Plain Weave Nonwovens Fabric is a type of nonwoven material used for a variety of applications, such as single use (or disposable) products, and durable clothing. They are usually produced with low-melt fibers and can be bonded together mechanically, chemically or thermally.
Plain weave fabrics have many of the same physical properties as woven or knitted fabrics but have more strength and less memory than those fabrics. They can be made from a wide range of fibers including polypropylene, polyester and viscose.
Traditionally, the majority of nonwovens have been made from cellulose fibres such as wood pulp and cotton linters but these fibers are not the only ones that can be used. For example, a number of high-performance, engineered plastics such as polyethylene terephthalate (PET) and polypropylene have excellent water resistance properties that make them suitable for some types of nonwovens.
In addition, some biodegradable materials have also been used to make nonwovens as they are naturally resistant to mold and mildew spores that are found in environments with heavy moisture. For this reason, a wide range of biodegradable nonwovens have been developed for use in medical and sanitary applications.
These biodegradable nonwovens are generally very soft and have excellent washability and odor removal capabilities. Some have also been formulated to be flame retardant or sterile.
There are a wide range of processes for making nonwovens from staple fibers such as cotton and polypropylene. These methods produce a nonwoven fabric using fewer steps than woven or knitted fabrics, allowing for production speeds of up to 400 yards per minute.
The most common process for manufacturing nonwovens from staple fibers involves a series of steps to produce a uniform web. The first step is to spin the fibers, which are then cut to a few centimeters long. This is called "opening." The fibers are then blended and "opened" in a multistep process before being dispersed on a conveyor belt and spread into a uniform web by wetlaid, airlaid or carding/crosslapping operations.
Another process for manufacturing nonwovens from staple fibers uses a thermoplastic binder to bind the nonwoven fibers together. These thermoplastics can be made from a variety of synthetic polymers or can be derived from oil-based materials.
Lastly, there are a number of special techniques that can be employed to increase the physical strength and other physical properties of nonwovens. These include point bonding, which is a technique for bonding thermoplastic fibers by applying heat and pressure to the fibers until a discrete pattern of fiber bonds is formed.
This process can also be used to create fabrics that have a woven or knit appearance, and are often used in the manufacture of surgical gowns and protective clothing.
Plain weave fabrics are available in a variety of thicknesses, colors and patterns. Some are very soft, and others are a bit stiffer. They can also be printed and patterned. Some can even be infused with chemicals to add specific properties to them.