contact it
is deflected 90° so that an air flow parallel to the web surface is formed, see Fig.
In the case of double-sided air jetting the web is not pressed against the belt, but rather
it floats on the bottom air flow and both sides of the web are bonded. Fibres within the web
structure are less effectively heated by the hot air and therefore limited bonding occurs within the
cross-section of the structure. The difference between the through-air and air jetting approaches
is given by the heat transfer coefficient ration between through air bonding and air jetting is 3:1.
This technique is preferred for products where a pile is to be raised by adjusting the top and
bottom air flows. It is mostly used in perforated belt systems. Figure below illustrates the
arrangement of typical one- and double-sided air jetting units.
ULTRASONIC BONDING

This process involves the application of rapidly alternating compressive forces to localized areas
of fibers in the web. 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. This method
is frequently used for spot or patterned bonding of mechanically bonded materials.
No binder is necessary when synthetic fibers are used since these are self-bonding. To
bond natural fibers, some amount of synthetic fiber must be blended with the natural fiber.
Fabrics produced by this technique are soft, breathable, absorbent, and strong. This bonding
method is used to make patterned composites and laminates, such as quilts and outdoor jackets.
RADIANT HEAT BONDING

Radiant heat bonding takes place by exposing the web or mat to a source of radiant energy in the
infrared range. The web, increasing its temperature, absorbs the electromagnetic energy radiated
from the source. The application of radiant heat is controlled so that it melts the binder without
affecting the carrier fiber. Bonding occurs when the binder resolidifies upon removal of the
source of radiant heat. Lower energy and equipment costs make this a favored method for
processing powder-bonded nonwovens. Versatility and lower shipping costs are also factors.
Post-calendared rolls can be shipped in thin, compacted form and rebulked by reapplication of
heat, without pressure or restraints, to the desired state at the time of use. Powder bonded
products made in this manner are soft, open, and absorbent with low-to-medium strength. They
also can be reactivated by heat for use in the manufacture of laminated composites.

SOME OF THE MAIN ADVANTAGES OF THERMAL BONDING ARE AS FOLLOWS:

• Products can be relatively soft and textile-like depending on blend composition and bond
area.
• Good economic efficiency compared to chemical bonding involving lower thermal energy
requirements and less expensive machinery.
• High bulk products can be bonded uniformly throughout the web crosssection.
• 100 % recycling of fibre components can be achieved.
• Environmentally friendly since no latex binders are required
CONCLUSION

Thermal bonding is much less energy intensive, kinder to the environment and more economical.
A wide range of products can be made with thermal bonding, depending on the options used for
processing. The bonding method has a significant effect on product properties. Depending on the
bonding method, product properties can vary from nonporous, thin, and non extensible, and
nonabsorbent to open, bulk, extensible and absorbent. All thermal bonding methods provide
strong bond points that are resistant to hostile environment and to many solvents too.

Bond strength increases up to a maximum and then decreases with increase in bonding
temperature for both staple fiber thermal bonding webs. Bond strength increases with increase in
bond area. Bond strength increases with increase in bond size. Effect of bonding temperature,
bond area, and bond size on fiber morphology in the unbonded region is negligible. In all cases,
crystal sizes were different in the unbonded and bonded regions, values being higher in the
bonded regions. This is due to the effect of heat in the bonded region. However, in the unbonded
regions, the effect is negligible at these processing conditions, for fibers investigated, which may
be due to fairly well-developed structure of the fibers.
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