Nonwoven fabric or non-woven fabric is a fabric-like material made from staple fibre (short) and long fibres (continuous long), bonded together by chemical, mechanical, heat or solvent treatment. The term is used in the textile manufacturing industry to denote fabrics, such as felt, which are neither woven nor knitted.Some non-woven materials lack sufficient strength unless densified or reinforced by a backing. In recent years, non-wovens have become an alternative to polyurethane foam. Non-woven fabric (NWF) is a type of textile produced by forming a network of fibres joined together by mechanical, thermal or chemical processes, but without being woven.
Advantages of Nonwoven Fabric
Versatility
Non-woven fabrics are incredibly versatile, with a wide range of types catering to diverse applications. Their properties can be tailored to suit specific needs, making them suitable for industries as varied as healthcare, agriculture, automotive, and fashion.
Cost-effectiveness
The manufacturing processes for non-woven fabrics often involve fewer steps compared to traditional woven fabrics. This can lead to cost savings in terms of labour, time, and energy. Additionally, non-woven fabrics are available in rolls, enabling bulk production and reducing overall costs.
Enhanced properties
Different types of non-woven fabrics possess unique properties that set them apart. For instance, spunbond non-woven fabric offers high tensile strength and dimensional stability, while meltblown fabrics exhibit exceptional filtration capabilities. These specialised properties make non-woven fabrics suitable for specific applications where these traits are crucial.
Eco-friendliness
As sustainability becomes a central concern, non-woven fabrics have gained attention for their eco-friendly attributes. Many non-woven fabrics are recyclable and can be repurposed for other applications. Non-woven fabric bags, for example, have become a popular alternative to single-use plastic bags, contributing to reduced plastic waste.
Ease of production
Non-woven fabrics can be produced relatively quickly using automated machinery. This efficiency in production translates to shorter lead times and quicker response to market demands. The ability to rapidly adapt to changing requirements is a significant advantage in industries with dynamic needs.
Lightweight and comfort
Non-woven fabrics are known for their lightweight nature, which makes them comfortable to wear and use. They are often preferred for applications like medical gowns, face masks, and apparel where comfort is of paramount importance.
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Types of Nonwoven Fabric
Spunlace nonwovens
It is a non-woven cloth, it is the direct use of polymer slices, short fibers or filaments into a network of fiber by air or mechanical, spunlace, acupuncture, or hot-rolled reinforcement, and finally after finishing the formation of spunlace nonwoven fabric.
Heat-bonded nonwoven fabrics
This type of non-woven fabric is mainly manufactured in several processes: adding fibrous or sticky reinforcement material into the fiber network, and then reinforcing the network into cloth via heating and cooling.
Pulp air-laid nonwovens
Air-laid nonwovens can also be called the dustless paper or dry paper nonwovens. It uses the air-laid technology to open the wood pulp fiberboard into a single fiber state, then uses the airflow method to make the fiber agglomerate on the net curtain, and then consolidates the fiber web into cloth.
Wet-laid non-woven
The manufacturing process of wet nonwoven fabric goes like this: open the fibrous raw material in the aqueous medium into single fibers, meanwhile forming a fibrous suspension slurry by mixing different fiber raw materials, then transport the suspended slurry to a mesh-forming mechanism, and the fibers are laid in a wet state to form a cloth.
Spunbond nonwovens
Spunbond-type of nonwoven fabric is processed as follows: extrude and stretch the polymer to form a continuous filament, laid the filament into web, then process the web into nonwoven fabric through their own bonding, thermal bonding, chemical bonding or mechanical reinforcement methods.
Meltblown nonwovens
Melt-blown nonwoven fabric is manufactured by extruding melted polymer fiber through a linear die containing several hundred small holes to form long thin fibers which are stretched and cooled by passing hot air as they fall from the linear die, then the resultant web is blown onto a collector screen forming fined-filtered, self-bond nonwovens. Usually, this type of nonwoven fabric is added to spunbond in order to form SM or SMS webs.
Stitch nonwovens
Stitched nonwoven is another type of dry nonwoven fabric. The manufacturing process uses a warp knitted loop structure to reinforce the fiber web, yarn layer, non-woven materials (such as plastic sheeting, plastic foil and etc.) or a combination thereof so as to form a nonwoven fabric.
The Difference Between Medical Non Woven and Ordinary Non Woven
Multiple antivirus compatibility of medical non woven
Good medical non woven fabrics need to be applied to various anti-virus methods at the same time, preferably choosing pressure steam method, ethylene oxide method and hydrogen peroxide method. Common non-woven fabrics have not been disinfected.
