Non-woven fabrics have become widely used in the production of non-durable garments, including spunlace medical protective clothing, PP disposable spunbond protective wear, and SMS medical protective clothing. The current development in this field is focused on two main directions: the enhancement of existing materials for apparel applications and the creation of 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 binding agents. These materials are widely used in medical and industrial filtration applications. Recently, they have found new uses in breathable, fiber-dust-free protective clothing that prevents particle exchange between the body and the environment. This makes them ideal for industries such as pharmaceuticals, biotechnology, optoelectronics, and semiconductor manufacturing, where clean environments are essential.
Spunbond nonwovens, made from continuous high-strength fibers, dominate the disposable protective clothing market. Recent advancements include the addition of special additives or finishes during the production process to enhance functionality, such as flame resistance, anti-static properties, radiation protection, moisture resistance, antibacterial features, and thermal insulation.
In terms of new fiber development, water-soluble non-woven fabrics have gained attention due to their eco-friendly nature. For instance, polyvinyl alcohol (PVA) spunlace nonwovens are used in radiation protection and pollution-resistant clothing. To improve performance, these fabrics can be combined with water-soluble films to increase barrier protection.
Another innovation involves the use of superabsorbent fibers (SAF) in non-woven production, enhancing softness and moisture absorption. These fabrics are particularly suitable for undergarments, as they quickly absorb sweat and improve comfort between the garment and the skin.
The U.S. has also developed cotton-fiber composite non-wovens, combining cotton with polypropylene in heat-bonded layers. These multi-layered materials offer a soft, cotton-like feel, good strength, moisture management, and low pilling. After finishing, they exhibit excellent elasticity and recovery, making them ideal for medical isolation gowns and disposable underwear.
Additionally, the U.S. military has introduced advanced biochemical protective clothing that integrates woven, knitted, and non-woven materials. The outer layer is a water-repellent nylon/cotton fabric, the middle layer is activated carbon non-woven, and the inner layer is a tricot knit. This design provides superior chemical protection while being lightweight, cost-effective, and durable enough for multiple washes.
Durable non-woven fabrics face challenges in terms of drape, flexibility, stretch, opacity, and aesthetic appeal. However, they offer advantages in ease of sewing, as they don’t fray easily and require no edge finishing. This simplicity has encouraged many researchers and companies to explore their potential for long-lasting garments.
Recent efforts have focused on improving non-woven properties such as drape, abrasion resistance, elasticity, and resilience to meet the demands of durable clothing. Joint ventures like BBA Fiberweb and Dow Chemical have developed elastic spunbond non-wovens using core-sheath bicomponent fibers, offering excellent elasticity and dimensional stability.
Kuraray and domestic partners have also created microfiber spunbond non-wovens using Excevalâ„¢ resin combined with PP or PE, offering improved water absorption and biodegradability. These materials are lightweight, strong, and easy to process, making them promising for durable apparel.
Spunlace non-wovens are considered the most suitable for garments due to their softness, bulkiness, and wide range of fiber options. They are extensively studied for use in durable clothing. A U.S. patent describes a durable spunlace non-woven with excellent wear resistance, drape, color fastness, and elasticity, capable of withstanding at least 25 washes. These fabrics provide comfort, strength, and aesthetics, making them ideal for everyday wear such as shirts and outerwear.
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