Before producing PET acoustic panels, we must first know where the raw materials come from. 60% of the raw material of the polyester fiber acoustic panels comes from and recyclable PET bottles. They must be broken into small pieces of a certain size before they can be processed further. After particles are washed and disinfected, the water in the plastic sheet is fully dried, and then melted at 270°C, extruded by a screw extruder and cooled into filaments (generally including staple fibers and filaments).
1. Mixing & Stacking
Next, we start the manufacturing process. First, we need to mix colored fibers with low-melting-point fibers. This process is called mixing. Maybe you will ask what is low melting point fiber? Is it different from other fibers? We will mention this later. This process is to ensure that the two raw materials are fully mixed and evenly distributed. The fully mixed raw materials enter the carding machine and comb the materials into loose fiber layers. Each polyester sound-absorbing board is made from non-woven felt.
2. Needle Punching & Rolling
We build density and thickness by needling and rolling the material together. The repeated needling that the PET felt receives is one of the keys to creating a stiff panel.
This process changes the material from a roll of soft felt to a hard polyester panel. Low-melting fibers that we mentioned at the beginning plays a very important role here. They can be melted and bonded with other fibers at a lower temperature of general polyester. When the temperature reaches the melting point of the low-melting fiber, it melts and flows, and firmly fixes other polyester fibers together. After cooling, it returns into a solid state to enhance the rigidity of the board.
The heat process is one of the most difficult part. This is because the material shrinks in three dimensions when heated. Any defect here will cause obvious surface defects.
The last step is to cut the panels into their final size or shape by the machine. Good tools are prerequisite to the successful execution of a job. Only by using state-of-the-art and precise cutting tools, such as CNC machines using vibrating blades and laser. can a nearly perfect panel can be cut We select the best cutting method according to meet the customer's requirements