Nonwoven fabric

Sheet of fibers

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Nonwoven fabric or non-woven fabric is created by bonding staple fibres and long fibres together using chemical, mechanical, heat, or solvent processes. These fabrics are often turned to as alternatives to polyurethane foam and other materials.

Applications

Nonwoven fabrics are broadly defined as sheet or web structures bonded together by entangling fiber or filaments (and by perforating films) mechanically, thermally or chemically. They are flat or tufted porous sheets made directly from separate fibres, molten plastic, or plastic film. They do not require converting the fibres to yarn and typically include a certain percentage of recycled fabrics and oil-based materials. The percentage of recycled fabrics varies based upon the strength of material needed for the specific use. Moreover, some nonwoven fabrics can be recycled after use, given the proper treatment and facilities. For this reason, they are often considered more ecological, especially in disposable or single-use products like those used in hospitals, schools, nursing homes, and luxury accommodations.

Characteristics

Nonwoven fabrics are engineered for specific functions such as absorbency, liquid repellence, resilience, stretch, softness, strength, flame retardancy, washability, cushioning, thermal insulation, acoustic insulation, filtration, and use as a bacterial barrier. These properties can be combined to create fabrics suited for particular jobs, offering a spectrum of products with diverse properties.

Manufacturing Processes

Nonwovens are typically made by putting small fibers together into a sheet or web (similar to paper) and binding them mechanically, with an adhesive, or thermally.

Staple Nonwovens

Staple nonwovens involve spinning fibers, cutting them to lengths, and blending and dispersing them on a conveyor belt to form a web, which is then bonded either thermally or with resin.

Spunbond Nonwovens

In spunbond nonwovens, fibers are spun and then dispersed into a web by deflectors or air streams, which is faster and more cost-effective. Variants like SM and SMS materials combine different layers for enhanced properties.

Spunlace Nonwovens

Spunlace nonwovens are made by hydroentanglement, where high-pressure water jets entangle the fibers, creating a strong, durable fabric.

Flashspun

Flashspun fabrics are produced by spraying a dissolved resin into a chamber where the solvent evaporates.

Air-laid Paper

Air-laid paper is made from wood pulp and uses air instead of water to form the structure of the material.

Other Techniques

Nonwovens can also start with films and be fibrillated or vacuum-formed with patterned holes, producing diverse materials like Tyvek.

Bonding

Various bonding methods ensure the mechanical resistance of nonwoven fabrics, including thermal bonding, hydroentanglement, ultrasonic pattern bonding, needlepunching, and chemical bonding.

Disposability

The industry is defining "flushability" and encourages producers to test and clearly mark non-flushable products, ensuring they are safe for septic and sewer systems.

See also

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