Uniform consolidation
Homogeneous distribution of the fibers used as a “binder” over the entire nonwoven structure during the web-laying process leads to uniform bonding and constant mechanical properties of the nonwoven.
Strong bonding. Without compromise.
When maximum stability, precise control, and chemical-free processing are required, thermal bonding is the solution. Through targeted heat application, heat-activated fibers fuse together with pinpoint accuracy – for textile materials that are tailored precisely to your requirements.
Thermal bonding – functionally strong, sustainably bonded
Whether dimensionally stable, soft, voluminous, or highly functional, our thermally bonded nonwovens offer technical performance paired with economic efficiency. They are used in numerous industries, such as healthcare, mobility, construction, and apparel. During thermal bonding, the loose fiber fleece is processed to a stable, homogeneous nonwoven fabric. What makes this process special is that it does not require any additional bonding agents – a clear advantage in terms of environmental compatibility. By using various polymers with different melting points (e.g. bicomponent fibers), the fibers bond together under the influence of heat to form a solid compound. The result is a high-performance material with precisely controllable properties, without compromising on quality and sustainability – stable, functional, and precisely tailored to your requirements.
Airthrough bonding
The airthrough bonding process is particularly suitable for thicker nonwovens and enables uniform consolidation. The bonding is performed by a bonding fiber with a lower melting point or a bicomponent fiber with two different melting temperatures. Thermal bonding is becoming increasingly important because the nonwoven fabric can be bonded easily and no chemical binders are required. Heat-sensitive components are a prerequisite for this nonwoven fabric formation process. The process allows precise control over structure, porosity, and strength.
- Mechanically gentle processing
- Precise control over structure, porosity, and strength
- High purity and surface quality
- Flexibility for customized products
Schematic process
In this process, hot air is passed through the nonwoven fabric to fuse the fibers together. The raw material is consolidated without pressure in a drum dryer or belt dryer.
High purity
No fiber residues, fiber breaking, or impurities, as there is no mechanical processing and no addition of chemical binders. This is particularly important for medical or filtration applications.
Improved permeability
The air through bonding process enables an open fiber structure with controlled porosity, which promotes a defined passage of air, liquids, or sound.
Calendering
The calendering process is a thermal-mechanical bonding process and is particularly well suited for uniform surfaces with excellent surface smoothness and a firm structure. The temperature and pressure of the rollers allow the nonwovens to be individually adjusted to meet any specific requirements. In this process, fusion takes place at the fiber junctions. This gives the materials high tensile strength and tear resistance despite their low basis weight. Precise control of the process reduces material waste and contributes to resource efficiency.
- High mechanical strength
- Dimensionally stable and flat
- Smooth surfaces
- No chemical binders
Schematic process
Two or more calender rolls are heated to a defined surface temperature and the nonwoven fabric passes between them. The pressure between the rolls (line pressure) creates thin, homogenous and well-consolidated nonwovens. The contact area and geometry influence the mechanical strength and softness of the nonwoven fabric. Typically the upper roller is engraved. This structuring specifically influences the mechanical strength and, at the same time, the softness of the end material. No chemical binder is required.
Dense consolidation
Defined temperatures and pressure of the heated rollers allow for individual consolidation structures.
Adaptability
Process parameters such as temperature and pressure can be finely controlled. Engravings on the rollers allow for targeted spot or surface bonding to control properties.
Smooth surfaces
The use of smooth roller surfaces creates uniform surfaces with a homogeneous basis weight. Calendered nonwovens show a high dimensional accuracy.
Mechanical strength
Thermal fusion at the fiber junctions creates a robust material with increased durability and tear resistance despite low basis weights.
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Whether you need dimensionally stable, flexible, or particularly sustainable nonwovens, our thermal bonding process offers you an efficient, binder-free solution for a wide range of applications. Take advantage of our technological expertise and let us work together to develop the right material for your products.