At the INDEX 26 nonwovens industry exhibition in Geneva,
The Lycra Company and Dukane showcased their latest co
developed advances in ultrasonic bonding.
Since 2014, the companies have collaborated to advance
ultrasonic bonding solutions that help diaper manufacturers
improve product softness, fit and performance while reducing
energy consumption, material waste and maintenance costs.
Ultrasonic bonding creates bonded channels between two layers
of nonwoven materials, mechanically securing elastic fibres
without using adhesives. Dukane’s patented rotary and rigid
ultrasonic bonding systems enable high-speed, adhesive-free
assembly by delivering precisely controlled ultrasonic energy
into nonwoven substrates.
Lycra Fusion fibre, originally developed to prevent snags in
hosiery from turning into runs, can now fuse to nonwoven layers
during ultrasonic bonding. Its sheath/core construction fuses
with surrounding materials, strengthens ultrasonic bonds, and
delivers superior yarn creep (snapback). When this fibre is
paired with Dukane’s advanced ultrasonic bonding modules,
manufacturers can achieve precise elastic placement, improved
bond integrity, and consistent product performance while
eliminating the variability associated with hot-melt adhesives.
“As ultrasonic bonding gains traction in the hygiene industry, our
longstanding collaboration with Dukane focuses on expanding
technical capabilities while preparing for commercial scale-up,”
says Doug Kelliher, Lycra’s executive vice president. “We’re
excited to introduce Lycra Fusion fibre for personal care, which
provides excellent performance with fewer breaking points and
improved bond integrity during the ultrasonic bonding process.”
“From ultrasonic lamination to precision sealing and cutting, our
technologies are engineered for consistent quality, global
scalability and sustainable production,” adds Justin Lafferty,
global product development manager for nonwovens at Dukane.
“By advancing ultrasonic bonding with Lycra Fusion fibre, we’re
helping customers improve product performance while enabling
more efficient production.”