Meltblown

Definition and Overview

Meltblown is a manufacturing method in which thermoplastic resin is melted, extruded from fine nozzles, and drawn into fibers by high-speed hot air. The collected fibers overlap randomly and become a nonwoven fabric with a finer fiber structure than woven or knitted fabrics.

The term refers to the manufacturing method, not the fiber raw material name or weave structure name. Therefore, properties such as strength, air permeability, and particle capture performance vary greatly depending on the raw resin, fabric weight, fiber fineness, and post-processing.

Texture and Functional Characteristics

Thin meltblown nonwoven fabric is light like paper and tends to have a slightly dry hand feel. It does not have the regular warp and weft appearance of woven fabric. Because fine fibers overlap densely, a single layer can be designed to capture fine particles more easily.

On the other hand, thin materials made of ultrafine fibers may not have sufficient tensile strength or abrasion resistance on their own. For applications that require it, they are layered with strength-bearing layers such as spunbond nonwoven fabric and used as composite nonwoven fabric.

• It is easy for the fibers to be fine and the structure to have a large surface area.
• Air permeability and particle capture performance are adjusted by the fabric weight and fiber structure.
• Depending on the raw material and electrostatic treatment, functions suited to the application may be added.
• For thin materials, care is needed to prevent tearing, stretching, and damage from friction.

Main Applications

Meltblown nonwoven fabric is used as an intermediate layer for capturing particles in hygiene masks, medical and sanitary supplies, filters, and similar products. It is also used in materials that absorb or filter liquids and oils, as well as disposable hygiene products.

In apparel, it is more often used as an inner layer or auxiliary material that provides function rather than as a face fabric chosen for its texture. Selection is based less on seasonality and more on product requirements such as air permeability, filtration performance, lightness, and whether the product is disposable or reusable.

Selection and Handling Notes

When selecting it, do not judge performance by the material name alone. Check the fabric weight, thickness, air permeability, strength, target particles to be captured, and whether electrostatic treatment has been applied if needed. For filter applications, the overall structure and fit of the product also affect performance, so evaluation should include the layer structure.

Resistance to washing and high-temperature processing depends on the raw resin and processing conditions. Since washing may change the fiber structure and the added functions, products intended for reuse should be checked in advance for performance and dimensional changes after washing.

In sewing, thin and lofty types require care to prevent tearing from needle holes or feeding, seam puckering, and seam splitting. When seam strength is required, it is important to design seam allowances appropriately, use reinforcement materials, and test the sewing conditions.

Differences from Similar Terms

Nonwoven fabric is a general term for materials made into sheet form without weaving or knitting fibers. Meltblown is one of the manufacturing methods for nonwoven fabric and is not synonymous with nonwoven fabric. It also differs from woven structures such as plain weave, and it does not have warp and weft.

Spunbond is a nonwoven fabric manufacturing method that forms continuous long fibers into a sheet and is generally characterized by being easier to give strength than meltblown. Spunlace is a method that entangles fibers with water jets, and needle punch is a method that entangles fibers with needles; the fiber bonding methods differ.

Frequently Asked Questions