What is needle-punched nonwoven?
Needle punched nonwoven is a type of nonwoven fabric produced through a mechanical process called needle punching. This process involves the entanglement of fibers by repeatedly inserting and withdrawing barbed needles, which bond the fibers together to form a cohesive fabric.
We sell needlepunch (felt) nonwovens, which are strong fabrics made by employing barbed needles to tangle threads together.
We make high-quality needlepunch nonwoven textiles that are strong, stable, and function consistently in the clothing, automobile, and home furnishings industries.
- Strong and long-lasting: Holds up to mechanical force and keeps its shape over time.
- Insulation for heat and sound: Great for controlling temperature and absorbing sound.
- Many Uses: Good for mats used in cars, construction, filtering, and industry.
- Standards Around the World: Made to meet ASTM, ISO, and EN standards for dependability.
We sell needle-punch nonwoven fabrics made using cutting-edge mechanical needle-punching technology. This process binds fibers together without the use of chemicals, making a robust, flexible fabric. Made to fulfill the high standards of industrial, automotive, and home furnishing uses.
Important Details:
- GSM Range: 100 to 1,000 gsm
- 100% polyester, 100% polypropylene, or a mix of the two
- Width: 320 cm at most
- Needle-punching is a bonding technology.
- Finish: smooth, rough, or patterned
We offer strong, high-density needlepunch (felt) solutions that are built to last and work well in a wide range of worldwide industrial settings.
- Soil stability, preventing erosion, and drainage layers
- Padding for the seats, headliners, trunk liners, and soundproofing
- Rugs, carpet backing, upholstery, and couch covers
- Protective layers, insulating matting, and filtration medium
- Geotextiles and Construction: fabrics that stabilize roads, layers that drain and filter water, roofing felt bases, mats that stop erosion, and ballast protection for railroads
- Car and transportation: floor mats, trunk liners, headliners, soundproofing for the hood, parcel shelves, and wheel arch liners
- Industrial and Filtration: HVAC filter media, synthetic leather substrates, polishing pads, geotubes, and industrial dust collection bags
- Home and lifestyle: carpets and rugs, mattress pads, shoe insoles and linings, furniture padding, and acoustic wall panels
Production Process of Needle-Punched Nonwoven
- Fiber Selection:
- Types of fibers used can include synthetic fibers (like polyester, polypropylene, and acrylic), natural fibers (like cotton, wool, and jute), or blends of fibers.
- Blending: Blending different fibers can enhance specific properties such as strength, absorbency, and thermal resistance.
- Web Formation:
- Carding: Fibers are opened, aligned, and layered into a web using carding machines.
- Air Laying: Fibers are dispersed into an air stream and then deposited onto a moving conveyor belt.
- Wet Laying: A web is created by suspending fibers in a liquid medium and then depositing them onto a screen.
- Needle Punching:
- Needle Loom: The formed web is fed into a needle loom where barbed needles penetrate and withdraw from the web repeatedly.
- Fiber Entanglement: The barbs on the needles catch and entangle the fibers as they move through the web, creating a mechanically bonded fabric.
- Density Control: Adjusting needle penetration depth, density of needles, and the number of passes through the loom allows control over the fabric’s density and strength.
- Finishing:
- Thermal Bonding: Additional bonding can be achieved by passing the fabric through heated rollers.
- Chemical Treatment: Applying binders or coatings to enhance properties like water resistance, flame retardancy, or durability.
- Calendering: Passing the fabric through heated rollers to improve surface texture and appearance.
Characteristics of Needle-Punched Nonwovens
- Durability: High tensile strength and durability due to mechanical entanglement.
- Versatility: Suitable for various applications because of varying fiber types, web formation methods, and finishing processes.
- Thickness and Loft: Capable of producing thick, lofty fabrics that provide cushioning and insulation.
- Permeability: Adjustable air and liquid permeability.
- Surface Texture: Can range from smooth to highly textured based on needle density and type.
Applications of Needle Punched Nonwovens
- Geotextiles:
- Soil Stabilization: Used in road construction, erosion control, and retaining walls.
- Drainage: Provides filtration and drainage in construction projects.
- Automotive:
- Interior Linings: Car carpets, headliners, and trunk liners.
- Filtration: Engine air filters and cabin air filters.
- Construction:
- Roofing and Insulation: Thermal and acoustic insulation materials.
- Flooring Underlayment: Cushioning and soundproofing under carpets and laminate flooring.
