PROCESSProcess

Manufacturing Methods of Felt & Nonwovens

Felt and Nonwovens are textile products made by three-dimensionally intertwining and bonding fibers to form a fabric.
From among the various manufacturing methods, let us introduce you to the typical processes we use at AMBIC.

1.Mixing Raw Material

The fibers are untangled and mixed.

原材料調合

2.Carding

The fibers are untangled to make a unidirectional aligned wraps.

カーディング

※ Click on the manufacturing method, you wish to know more about:

Pressed Felt

Features
They use the wool as main material. They can be take advantage of wool-specific heat retention, moisture absorption & desorption, flame resistance, water repellency, and dyeing properties.
Uses
Parts for musical instruments, colored felt, carpets, interlining, gaskets, abrasives, etc.

3-1.Hardening

ハードニング

This process uses the felting (wrinkling) properties of wool. Moisture and heat are applied to the wrap, and then force is applied to the wrap to intertwine the fibers.

3-2.Wrinkling

縮絨

The Felt is sandwiched between the upper and lower rolls, and pressure is applied to adjust the specified hardness.

3-3.Dyeing

染色

The Felt is dyed to the specified color.

3-4.Drying

乾燥

The excess water is removed.

3-5.Pressing

プレス

The Felt is sandwiched between the upper and lower hot plates, and pressure is applied to adjust the surface smoothly.

Needle-Punched Nonwovens

Features
They can be made from all kinds of fibers.
They can be added a wide range of specifications and characteristics – from thin (about 1 mm) to thick (>10 mm) and from soft to hard.
Uses
Filters, industrial materials, padding materials, carpets, interlining, etc.

3.Needle Punching

ニードルパンチ

Needles with barbs (notches) are inserted into the wrap from the top and bottom to intertwine the fibers mechanically.

Thermal-Bonded Nonwovens

Features
They require mixing in thermally-bondable fibers.
They can be added a range of specifications ― from thin to bulky in thickness, by changing the melting method.
Uses
Insulators, cleaning materials, cushioning materials, sanitary materials, etc.

3.Thermal bonding

サーマルボンド

Thermally-bondable fibers are melted to bond the other fibers together.
There are two methods of melting: crimping with thermal rollers or blowing hot air through.

Chemically-Bonded Nonwovens

Features
The functions of adhesive polymers can be change the hardness. One of their features is that it is easy to add values, such as flame resistance and deodorization, by containing in functional polymers.
Uses
Cushioning materials, industrial materials, filters, interlining, etc.

3-1.Chemical Bonding

ケミカルボンド

The wrap is immersed in liquid resin containing adhesive polymer to bond the fibers together.

3-2.Drying

乾燥

The excess water is removed, and the resin is fixed.

Spunlace Nonwovens

Features
Their most notable feature is their thin and soft finish. They can be added minimal fiber damage and smooth surface.
Uses
Cushioning materials, industrial materials, sanitary materials, wipers, etc.

3-1.Water Jet

ウォータージェット

The fabrics is passed through the water flow with several nozzles to interwine the fibers.

3-2.Drying

乾燥

The excess water is removed.

4.Inspection

The finished products are inspected to ensure that there are no defects.

検査

Composite Processing

We make high functionality and high performance products by combining of processing technologies ― not just to our products but also to various Felt and Nonwovenss.

Cut Processing

断裁加工

We specialize in “half-cut” processing as well as cutting to high-precision dimensions and shapes.

Sewing Processing

縫製加工

We excel in sewing to make unique shapes for various applications with high-precision dimensions.

Slit Processing

スリット加工

We can slit Felt & Nonwovens as well as composite products as small as a few millimeters class.

Precision Thickness Slicing

厚み漉き加工

One of our signature technologies is slicing Felt & Nonwovens in the hundreds-of-microns class.

Resin Processing

樹脂加工

Felt and Nonwovens can be augmented with high functionality such as flame resistance and water repellency by immersing them in resin.

Pleat Processing

プリーツ加工

We can fold in layers, and Nonwovens with various functionalities while compositing them.

Electret processing

エレクトレット加工

The Nonwovens are charged by applying a strong electric charge, enabling fine dust to be collected.