F&A Nonwovens Corporation 株式会社エフアンドエイノンウーブンズ

PROCESS

Production Process

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.

原材料調合

2. Carding

Fibers are carded so that they are parallel to one other and laps are made.

カーディング

※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

ハードニング

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

縮絨

Felt is sandwiched between the upper and lower rolls and compressed to get the specified hardness.

3-3. Dyeing

染色

Felt is dyed the specified color.

3-4. Drying

乾燥

Excess water is removed.

3-5. Pressing

プレス

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

ニードルパンチ

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

サーマルボンド

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

ケミカルボンド

Fiber webs are impregnated with liquid resin containing adhesive polymers to bond fibers each other.

3-2. Drying

乾燥

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

ウォータージェット

Water jets are emitted for fabrics from many nozzles to entangle fibers.

3-2. Drying

乾燥

Excess water is removed.

4. Inspection

Finished products are inspected to ensure that there are no defects.

検査

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

断裁加工

We have particular strengths in cutting precisely in half or in precise size and desired shape according to your specifications.

Sewing

縫製加工

Our sewing technique is excellent in sewing materials in unique shape and can sew to your exact specifications in size and shape.

Slitting

スリット加工

Our slitting machines can slit not only single body of felt and nonwoven but also composite materials as narrow as a few millimeters.

Slicing

厚み漉き加工

Our technology, which we are proud of, can make felts and nonwovens sliced as thin as several hundred microns of thickness.

Resin Treatment

樹脂加工

Felts and nonwovens are impregnated with resin and additional functions are available, such as flame resistance and water repellency.