What is the difference between meltblown and spunbond? Meltblown fabrics (1-5μm fine fibers) are highly efficient for filtering and are suitable for masks; spunbond fabrics (10-30μm filaments) are strong and durable and are used for packaging/medical supplies. Analyze the performance differences and composite applications of the two to help you choose the process according to your needs. Click to
1. Process principle and flow
1.1. Spunbond process
Principle: After the high molecular polymer (such as polypropylene PP, polyester PET, etc.) is melted, it is extruded through the spinning hole to form a thin stream, stretched into continuous filaments by the drafting device (mechanical or air drafting), and then evenly laid into a fiber mesh, and finally consolidated and formed by hot rolling or needle punching.
Core steps:
Melt extrusion → spinning → drafting (mainly mechanical drafting) → laying → hot rolling/needle punching consolidation → cloth.
Features: The fiber is relatively coarse (diameter 10-30 microns), the web is uniform, the fiber is filamentous and directional, the cloth surface has high strength and good wear resistance.
1.2. Meltblown process
Principle: The polymer melt is sprayed through a high-speed hot air flow (such as high-temperature and high-pressure air) to cause the melt to be stretched violently, forming extremely fine short fibers (diameter 1-5 microns), which are randomly deposited on the condensation curtain, and rely on thermal bonding between fibers or self-residual heat bonding to form non-woven fabrics.
Core steps:
Melt extrusion → high-speed air flow stretching (key: air flow speed can reach 1000-2000 m/s) → random fiber laying → self-bonding (no need for additional hot rolling, relying on ultra-fine fibers and mutual entanglement) → fabric.
Features: The fibers are extremely fine and randomly interlaced, forming a porous, fluffy three-dimensional structure with a large surface area, strong adsorption and filtration properties, but low strength.
2. Raw material differences
Spunbond process:
Common raw materials are polypropylene (PP), polyester (PET), polyethylene (PE), etc., which require the polymer melt viscosity to be moderate and easy to mechanically stretch. For example, the melt index (MFI) of PP is usually 100-400 g/10min.
Meltblown process:
The main raw material is high-fluidity polypropylene (MFI is usually 800-1500 g/10min), which requires low melt viscosity and good fluidity to facilitate high-speed airflow stretching; a small amount of additives (such as electret masterbatch to enhance electrostatic adsorption) can also be added.
3. Product structure and performance
| Comparison Item | Spunbond Fabric | Meltblown Fabric |
|---|---|---|
| Fiber Diameter | Thicker (10–30 microns), long filaments with oriented arrangement | Extremely fine (1–5 microns), short fibers with random and non-oriented arrangement |
| Fabric Structure | Neat fiber arrangement, larger pores, uniform structure | Random and interlaced fibers, forming dense micro-pores with high porosity (70%–90%) |
| Strength | High longitudinal strength, good tensile properties, tear-resistant | Low strength, easily torn; requires composite reinforcement with spunbond fabric (e.g., SMS material) |
| Filtration Performance | Poor (large pores, mainly relies on mechanical interception of large particles) | Excellent (ultrafine fibers + micro-porous structure, captures small particles like viruses/bacteria via Brownian motion) |
| Air Permeability | Good, suitable for scenarios requiring breathability | Moderate; balance between air permeability and filtration efficiency is needed due to dense pores |
| Hand Feel | Stiffer and smoother surface | Soft, fluffy, and delicate hand feel |
4. Typical application areas
4.1. Application of spunbond fabrics
Packaging areas: shopping bags, express bags, garbage bags (due to high strength and low cost).
Medical areas: surgical gowns, medical sheets, dressings (need certain strength and barrier properties).
Agriculture and building materials: greenhouse coverings, seedling substrates, waterproof and breathable membranes.
Others: wet wipes, rags (need wear resistance).
4.2. Application of meltblown fabrics
Filter materials: core filter layer of masks (such as the meltblown layer of N95 masks), air purifier filter elements, liquid filtration (such as oil filter elements).
Sanitary materials: baby diaper absorption layer, medical absorbent pads (using high adsorption).
Special areas: battery separators, sound insulation materials (using porous structures).
Composite products: compounded with spunbond fabrics to form SMS (spunbond-meltblown-spunbond) non-woven fabrics, which have both high strength and filtration properties and are used in medical protective clothing, high-end masks, etc.
5. Summary of core differences
Fiber formation method: spunbond relies on mechanical stretching to form filaments, and meltblown relies on high-speed airflow to form short and fine fibers.
Structure and performance: spunbond fabrics are strong and durable, and meltblown fabrics have outstanding filtering and adsorption properties.
Application focus: spunbond fabrics are used in scenarios that require strength, and meltblown fabrics are used in scenarios that require efficient filtration or adsorption. The two are often used in combination to optimize performance.
About Qibo Flame Retardant
As a professional flame retardant material supplier, Qibo Flame Retardant's flame retardant masterbatch can be efficiently adapted to meltblown and spunbond non-woven fabric processes, while maintaining the original strength and filtration performance of the material, giving it excellent flame retardant effect to meet the safety needs of medical, industrial and other fields. Welcome to contact us for customized solutions to empower non-woven fabrics with flame retardant properties.