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Ultrasonic Bonding in the Nonwoven Industry

In my recent article for Nonwoven Industry I discussed the advantages of using ultrasonic bonding for the nonwoven industry. The nonwoven industry has been a long-time customer of ultrasonic equipment.  Emerson offers Branson ultrasonic equipment that can slit, bond, seal or quilt nonwoven synthetic materials to meet a wide range of medical and non-medical application requirements. Medical applications include surgical face masks, face shields, disposable hygiene products, gowns, and filter media. Non-medical uses for this versatile technology include consumer and personal care products, baby diapers and training pants, mattress pads, seat cushions and covers, household mops and cleaning products, disposable vacuum and filter bags, and more.  


The biggest growth we have seen for ultrasonic technology in recent years is in the medical industry. Because ultrasonic technology can create strong, repeatable results, withstand sterilization processes all while lowering the risk of contamination by eliminating the introduction of solvents and glues to the manufacturing process makes it valuable for medical customers.


New opportunities are everywhere, driven in the short term as manufacturers learn more about the value and versatility of this process and in the longer term by changing demographics. As the number of older citizens in the U.S. and many western countries continues to grow as a share of total population, the demand for medical, sanitary, consumer care, bedding, seating, cleaning, and filtration products will only continue to grow. So too will the need to produce these products efficiently, with maximum cleanliness and minimum risk of contamination. 


The unique ability of ultrasonics equipment to handle a broad scope of nonwoven product manufacturing—slitting, cutting, embossing, quilting and bonding—offers the perfect solution to this growing need. In addition, Branson ultrasonics technology can meet clean room manufacturing requirements, where required, and provide the data monitoring and storage capabilities needed to meet the highest regulatory requirements. These and other ultrasonics capabilities will only continue to evolve and expand in the future.


Ultrasonics bonding offers several advantages over other bonding methods: Because it uses friction to heat the material so that it bonds to itself without the use of glue or solvents which in turn creates a huge cost savings for customers. It also lowers the risk of contamination by eliminating the introduction of another product. Ultrasonics also can lower the likelihood of damaging nonwoven filter media, even the most delicate, thanks to our range of frequencies.


What are some nonwoven textile applications you or your customers have that could benefit from ultrasonic bonding over traditional solvents or glue?