The anti-virus effect of medical non woven
Medical non woven fabrics generally have a three-layer SMMMS meltblown layer structure. Common medical non woven fabrics in the industry use a single-layer SMS melt-blown layer. In contrast, the anti-toxicity of a three-layer structure is better than that of a single layer. The common non woven fabric is not for medical use, so there is no melt-blown layer in the middle and no antivirus effect.
Medical non woven is environmentally friendly
High-quality medical non woven fabrics use PP environmental protection particles. It is recommended that reports related to health and toxicology requirements be issued. However, ordinary non-medical non woven fabrics cannot withstand high humidity conditions and certainly do not require toxicology reports.
Strict quality control of medical non woven
The production process of a high-quality medical non woven fabric needs to pass the ISO13485 international medical product quality management system certification, and conduct real-time online inspections at every step of the production process. This ensures that each non woven fabric is sent to the quality inspection department and has a related batch inspection report. However, ordinary non-medical non woven fabrics do not need to be tested at the medical level.
How to Choose Nonwoven Fabric
Strength
If strength is an important feature of the finished product, synthetic fibers provide high tensile strength. High-strength synthetic fibers can be mixed with weaker fibers to create durable bicomponent fiber nonwovens. Polyester nonwovens have a high density, so polyester filaments or polyester blends are excellent choices for strength. Medical and hygiene products, building materials, telecommunication products, agricultural fabrics, etc. Require high-strength nonwovens.
Temperature resistance
A variety of fibers such as cotton, rayon, polyester, and blends can be used to make temperature-resistant nonwovens. Chemical bonding is very effective for developing temperature-resistant nonwovens. The chemical bonding process involves the application of chemical adhesives to join polyester and rayon fibers to impart unique and beneficial properties to the nonwoven, such as temperature resistance.
Shape
Polyester fibers are the best choice for products that need to retain their shape without shrinking, stretching or creasing. Chemically bonded and bicomponent fibers also help impart properties such as resistance to washing or dry cleaning, aging resistance, and excellent flexibility and handling.
Water absorption
Cotton fibers have superior absorption and release properties, with a high degree of comfort and softness, making them an excellent choice. Rayon filaments or rayon blends are natural fibers derived from wood pulp that provide high absorbency, softness and a comfortable finish. Nonwovens are ideal materials for the needs of hygiene applications, including cosmetic wipes, baby diapers, adult incontinence products, hygiene products, cleaning wipes, medical bandages, and more. When durability is also required, other types of fibers can be processed or blended to form hydrophilic nonwovens.
Application of Nonwoven Fabric
Medical Applications
One of the most important applications of non-woven fabric is in the medical industry. Non-woven fabric is often used to create surgical gowns, masks, and other medical equipment because it can provide a barrier against fluids and bacteria. Non-woven fabric is also hypoallergenic and gentle on the skin, making it an ideal material for use in medical settings.
ltration
Another important application of non-woven fabric is filtration. Non-woven fabrics are often used to create air and liquid filters due to their ability to trap particles and pollutants. These filters are used in various applications, from home HVAC to industrial air filtration systems. Non-woven fabrics can also be used in water filtration systems to remove impurities and bacteria.
Home Furnishings
Non-woven fabric is also commonly used in home furnishings. Non-woven fabrics can be used to create various products, including curtains, drapes, and upholstery. Non-woven fabrics are often preferred for these applications due to their durability, breathability, and ease of cleaning.
Automotive Applications
Non-woven fabric is also used in a variety of automotive applications. Non-woven fabrics are often used as insulation and soundproofing materials in cars and trucks. They can also be used in seat covers and headliners due to their durability and resistance to wear and tear.
Agriculture
Non-woven fabric is also used in the agriculture industry. Non-woven fabrics can be used to create agricultural covers and weed barriers. These fabrics are often used to protect crops from pests and harsh weather conditions and to prevent weeds from growing in fields.
Packaging
Non-woven fabric is also used in packaging. Non-woven fabrics are often used as a substitute for traditional plastic packaging materials due to their ability to be recycled and their biodegradability. Non-woven fabrics can also create reusable shopping bags and other eco-friendly packaging solutions.
Industrial Applications
Non-woven fabric is also used in a wide range of industrial applications. Non-woven fabrics can be used as insulation materials in buildings and the construction industry. They can also be used to manufacture electronic devices to protect against static electricity.
