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—CONTENT LIST
Introduction
Types Of Bonding Process
1.Thermal Bonding
Fibers suitable for thermal bonding
Principle of thermal bonding
Methods of thermal bonding
Applications
Market dealers
2.Adhesive Bonding
Fibers suitable for adhesive bonding
Principle of adhesive bonding
Methods of adhesive bonding
Applications
Market dealers
Conclusion 2
After web formation, the next
process is web bonding.

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 TYPES OF BONDING PROCESS

Mechanical Bonding Thermal Bonding Adhesive/Chemical

Bonding

The first
The basic
thermally
concept of
bonded
thermal
nonwovens
bonding was
were
introduced
produced in
by Reed.
the 1940s.

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 THERMAL
BONDING !
Reed 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.
It offers high production rates.
Successfully employed in bonding dry-laid, polymer laid and wet-laid webs as well as
multi-layer materials.
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 non-binder fiber components may be referred to as

the base fibers or sometimes, carrier fibers

The binder fiber component normally ranges from 5-50

% on weight of the fiber depending on the targeted
properties of the final product made there upon

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FIBERS SUITABLE FOR THERMAL BONDING
Natural

Synthetic
Base Fiber
Metallic
PET
Mineral
Types of PA
Fibers Mono-
component
PP

Binder PE
Fiber
PE/PET
Bi- PE/PP
component
CoPET/PET
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 MELTING TEMPERATURES OF FIBERS
MELTING
FIBERS TEMPERATURE
(Degree Celsius)
PET (Polyester) 245-265

PP (Polypropylene) 160-175

PA (Polyamide) 210-230

PE (Polyethylene) 115-135

PE/PET 130/250

PE/PP 130/175

CoPET/PET 110/250
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 PRINCIPLE OF THERMAL BONDING

1 2 3
Heating the web Repetition of the Subsequent cooling of
to partially melt newly released the web to re-solidify
the crystalline chain segments it and to trap the chain
region across the fibre- segments that diffused
fibre interface across the fibre-fibre
interface

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 METHODS OF
THERMAL 1. HOT CALENDARING
BONDING
• The batt is passed through the nip of a pair of calendar rollers.
• One or both calendar rollers are heated to a temperature above the melting point of binder fiber.
• The fiber having low melting point softens or melts to form bonds between the fibers.
• Heating of calendar rollers is usually by oil which is heated in a separate unit by gas burner or
electric heater. Oil is circulated through the calendar rollers by a centrifugal pump

Area Bonding

Point Bonding

Embossing
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 AREA BONDING
This method 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 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.
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.

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 POINT BONDING
This method involves the use of two-roll nip consisting of
heated patterned metal roll and a smooth or patterned
metal roll
• The web is fed by an apron leading to a calendar nip.

• The fiber temperature is raised to the point at which tackiness and

melting of fibers adhere them together.
• The smooth roll may or may not be heated, depending on the
application. The heating time is typically of the order of milliseconds

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 EMBOSSING
This method involves the use of both calendar rollers engraved
with an identical pattern of raised and depressed areas
Two engraved rollers may be designed in such a way that the raised area
of one registers with the depressed area of the other to create a highly
compressed area. The exact positioning of both rollers is essential to
achieve.

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 2. BELT CALENDARING
In belt calendaring, time in the nip is 1-10 seconds and the pressure applied is about 1/10th of the
pressure applied in the hot calendaring 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.
Pressure is applied by varying:
• The tension on the blanket against the heated roll.
• The pressure on the exit guide roll inside the rubber blanket.

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 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. Negative
pressure or suction, pulls the air through the open conveyor apron that supports the nonwoven as it
passes through the oven.
Perforated drum
through air bonding

Perforated conveyor
through air bonding

Impingement bonding
(air jetting system)
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 4. ULTRASONIC BONDING
Ultrasonic bonding involves the application of rapidly alternating compressive forces to localized
areas in the web. The stress created by these compressive forces is converted to thermal energy,
which softens the fibers. Upon removal from the source of ultrasonic vibration, the softened fibers
cool, solidifying the bond points. 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.

