Posted & filed under Through Air Bonding.

There are a variety of ways to create nonwovens. Through air bonding is a type of thermal bonding that involves the application of heated air to the surface of the nonwoven fabric. In addition to the desirable characteristics provided by this versatile nonwoven material, it has the benefit of being lightweight and safer for the environment.

Person wiping off face with nonwoven material

Through air bond nonwovens are used for makeup wipes, hygiene products, filtration materials, bedding, carpet backing, cleaning wipes, dryer sheets, and other durable end use disposable products.

Through air bonding nonwovens have the characteristics of being:

  • Bulky
  • Open
  • Soft
  • Strong
  • Extensible
  • Breathable
  • Absorbent
  • Lightweight

The Through Air Bonding Process

The through air bonding process involves heated air flowing through holes in a plenum above the nonwoven material. As the nonwoven is drawn through the oven, the negative pressure of suction pulls the air through an open conveyor apron that holds the material, unlike hot ovens that push air through the material. The through air bonding process provides a rapid and even transmission of heat to minimize distortion of the nonwoven material.

Crystalline binder fibers and powders are used as binding agents in the through air bonding process. They melt to form molten droplets throughout the cross-section of the nonwoven. As the material is cooled, bonding occurs at these droplet points. Following production, through air bonding material is treated using a smoothing process called calendering. Hot roll calendering results in a thinner fabric, while cold calendering creates a thicker material. After calendering, the through air bond material remains flexible.

Person holding dirt with plant in dirt

Environmentally Friendly Nonwovens

For some time, through air bonding has been replacing the long-used process of spray latex bonding. Through air bonding is superior to spray bonding, which only sprays the outer layers of the web. The through air bonding process bonds thicker webs uniformly throughout the core. Since through air bonding relies on hot air instead of sprays, resins, and solvents, it is also naturally more environmentally friendly and hygienic.

WPT Nonwovens is your domestic source for through air bonded nonwoven material. Contact us to learn more about how we can meet your needs.