- Furniture and Bedding:
- Mattress Pads and Toppers: Provides cushioning and comfort.
- Upholstery: Adds structure and durability.
- Industrial Applications:
- Filtration: Industrial filtration systems for liquids and air.
- Abrasives: Backing material for abrasive pads and belts.
- Consumer Products:
- Carpets and Rugs: Durable and wear-resistant.
- Wipes and Cleaning Pads: Durable and absorbent for cleaning purposes.
Advantages of Needle Punched Nonwovens
- High Strength and Durability: Suitable for heavy-duty applications.
- Customizable: Properties can be tailored by adjusting fiber types, needle density, and processing conditions.
- Cost-Effective: Economical production process, especially for high-volume applications.
- Recyclability: Many can be made from recycled fibers and are recyclable.
Disadvantages of Needle-Punched Nonwovens
- Surface Uniformity: May have a less uniform surface compared to other nonwoven fabrics.
- Limited Fine Filtration: Not as effective as meltblown fabrics for capturing very fine particles.
Shoe materials
Needle-punch nonwoven fabrics are manufactured for shoe materials. There are several needle machines in the whole production line, offering the products with specifications of basis weight 80-1500 gsm/m², single or multi-layered, different hand feel, different luster and surface appearance, different requirement for use, absolute up-to-related standards in the physical mechanical performance, and also manufactured according to customers’ specific requirements
Filtration Materials
The filtration felt is widely used and usually refers to filter cotton, which is commonly used in air filtration, such as in air and air-conditioning filters. The filter material is divided into four types: synthetic fiber filter cotton, non-woven fabric filter cotton, glass fiber filter cotton, and activated carbon filter cotton.
The filter felt can also be categorized based on efficiency and will be divided into three types: first effect filter cotton, filter cotton, and high efficiency filter cotton.
The first effect of filter cotton: It can be used in the wind system as a high dust exposure of the pre-filtering spray system and baking device in the pre-filtration and the flow of the material and characteristics of the filter material.
High-efficiency filter cotton: Mainly used in hospitals or laboratories and other environments.
Specification: basis weight 100-600 g/m²; width within 2.2 m is available.
Product type: Filtration
Application: The surface treatment and coating industry will always widely use filter cotton, automotive air filters, air conditioning air filters, etc.
Fire-retardant materials
Flame retardant non-woven material can be divided into three categories: flame retardant polyester non-woven fabrics, non-woven fabric and non-woven fabrics.
It emits minimal smoke and no poisonous gas, is a non-melting drop, and is self-extinguishing when burning. It passed the American CFR1633 flammability test, the English BS5852 flammability test, and the American TB117 flammability test.
Specification: basis weight 100-1200 g/m²; width within 2.2 m is available.
Product type: FR-thermal bonding nonwovens. FR-Needlepunch Felt, FR-Fiber Foam and so on.
Application: This product is used for constructing the FR layer in furniture such as mattresses and sofas, as well as in automotive FR interlining.
Civil engineering materials
Geotextiles, also known as geotextiles, are made of synthetic fibers by needling or weaves of permeable geosynthetics.
Average width: 4-6 meters; length: 50-100 meters/roll.
Geotextiles are divided into woven geotextiles and non-woven geotextiles. Geotextile has good filtration, drainage, insulation, reinforcement and protection, with lightweight, high tensile strength, high permeability, high temperature resistance, antifreeze, anti-aging, and corrosion characteristics.
Geotextile is one of the geosynthetic materials. The geotextile, which originated with the application of geosynthetic material in the 1950s, is one of the 85 national projects in the country. In 1998, China promulgated the geosynthetics short-fiber needle-punched nonwoven geotextile (GB/T 17638-1998) standard. Currently, geotextile has been widely applied in many fields.
Specification: basis weight 150-800 g/m², width within ~4~6 m.
Application: It was widely used in water conservancy, electric power, mining, highways, and railways.
Thermal insulation material
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Functional bedding
Key Considerations
- Fiber Type and Blend: Determines the final properties of the fabric.
- Needle Specifications: Type, density, and arrangement of needles influence texture and strength.
- End-Use Requirements: Specific applications dictate the choice of fibers, web formation, and finishing processes.
Needle punched nonwovens are versatile and durable fabrics used across various industries due to their strength, customization options, and cost-effectiveness. Their wide range of applications from geotextiles and automotive components to consumer products and industrial uses highlight their importance and adaptability.
