Toray Industries, Inc., has created a spunbond nonwoven fabric that is persistently hydrophilic and is gentle on the skin. This fabric is suitable for disposable diapers, masks, feminine hygiene products, and other sanitary applications.  The company plans to start full-scale production when the production technology is well established.

Spunbond nonwoven fabrics for sanitary applications are normally made of polypropylene, which is softer than polyester. Since polypropylene is hydrophobic (glossary note 2), polypropylene spunbond nonwoven fabrics must be coated with hydrophilic agents for the application of diapers, masks, and feminine hygiene products. However, the coated hydrophilic agents are easily runoff from the fabrics on contact with water. Consequently, the fabrics lose hydrophilicity.

Toray has been addressing this issue by researching the hydrophilized polymer itself rather than focusing on surface treatment. The compnay has developed special domain structures by copolymerizing polyester with a well-defined moalr mass hydrophilic component. The domain structures enable the company to significantly improve the hydrophilicity of the polyester and result in a new spunbond nonwoven fabric that is persistently hydrophilic.

The polyester can be polymerized using bio-based or recycled materials. Toray will push ahead with efforts to reduce environmental impact and achieve a sustainable economy. Toray will continue to provide innovative technologies and advanced materials to transform societies in keeping with its commitment to innovating ideas, technologies, and products that deliver new value.