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 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. The application of radiant heat is controlled so that it melts the binder without affecting
the carrier fiber. Bonding occurs when the binder solidifies upon removal of the source of radiant
heat.

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 APPLICATIONS
OF THERMAL
BONDING

Upholstery | Building material | Medical products | Automotive |Protective wrapping

MARKET
Dora Enrico - India
AB Harris Co. (Nikoo group) - Iraq
Albis SPA- Italy

SUPPLIERS Allara- Kenya

CHA technologies Group- United
kingdom

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 ADHESIVE
BONDING !
In adhesive bonding, the fibres are interlock by the application of a chemical binder.
It offers high production rates.

The most frequently used chemical binder to consolidate fibre webs is water-borne
latex.

Most latex binders are made from vinyl materials, such as polyvinyl
acetate, polyvinylchloride, styrene/butadiene resin, and polyacrylic.
FIBERS SUITABLE FOR
ADHESIVE BONDING
Mostly cotton, polyester and viscose fibers and their
blends are use in adhesive bonding as base fibers.

The non-binder fiber components may be referred to as

the base fibers or sometimes, carrier fibers

The binder fiber component is also added along with base

fibers. Basically three groups of materials are commonly
used as binders-acrylate polymers and copolymers,
styrene-butadiene copolymers and vinyl acetate ethylene
copolymers

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 PRINCIPLE OF ADHESIVE BONDING

1 2 3
Fabric formation is As the viscosity of After application of
materialized by the these resin or latex binder, they are dried
application of resin is close to that of and the water
or latex to the evaporates. The
structure. Binder is water so they can
easily penetrate binder then forms an
applied in a manner
to interlock the fibers into nonwoven adhesive film across
and provide fabric structure by or between fiber
properties required emulsion. intersections and
of the intended fabric fiber bonding takes
usage place
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MARKET
A B Harris Co. (Nikoo Group- Iraq)

Aashika Textile- India

Albis SPA- Italy

SUPPLIERS Colbond (Law & Bonar) -United

States of America

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 SATURATION
ADHESIVE
BONDING

Fabrics can be produced by

total saturation of the dry
laid web of fibers in
suitable adhesive. this is the
simplest technique of
applying adhesives to such
webs, which are often light
weight.
 SPRAY
ADHESIVE
BONDING
The bonding by means of
spraying the binders is
produced into or onto the
textile structure by means of
sprayers arranged above the
moving web. the binder is
saturated on the surface
layers and does not penetrate
far in the structure, which is
normally quite thick.
 FOAM BONDING

Spray bonding is now being

replaced by foam-impegration
process for light weight webs.
this high speed process is
carried out by the Fleisher static
foaming box. the foam is
applied over the full width of
the fabric by means of an
adjustable slot in the foam box.
 APPLICATION
OF POWDERS

The powder is poured from Feed container

the feed container into the Brush roller with powder

grooves running parallel to

the axis of the dosing roller.
when the powder comes
Corrugated
into the area of contact of Vibrating
disposing roller
traveling screen
the brushing roller it is
Web saturated
brushed out of the grooves Web with powder
and thrown on to the web in
a finely distributed layer.
 PRINT
BONDING

In print bonding, the binders

turned into the paste are Dr. Blade Screen roller

transferred to the web by the

Unbounded web Bonded fabric
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
Adhesive paste
from sticking to the screen Matting roller
roller or matting roller or web
for splitting.
 APPLICATIONS

To have better abrasion resistance and good handling, the outer part of the shoes are made
from chemically bonded nonwovens. Also in automotive industry, upholstery and bedding
applications, insulation applications, pre-filters and roofing membrane applications,
chemical bonding methods are used. Other include:
Wipes and towels, Medical nonwovens, Roofing products, Apparel interlinings, Filter
media,
Coating substrates, Automotive trim, Carrier fabrics, Bedding products, Furniture
applications,
Apparel, Pillows (high loft)
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 Any Question ??

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