The Nonwoven Fabrics Industry
COURTESY AMERICAN FELT 0 0 .
This printed drapery material is based on a mechanically interlocked and chemically felted blend fabric of polyester and viscose fibers
NONWOVEN
FABRICS may be considered as either the oldest or newest of fabric constructions depending upon one’s viewpoint. Felt fabrics derived from animal fibers provided shelter and clothing to all ancestors of all races. The methods and materials of mandfacture were crude yet effective when compared with today’s scientific methods. Within the past generation the development and manufacture of bonded nonwoven fabrics based upon vegetable, synthetic, and animal fibers or hair have focused attention upon markets and potentials for restoring these fabrics to their former prominence. Nonwoven fabrics are defined as a continuous web of fibers, treated or processed in a manner other than knitting or weaving, which results in a strengthened construction. The problems, methods, and theory of web composition and formation are reviewed ; treatment methods are discussed with emphasis upon the mechanical, chemical, and esthetic properties as well as processing; the changing status of the industry is emphasized and analyzed. The output of nonwoven fabrics has mushroomed since World War I1 and currently represents a market well in excess of 100,000,000 lb. per year and shows a growth rate of about 25% per year. Such a growth is highly significant and built upon sound economics and per-
formance coupled with intelligent merchandising and promotion. All these factors are controlled or influenced by a technical understanding of the manufacture and markets for nonwovens. Equally important is a realization that nonwoven fabrics are limited in use and application. Much speculation has involved the possibility of the paper industry gradually taking over the nonwoven fabrics industry and market. Actually the broadening use and application of nonwoven fabrics and constructions are creating a potentially important commercial position for both paper and textile interests and by bridging the gap between these basic industries may aid in carrying to each the attributes, skills, and techniques of the other. Bonded nonwoven fabrics are a means of upgrading scrap fibers and because of low cost rapidly invaded the market for disposable textile products. Through the efforts of producers and suppliers better binders, combined with selected fibers, have resulted in more serviceable constructions for both single use and repeated service conditions. The improvement continues with products already introduced in the apparel, industrial, automotive, and housewares markets. The applications already proved for nonwovens include garment interlinings, wall coverings, furniture pad-
ding, wiping cloths, packing materials. liquid and gas filters, upholstery backing, shoe components, packaging materials, etc. Another equally important phase is to learn how better to apply the properties readily available in nonwovens-e.g., heat-sealability. The automotive industry has capitalized upon this property of a properly bonded nonwoven “plumper” fabric in the assembly of door panels and headlinings. The result is a more acceptable assembly which is inexpensive, easily styled, assembled, installed with minimum requirements of labor and skill and without the traditional maintenance problems and attendant expense. Little exploitation of these methods is made outside of the automotive industry yet there is certainly a potential impact to be made upon such markets as the furniture, luggage, packaging, and building industries. The continued future growth of this industry depends heavily upon the skill and ingenuity of chemists and engineers of all types. The articles which follow should stimulate thoughts for fundamental studies involving t e theories of fiber adhesion ; web formation ; binder selection, form, and application; and product evaluation and application.
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L. SHAILER, Jr.
B. F. Goodrich Chemical Co., Chairman VOL. 51, NO. 8
AUGUST ‘1959
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