Non-woven fabrics have become widely used in the field of non-durable garments, including spunlace medical protective clothing, PP disposable spunbond suits, and SMS medical protective wear. The current development of new products in this area mainly involves two directions: one is the innovation and application of existing materials in apparel, and the other is the creation of entirely new types of non-woven fabrics.
SMS non-woven fabrics, which are a combination of spunbond and meltblown layers, are known for their high strength, excellent filtration properties, and lack of chemical binders or toxins. They have played a crucial role in medical and industrial filtration applications. Recently, they have been utilized for breathable, fiber-dust-free protective clothing that minimizes particle exchange between the body and the environment. This makes them ideal for cleanroom environments in pharmaceuticals, biotechnology, electronics, and semiconductor manufacturing.
Spunbond nonwovens, made from continuous high-strength filaments, dominate the disposable protective clothing market. Recent advancements involve incorporating special additives during production to enhance functionality, such as flame resistance, anti-static properties, radiation protection, moisture repellency, antibacterial effects, and thermal insulation.
In terms of new fibers, water-soluble nonwovens have emerged as an eco-friendly option, with expanding applications. For instance, polyvinyl alcohol (PVA) spunlace nonwovens are used in radiation protection and pollution-resistant clothing. These materials can be combined with water-soluble films to further improve barrier performance.
Additionally, foreign countries have introduced superabsorbent fiber (SAF) technology into non-woven fabric production. SAF-containing nonwovens offer superior softness and absorbency, making them ideal for undergarments that quickly wick away sweat, enhancing comfort in the micro-environment between the garment and the body.
The U.S. has also developed a new type of cotton-fiber composite nonwoven, combining cotton and polypropylene through heat-bonding. These multi-layered materials mimic the feel of cotton knitwear, offering good strength, elasticity, moisture absorption, and low pilling tendency. After finishing, they can recover up to 93% of their original shape after stretching, making them suitable for medical isolation gowns and disposable undergarments.
Another innovation comes from the U.S. military, which has created advanced biochemical protective clothing that integrates woven, knitted, and non-woven materials. The outer layer is water-repellent nylon/cotton poplin, followed by activated carbon nonwoven, and a tricot inner lining. This design offers enhanced chemical protection, reduced weight, and cost efficiency, while being durable enough for at least three washes.
Despite challenges in drape, flexibility, stretch, opacity, and aesthetic appeal, non-woven fabrics offer unique advantages in garment construction. Their resistance to fraying allows direct integration into design without the need for edge finishing, simplifying the sewing process. This has encouraged many researchers and companies to explore new possibilities in durable non-woven garments.
Recent research has focused on improving non-woven fabric properties such as drape, abrasion resistance, elasticity, and resilience to meet the demands of durable clothing. For example, BBA Fiberweb and Dow Chemical have developed a new elastic spunbond nonwoven using core-sheath bicomponent fibers, offering excellent stretch and dimensional stability.
In Japan, Kuraray and local companies have developed microfiber spunbond nonwovens using Exceval™ soluble resin combined with PP, PE, or PA. Exceval™ dissolves at 90°C, is biodegradable, and highly absorbent, making it easy to process into webs. These fabrics outperform traditional spunbond in water absorption, despite lower weight and comparable strength.
Spunlace nonwovens, known for their softness, bulkiness, and wide range of fiber options, are considered the most suitable for garments. Research has shown that durable spunlace nonwovens can withstand 25 washes, have good wear resistance, and recover 90% of their shape after 50% elongation. With excellent elasticity, mechanical strength, and aesthetics, they are becoming a preferred material for everyday wear like shirts and outerwear.
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