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Non-woven fabrics are categorized based on their durability into two main types: durable and non-durable (one-time use). While non-durable applications of non-woven fabrics are well-established, especially in the medical and protective clothing sectors, their use in durable clothing remains limited. This distinction highlights the evolving role of non-woven materials in the textile industry.
In the realm of non-durable clothing, non-woven fabrics have gained widespread popularity. Examples include spunlace medical gowns, PP disposable spunbond suits, and SMS (spunbond-meltblown-spunbond) medical protective wear. These materials are favored for their cost-effectiveness, ease of production, and functional properties. Recent advancements in this area focus on expanding the range of existing materials and developing new types of non-woven fabrics tailored for specific applications.
SMS non-woven fabric is a composite material made from spunbond and meltblown layers. It offers high strength, excellent filtration, and is free from harmful binders. Traditionally used in medical and industrial filters, it has found new applications in cleanroom environments such as pharmaceuticals, bioengineering, and electronics. Spunbond non-woven fabrics, composed of continuous filaments, are widely used in disposable protective wear. Innovations now include adding special additives or post-treatments to enhance features like flame resistance, anti-static, and moisture management.
Water-soluble non-woven fabrics represent an eco-friendly development. Made from polyvinyl alcohol fibers, they are ideal for radiation- and pollution-proof garments. Combining them with water-soluble films can further boost their protective qualities. Similarly, superabsorbent fiber (SAF) technology improves softness and absorbency, making these fabrics suitable for undergarments that enhance comfort by quickly wicking away sweat.
In the U.S., a cotton-polypropylene composite non-woven fabric has been developed for medical and disposable wear. This material mimics the feel of pure cotton while offering superior strength, breathability, and elasticity. Another innovation involves combining woven, knitted, and non-woven elements in military protective gear. The outer layer uses treated nylon-cotton fabric, the middle layer contains activated carbon non-woven, and the inner layer is a knitted fabric. This design enhances protection, portability, and washability.
Durable non-woven fabrics face challenges due to their lack of drape, stretch, and aesthetic appeal compared to traditional textiles. However, their advantages—such as no need for ironing or seaming—make them appealing for certain applications. Researchers are focusing on improving drape, abrasion resistance, and elasticity to make non-woven fabrics more suitable for long-term use.
A joint venture between BBA Fiberweb and Dow Chemical introduced a spunbond elastic non-woven fabric using bicomponent fibers. This material offers high elasticity and stability, making it viable for durable clothing. Meanwhile, Japanese company Kuraray is working on ultrafine fiber spunbond fabrics using water-soluble resins. These fabrics show improved moisture absorption and strength, making them ideal for long-lasting garments.
Spunlaced non-woven fabrics, known for their softness, breathability, and versatility, are considered the most suitable for clothing. A U.S. patent describes a durable spunlaced fabric with excellent abrasion resistance, drape, and color fastness. It retains 90% of its shape after stretching and can be washed over 25 times. Its combination of comfort, strength, and aesthetics makes it a top choice for everyday wear.