In the present era, nonwoven fabric is one of the most versatile and widely used materials. Nonwoven fabrics are everywhere around us, starting from face masks, filters, wipes, medical gowns, diapers, and packaging material to automotive products. They are valued for their lightweight, cost-effective, and multifunctional properties.
What is Nonwoven Fabric?
A fabric sheet or web structure made from fibers that are bonded together thermally, chemically, or mechanically, but not by the woven method or knitted method, is called a nonwoven fabric. This type of material is directly made from fibers without weaving or knitting. In traditional textiles, fibers are spun into yarn and then transferred to the weaving or knitting department to produce fabric. In contrast, they are created by binding fibers together using heat, chemical, or mechanical processes.
How Nonwoven Fabric Differs from Woven & Knitted Fabrics?
To differentiate among Woven fabric, knitted fabric & nonwoven fabric, we will have to review some basic features of these fabrics.
- Construction
For the preparation of woven fabric, we have to interlace yarn, and for knitted fabric, we have to interloop yarn, but in the case of non woven cloth, we bond fibers directly.
- Strength
The strength of woven fabrics is consistently high. In contrast, knitted fabrics have moderate strength, while nonwoven fabrics exhibit variable strength, which can be high or low, depending on the type of fiber bonding used.
- Cost
Woven fabric has a higher cost, knitted fabrics have a moderate cost, but non woven cloth has a lower price than woven or knitted fabrics.
The basic points are that non woven cloth allow the manufacturer to create customized material with required properties such as stretch, repellency, absorbency, flame resistance, softness, and durability.
Main Characteristics of Nonwoven Materials
- Nonwoven materials are breathable and lightweight.
- It can be made soft or rigid as per your requirements.
- These fabrics can be highly absorbent and water-resistant, allowing for customization to meet your specific requirements.
- Its production is cost-effective compared to woven and knitted fabrics,
- There is an eco-friendly option available in nonwoven fabric
- These fabrics are used in medical and healthcare products such as surgical masks, gowns, and drapes.
- Hygiene products such as baby diapers and sanitary pads are usually made of nonwoven fabrics.
- Filters, wipes, and protective clothing made of nonwoven materials are used in industries.
- Seed blankets and crop covers, which are agricultural products, are also available, made of nonwoven fabric.
Raw Material of Nonwoven Fabrics
Nonwoven fabrics can be made of manmade fibers, natural fibers, and a blend of both manmade and natural fibers. The selection of raw material depends on the end use and performance requirements. Below are some commonly used raw materials.
- Polypropylene (PP)
The chemical formula of polypropylene is (C3H6)n. It is the most widely used fiber due to its lightweight, durability, and cost-effectiveness, and is commonly used in face masks, medical gowns, and shopping bags.
- Polyester (PET)
The chemical formula of polyester is (C10H8O4)n. Polyester fibers are strong and wrinkle-resistant, which makes them often used in geotextiles, packaging, and filtration.
- Polyethylene (PE)
The chemical formula of polyethylene is (C2H4)n. Polyethylene fibers are flexible and water-resistant, and are usually used in disposable medical products and hygiene items.
- Rayon & viscose
Both rayon and viscose fibers are soft, smooth, and highly absorbent, and ideal for wipes, tissues, and feminine hygiene products.
- Cellulose and other natural fibers
These fibers, which are eco-friendly and biodegradable, are used for medical bandages, wipes, and filters.
- Additives and binders
The most crucial uses of additives and binders are anti-bacterial properties, fire resistance, color, softness, and durability.
Do Nonwoven Fabrics Absorb Moisture?
There are two terms used in the textile universe for any fabric, made of any fibers, including both synthetic and natural, hydrophilic and hydrophobic. Hydrophilic fabrics are those that absorb water, and hydrophobic fabrics are those that repel water and show zero percent absorbency. The ability of nonwoven fabric to absorb or repel depends on the type of fibers and the manufacturing process.
Hydrophobic nonwovens are made from polypropylene or polyethylene, and their common uses are in surgical masks, protective gowns, and packaging.
Hydrophilic nonwoven is made of rayon, cotton, and treated synthetic fibers, which are usually used in diapers, sanitary pads, and wipes.
Types of Nonwoven Fabrics
There are many types of nonwoven fabrics, which are based on their manufacturing techniques.
- Spunbond Nonwoven
These types of nonwovens are made by spinning polymer filaments and bonding them using heat or thermal energy. These are lightweight and durable and used in face masks, hygiene products, and shopping bags.
- Meltblown Nonwoven
These are made from fine fibers for high filtration characteristics and used in N95 masks, air purifiers and medical filters.
- Needlepunch Nonwoven
Fibers are mechanically interlocked using barbed needles and commonly used in carpets, insulation and furniture padding.
- Spunlace Nonwoven
A machine called a high-pressure water jet is used to entangle the fibers. These fibers are soft, absorbent, and skin-friendly and are usually used in wipes, medical fabrics, and tissues.
Manufacturing Process of Nonwoven Fabrics
Step 1) Fiber Preparation
Choose the right fibers while keeping the end product in mind
Step 2) Web Formation
Laid out the fibers with the help of air or the wet-laid method
Step 3) Bonding
Bind the fiber together with the help of thermal bonding, chemical bonding or mechanical bonding as per available resources
Step 4) Finishing
Apply finishing agents as per your requirements, such as water resistance, fire retardancy, or antibacterial properties.
Application of Nonwoven Fabrics
Nonwoven fabrics are used almost everywhere. Some uses are below
- Medical uses such as masks, gowns, and surgical drops
- Hygiene uses such as diapers, wipes, and sanitary pads
- Automotive uses such as filters, carpet,s and insulation
- Agricultural uses such as crop covers and plant protection
- Home uses such as mattress covers and upholstery lining
- Industrial uses such as geotextiles and protective clothing
FAQs
What is Nonwoven Material?
Engineered fabrics made from short fibers or continuous filaments bonded together in a sheet or web are referred to as nonwoven materials.
Is nonwoven fabric the same as plastic?
No, not all nonwoven fabrics are pure plastic; some are made from natural fibers like cotton, rayon, and cellulose.
Is nonwoven fabric waterproof?
It depends on the finish of the fabric. You can make it waterproof to your liking.
Is nonwoven fabric eco-friendly?
Nonwoven fabrics made from natural fibers are eco-friendly, but nonwoven fabrics made from synthetic fibers may contribute to pollution.