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Abstract
The term ‘composite nonwovens’ refers to a category of materials different from ‘nonwoven composites’, which consist of a resinous matrix reinforced by an embedded nonwoven fabric. Many scientists would like to rename ‘composite nonwovens’ as ‘soft nonwoven composites’ and ‘nonwoven composites’ as ‘hard nonwoven composites’. Composite nonwovens are created by a modern and innovative industry employing nonwoven technologies to bring together fibres of different origins, different characteristics or a combination thereof. Combination of different nonwoven preforms prepared either by employing a variety of process technologies or by combining nonwoven preforms with traditional textile preforms into a consolidated structure can also result in the creation of composite nonwovens. Composite nonwovens can provide an engineered solution by creating multifunctional products as well as an economical solution by eliminating manufacturing processes and replacing two or more products by a single product. Business activity in the field of composite nonwovens is therefore expected to grow substantially. In this paper, recent research into composition, manufacture, structure–property relationships and applications of composite nonwovens is reviewed beginning with an overview of composite nonwovens encompassing definitions, types, scope and business-related aspects. It then proceeds to discuss the characteristics of both natural and man-made fibres along with some speciality fibres such as bicomponent fibres and micro- and nanofibres in the development of composite nonwovens before exploring manufacturing processes used in creating composite nonwovens. The underlying nonwoven preparation methods and composite processes, such as multi-forming and multi-bonding, together with other more unusual composite processes are described before exploring structure–property relationship in composite nonwovens, including multicomponent nonwovens, multilayered nonwovens, hybrid nonwovens and nonwovens containing particulates or active ingredients. Applications of composite nonwovens in diverse products ranging from wound dressings, surgical gowns, facemasks to absorbent wipes and respirator filters are described. Finally, the review highlights the future prospects for composite nonwoven materials.