Microstructure and physical properties of composite nonwovens produced by incorporating cotton fibers in elastic spunbond and meltblown webs for medical textiles

The objective of this research was to produce elastomeric nonwovens containing cotton by the combination of appropriate process. Such nonwovens are in demand for use in several healthcare, baby care, and adult care products that require stretchability, comfort, and barrier properties. Meltblown fabrics have very high surface area due to microfibers and have good absorbency, permeability, and barrier properties. Spunbonding is the most economical process to produce nonwovens with good strength and physical properties with relatively larger diameter fibers. Incorporating cotton fibers into elastomeric nonwovens can enhance the performance of products, such as absorbency and comfort. There has not been any study yet to use such novel approaches to produce elastomeric cotton fiber nonwovens. A hydroentangling process was used to integrate cotton fibers into produced elastomeric spunbond and meltblown nonwovens. The laminated web structures produced by various combinations were evaluated for their physical properties such as weight, thickness, air permeability, pore size, tensile strength, and especially the stretch recovery. Incorporating cotton into elastic webs resulted in composite structures with improved moisture absorbency (250%-800%) as well as good breathability and elastic properties. The results also show that incorporating cotton can significantly increase tensile strength with improved spontaneous recovery from stretch even after the 5th cycle. Results from the experiments demonstrate that such composite webs with improved performance properties can be produced by commercially used processes.