All You Need to Know About the Hot-Air Through Nonwoven Pattern

The hot-air-through bonding process

Also known as through-air bonding, this technique involves passing a fibrous web through a controlled stream of hot air. 

1. Web formation: First, fibers (often containing a low-melting-point component) are formed into a web using processes like carding or air-laying.
2. Thermal bonding: The web is then passed through an oven where hot air is pulled through it with suction. This melts the binder fibers at their intersection points, creating a soft, strong bond as the fabric cools.
3. Patterning: To create a specific pattern, the web can be pressed against an embossed roller or a patterned conveyor belt while it is still warm and pliable. The patterned surface causes the fabric to bond and consolidate in certain areas, leaving other areas with a more open, lofted structure. 

Characteristics of patterned hot-air-through nonwovens

The process results in a fabric with a combination of unique properties: 

• Enhanced softness: The bulkier, unbonded areas provide a premium, cotton-like feel.
• Breathability: The open, patterned structure allows for superior air circulation, which is crucial for hygiene products like Diapers.
• High loft: The process creates a thick, three-dimensional structure that is highly absorbent and provides a cushiony feel.
• Strength: The heat-bonded pattern ensures the fabric is strong and durable enough for its intended use. 

Common applications

This technology is primarily used for products where softness and absorbency are critical. 

• Hygiene products: It is widely used for the topsheets of diapers, Sanitary Napkins, and adult incontinence products.
• Medical products: The breathable and soft nature of the fabric makes it suitable for certain face masks and other medical materials.
• Wipes: The texture from patterning can improve the cleaning efficacy of wipes.