With the exception of felt, nonwoven materials are in the early stages of development. There is controversy about the precise meaning of the term nonwoven, but one authority defines nonwoven fabrics as textile fabrics made of a fibrous layer having randomly laid or oriented fibres or threads.
Felts are a class of fabrics or fibrous structures obtained through the interlocking of wool, fur, or some hair fibres under conditions of heat, moisture, and pressure. Other fibres will not felt alone but can be mixed with wool, which acts as a carrier. Three separate industries manufacture goods through the use of these properties. The goods produced are wool felt, in rolls and sheets; hats, both fur and wool; and woven felts, ranging from thin billiard tablecloths to heavy industrial fabrics used for dewatering in the manufacture of paper. Felts of the nonwoven class are considered to be the first textile goods produced, and many references may be found to felts and their uses in the histories of ancient civilizations. The nomadic tribes of north central Asia still produce felts for clothing and shelter, utilizing the primitive methods handed down from antiquity.
Several methods for making nonwoven materials are now firmly established, and others are being developed.
In adhesive bonding, fabrics are made by forming a web of fibres, applying an adhesive, then drying and curing the adhesive. The web can be produced by a garnett machine or a conventional card, several layers being piled up to obtain the required thickness. Such webs are weak across the width, but this does not limit their use for certain end products. A more uniform product results from cross laying the web. Other machines, such as the Rando-Webber, lay down the fibres by an airstream.
The fibres in the web may be stuck together in various ways. The web may be sprayed with an emulsion of an adhesive—e.g., a latex based on synthetic rubber, acrylic derivatives, or natural rubber—or, alternatively, may be carried on a mesh screen through a bath of latex, the excess being squeezed out by a pair of rollers. Adhesives may also be applied as a foam or a fine powder. Thermoplastic fibres can be incorporated in the blend and on heating will bond together, giving strength to the mass of fibres.
Mechanically bonded nonwoven products (or fibre-bonded nonwovens) are webs strengthened by mechanical means. The web, sometimes reinforced by a thin cotton scrim in the middle or by texturized yarns distributed lengthwise through it, is punched by barbed needles mounted in a needle board. The fibres in the web are caught up by the needle barbs, and the resulting increased entanglement yields a compact product sufficiently strong for many purposes. Modern needle-felting or punching machines perform 900 punches per minute, and selection of appropriate needles is based on the fibre being processed and the desired product.
The Arachne machine, the best known unit for stitch bonding, operates much like a warp-knitting machine. Fibrous web is fed into the machine, and stitches are made by a series of needles placed about eight millimetres apart, giving the web longitudinal strength; lateral strength is provided by the fibre interactions. The products are attractive for many purposes and can be improved by treatment with polyester resins to increase their wear resistance and with thermosetting precondensates to reduce their tendency to pill (e.g., to form small tangles). A new device attached to the Arachne machine permits introduction of weft ends at every single course, making colour effects possible. Araloop machines yield loop-pile fabric suitable for towels and floor coverings.
Three sewing-knitting machines were invented in East Germany in 1958. In the Malimo machine process, warp yarns are placed on top of filling yarns and stitched together by a third yarn. The Maliwatt machine interlaces a web of fibres with a sewing thread, giving the effect of parallel seams. The Malipol machine produces a one-sided pile fabric by stitching loop pile through a backing fabric. A new British process makes double-sided terry fabric, called Terrytuft, by inserting pile yarn into a backing and knotting it into position.
Webs made of yarns having a core of one polymer and an outer sheath of another material having a lower softening point may be lightly pressed and then heated to an appropriate temperature. The core yarn will “spot weld” together at the junction points, binding the mass of fibres together. Products made in this way find uses as industrial fabrics, coatings, and interlinings.
The joining of one fabric to another by an adhesive such as natural rubber has long been practiced in rainwear manufacture. Composite materials were later joined by bonding a layer of polyurethane or other foam to a conventional textile fabric. The two components were stuck together by flame bonding or by an adhesive in the form of a continuous coating, in spots, or as a powder. This laminating process has been extended to the joining of two layers of fabric. Each fabric layer can be quite thin, and the amount and type of adhesive are chosen to add only minimum stiffening. Such materials offer a variety of applications. A coating fabric, for example, may be joined to a lining; dimensionally stable composites can be made from cloth layers that are in themselves dimensionally unstable. Acetate knitted fabrics are frequently used as backing material in laminates.