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Non-woven fabrics are generally categorized based on their durability into two main types: durable and non-durable (single-use). While non-woven materials have found widespread use in the realm of disposable clothing, their application in long-lasting garments remains limited. This distinction highlights the evolving role of non-woven fabrics in the textile industry.
In the field of non-durable clothing, non-woven fabrics have gained significant popularity. Examples include spunlaced medical protective wear, PP disposable spunbond suits, and SMS (spunbond-meltblown-spunbond) medical gowns. The current trend in this area involves expanding existing material applications and developing new types of non-woven fabrics to meet growing demands.
SMS non-woven fabric is a composite of spunbond and meltblown layers, offering high strength, good filtration, and no toxic binders. It's widely used in medical and industrial filters. Recently, it has been adapted for cleanroom environments, such as pharmaceuticals, bioengineering, and electronics, where maintaining a particle-free environment is critical. Spunbond nonwovens, made from continuous filaments, are commonly used in disposable protective wear. Recent advancements include adding flame retardants, antistatic agents, and antibacterial treatments during production to enhance functionality.
Water-soluble non-woven fabrics represent an eco-friendly innovation. Made with polyvinyl alcohol fibers, they are ideal for radiation and pollution protection. Combining them with water-soluble films can further improve their barrier properties. Similarly, superabsorbent fibers (SAF) have been integrated into non-woven fabrics, enhancing softness and moisture absorption, making them suitable for undergarments that improve comfort by quickly wicking away sweat.
In the development of composite non-woven materials, the U.S. has introduced a cotton-polypropylene thermally bonded fabric. This multi-layer structure mimics the feel of cotton while offering better strength, moisture retention, and elasticity. It’s ideal for medical isolation gowns and disposable underwear. Meanwhile, the U.S. military has developed advanced biochemical protective gear using a combination of woven, knitted, and non-woven materials. The outer layer is treated nylon-cotton fabric, the middle layer includes activated carbon nonwoven, and the inner part is a knitted fabric. This design offers superior chemical protection, portability, and cost efficiency, lasting at least three washes.
Despite challenges like poor drape, elasticity, and aesthetic appeal, non-woven fabrics offer advantages such as minimal fraying and simplified sewing processes. Companies like BBA Fiberweb and Dow Chemical have created elastic spunbond nonwovens using bicomponent fibers, offering improved stretch and stability. In Japan, Kuraray and local firms are working on ultrafine fiber spunbond fabrics that combine water-soluble resins with polypropylene or polyethylene, enhancing absorbency and strength.
Spunlaced nonwovens are considered the most suitable for durable clothing due to their soft texture, breathability, and versatility. A U.S. patent describes a durable spunlaced fabric with excellent abrasion resistance, drape, and color fastness. It maintains 90% recovery after 50% elongation and can be washed up to 25 times. These features make it ideal for everyday wear, combining comfort, durability, and aesthetics. As research continues, non-woven fabrics are gradually becoming a more viable option for long-term apparel applications.