Personal Care Products
Non-woven fabric is a popular choice for personal care products such as wipes, diapers, and sanitary napkins. This is because non-woven fabrics are soft and gentle on the skin, making them an ideal choice for sensitive skin. Non-woven fabrics are also highly absorbent, making them effective for use in products requiring high moisture absorption levels.
Geotextiles
Non-woven fabrics are also commonly used in geotextiles, which are porous fabrics used to improve soil stability, prevent erosion, and manage water. Geotextiles from non-woven fabric can reinforce embankments and retaining walls, prevent soil erosion on steep slopes, and protect drainage systems from clogging. Non-woven geotextiles are also used to construct roads and railways to stabilize and drain.
The Production Process of Nonwoven Fabric
Non woven fabric manufacturing is a complex and intricate process that involves a number of steps. The process begins with the selection of raw materials, which are then passed through a series of machines that perform various operations to convert them into finished products.
The non woven fabric manufacturing process is carried out in two main stages: the spinning stage and the finishing stage. In the spinning stage, the raw materials are converted into yarn, which is then used to weave the fabric. In the finishing stage, the fabric is given its final shape and properties.
Raw Materials Selection
The primary raw materials used in non woven fabric manufacturing include fibers such as polyester, polypropylene, nylon, and rayon. These fibers are selected based on their properties such as strength, color, and texture.
Preparation
The fibers are first cleaned and made free from any impurities. The fiber is then processed into smaller filaments through mechanical methods such as carding or combing. Alternatively, synthetic fibers are melted and extruded as fine threads.
Web Formation
The next step involves the formation of a web from the prepared fibers. This can be done through various techniques such as air laying, carding, or spunbonding.
Air Laying – The fibers are blown through a nozzle and deposited onto a conveyor. This technique allows the fibers to be deposited uniformly and randomly.
Carding – The fibers are placed through a series of rollers which separate and align the fibers into a web.
Spunbond – In this process, molten polymer material is extruded to form continuous filaments. The filaments are then laid on a conveyor belt and bonded together with heat and pressure.
Bonding
Once the web is formed, it must be bonded together. This is done through various techniques such as thermal, mechanical or chemical bonding.
Thermal Bonding – In this process, heat is used to melt the fibers and bond them together.
Mechanical Bonding – In this process, the fibers are mechanically entangled with each other through needles or water jets. This technique results in a stronger and more durable fabric.
Chemical Bonding – In this process, chemicals are used to bond the fibers together at a molecular level.
Finishing
After bonding, the fabric is given its final properties such as strength, water resistance, or fire resistance. The fabric may also be treated with dyes or coatings to improve its appearance or functionality.
Cutting and Packaging
The final step involves cutting the fabric according to the desired size and packaging it for shipment.The non-woven fabric manufacturing process is a complex and automated process that requires specialized equipment, skilled labor, and a thorough understanding of the properties of different materials. Non-woven fabrics have wide applications in various industries due to their unique properties such as lightweight, durability, and water resistance.
How to Maintain Nonwoven Fabric
Keep clean, change and wash frequently to prevent the breeding of moths. When storing in different seasons, wash, iron and dry them, seal them in plastic bags and put them flat in the wardrobe
Pay attention to shading to prevent fading. Ventilation, dust removal and dehumidification shall be carried out frequently, and exposure is not allowed.
Mildew proof and moth proof tablets should be put in the wardrobe to prevent the cashmere products from damp, mildew and insects. When wearing inside, the lining of the matching coat should be smooth. Do not put hard objects in the pocket, such as pens, key bags, mobile phones, etc., to avoid local friction and pilling
When wearing out, try to reduce friction with hard objects (such as sofa backrest, armrest and desktop) and hook hanging.
The wearing time is not easy to be too long. You must stop wearing or change clothes for about 5 days to restore the elasticity of clothes and avoid fiber fatigue damage.
In addition, the following aspects should also be noted
1. Avoid exposure to the sun. It is easy to decompose and put it in a dry place
2. Try to avoid friction. The friction resistant cloth is brittle, and the cloth with good tension will fuzz if it is rubbed vigorously
3. In case of pilling, do not pull it forcibly. Use scissors to cut off the POM, so as not to be irreparable due to off-line.
FAQ
Q: Is non woven fabric good or bad?
Q: Is polyester non-woven?
Q: Is non-woven stretchy?
Q: How long does it take for non-woven fabric to decompose?
Q: Are Nonwoven Fabrics breathable?
Q: Is Non-Woven Fabric Recyclable?
Q: What is Non-Woven Fabric?
Q: Is non-woven natural or synthetic?
Q: What are Nonwoven Fabrics made of?
Q: What are the raw materials of non-woven fabric?
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