Needle-punched nonwoven fabric is formed by laying short fibers into a web and then repeatedly puncturing it with barbed needles, causing the fibers to entangle with each other. This method produces nonwoven fabric with good strength, breathability, and thermal insulation.

Process Flow: Raw Material → Opening Machine → Feeder → Carding Machine → Web Forming Machine → Needle Loom → Calendering Machine → Winding Machine → Finished Product

● Fiber Opening and Blending: Various short fibers (such as polyester, polypropylene, cotton, etc.) are opened, blended, and carded to achieve uniform distribution.

● Fiber Selection and Ratio: The choice of fiber directly affects the properties of the nonwoven fabric. For example, polyester fiber, known for its high strength and wear resistance, is often used in automotive interiors; viscose fiber, being soft and skin-friendly, is commonly used in hygiene products. Blending different fibers in specific ratios can yield nonwoven fabrics with varying properties.

● Web Forming: The blended fibers are evenly laid into a fiber web.

● Needle Punching: The fiber web is repeatedly punctured by high-speed, reciprocating needle boards. The barbs on the needles catch and entangle the fibers, forming a network structure.

● Needle Punch Density and Depth: Needle density refers to the number of needle punches per unit area; a higher density results in tighter fiber entanglement and greater strength. Needle penetration depth affects the degree of fiber interlocking, thereby influencing the thickness and bulkiness of the nonwoven fabric.

● Post-Treatment: Based on product requirements, post-treatment processes such as heat setting, embossing, or coating are carried out to improve the fabric's properties. These processes are diverse and include heat setting (to enhance dimensional stability), embossing (to add surface patterns), coating (to improve waterproof, oil-proof, etc., properties), and laminating (to combine nonwoven fabric with other materials, enhancing overall performance).

Characteristics of Needle-Punched Nonwoven Fabric

● High Strength: The interlocking of fibers gives the nonwoven fabric high strength.

● Good Breathability: The spaces between the fibers provide good air permeability.

● Good Thermal Insulation: The air trapped within the voids provides thermal insulation.

● Low Cost: The production process is relatively simple and low-cost, making it suitable for various applications.

● Wide Range of Applications: It can be used to make filter materials, thermal insulation materials, carpet backing, geotextiles, etc.

Future Development of Needle-Punched Nonwoven Fabric

● Intelligentization: Introduce smart manufacturing technologies to achieve automation and intelligence in the production process, improving efficiency and product quality.

● Functionalization: Endow needle-punched nonwoven fabric with more functions, such as conductivity, anti-static, antibacterial, and flame retardancy, to meet specific needs in different fields.

● Eco-friendliness: Develop needle-punched nonwoven fabrics using biodegradable and recycled materials to reduce environmental impact.

Changshu Yanrui Nonwoven Products Co., Ltd. has been dedicated to the nonwoven needle-punching industry for decades, striving to provide professional solutions for clients with diverse application needs.