Manufacturing Methods of Felts & Nonwovens
Felts and Nonwovens are fiber products, which are fabrics made by three-dimensionally entangling and bonding fibers.
From among the various manufacturing methods, we introduce our typical processes.
1. Compounding
Raw material fibers are untangled and compounded.
2. Carding
Fibers are carded so that they are parallel to one other and laps are made.
※Click on the manufacturing method you want to know.
Pressed Felt
- Features
- Wool is used as a main raw material. The unique characteristics of wool, such as heat-retaining property, moisture absorption & desorption properties, flame retardancy, water repellency and dyeability, are utilized.
- Uses
- Parts of musical instruments, colored felt, rugs, interlining, gaskets, polishers and etc.
3-1. Hardening
The felting (fulling) property of wool is utilized in this process. Moisture and heat are applied to the laps, and then force is applied to them to entangle fibers.
3-2. Fulling
Felt is sandwiched between the upper and lower rolls and compressed to get the specified hardness.
3-3. Dyeing
Felt is dyed the specified color.
3-4. Drying
Excess water is removed.
3-5. Pressing
Felt is sandwiched between the heat press plates and the surface is smoothed.
Needle-Punched Nonwovens
- Features
- Various kinds of fibers can be used. We support a wide range of specifications and characteristics, from thin (1mm) to thick (over 10 mm) and from soft to hard.
- Uses
- Filters, industrial materials, padding materials, carpets, interlining and etc.
3. Needle Punching
Fibers are entangled mechanically by sticking webs repeatedly from above and below with barbed needles.
Thermal-Bonded Nonwovens
- Features
- They require mixing of thermal-adhesive fibers. We support a wide range of specifications from thin to thick by changing fusing method.
- Uses
- Insulators, cleaning materials, cushioning materials, sanitary materials and etc.
3. Thermal bonding
Thermal-adhesive fibers are fused and fibers are bonded each other. There are two methods of fusing: pressing by heated calender roller and applying heated air.
Chemical-Bonded Nonwovens
- Features
- Hardness can be changed depending on properties of the adhesive polymers used. It is easy to add value such as flame resistance and deodorant effect by using functional polymers.
- Uses
- Cushioning materials, industrial materials, filters, interlining and etc.
3-1. Chemical Bonding
Fiber webs are impregnated with liquid resin containing adhesive polymers to bond fibers each other.
3-2. Drying
Excess water is removed and resin is fixed.
Spunlace Nonwovens
- Features
- The most notable feature is their thinness and soft texture. Because fibers are not damaged much, the surface is smooth.
- Uses
- Cushioning materials, industrial materials, sanitary materials, wiping materials and etc.
3-1. Water Jet entangling
Water jets are emitted for fabrics from many nozzles to entangle fibers.
3-2. Drying
Excess water is removed.
4. Inspection
Finished products are inspected to ensure that there are no defects.
Composite Processing
We produce highly functional and high-performance products by applying our wide-range processing technologies to various felts and nonwovens regardless of our products or not.
Cutting
We have particular strengths in cutting precisely in half or in precise size and desired shape according to your specifications.
Sewing
Our sewing technique is excellent in sewing materials in unique shape and can sew to your exact specifications in size and shape.
Slitting
Our slitting machines can slit not only single body of felt and nonwoven but also composite materials as narrow as a few millimeters.
Slicing
Our technology, which we are proud of, can make felts and nonwovens sliced as thin as several hundred microns of thickness.
Resin Treatment
Felts and nonwovens are impregnated with resin and additional functions are available, such as flame resistance and water repellency.
Pleating
Our pleating machines can fold multi-layer nonwovens with different functions.
Electret processing
Nonwovens are electrically highly charged and become capable of catching fine dust.
