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The binder is applied by several methods: Saturation: the fabric is immersed in a bath containing the latex, excess is squeezed out and the wet fabric is dried; Spraying: the binder is sprayed onto the surface and penetrates a distance into the fabric; Page 44 © Copyright Pira International Ltd 2006 Developments in Nonwovens for Filtration Processing developments Printing: 4 the binder is applied to the surface in a printed pattern. The most common latex binders are made from vinyl polymers such as vinyl chloride, vinyl acetate, styrene, butadiene, acrylic or a combination.
Bonding processes include chemical and thermal bonding, needling, hydroentanglement and stitch bonding. The main nonwoven manufacturing processes are dry laying, wet laying, spunbonding, melt spinning and electrospinning. Two less well-known techniques are flash spinning and centrifugal spinning. Spunbonding and melt blowing are often called polymer laying, melt laying or extrusion forming. Dry-laid webs provide considerable versatility because they are not a direct polymer-to-web conversion: fibres of different polymer types, diameters and cross-sectional shapes can be blended together easily before the web is formed.
The metal ions are slowly released over time. Biocide-treated fibres include fibres with zeolites where the pores contain biocides, fibres with chemical additives, core/sheath fibres where the sheath contains the biocide, and coated fibres. Flame retardants Flame retardants are often added to fibres but, over the past few decades there has been increasing concern about their environmental impact and the tendency of some flame retardants to release large quantities of smoke and toxic gases. Flame retardants can be classified into inorganic compounds such as aluminium hydrate, ammonium polyphosphate, antimony trioxide and magnesium hydroxide; halogenated organic compounds such as brominated and chlorinated compounds; organophosphorus compounds such as triphenyl phosphate; nitrogen-based compounds such as melamines; and boron and zinc compounds.