Spunbonded

Spunbonded refers to a category of nonwoven fabric produced by the spunbond process. In this process, thermoplastic polymer resin is melted and extruded through spinnerets to form continuous filaments that are drawn and deposited onto a moving belt to form a web. The web is then bonded to impart strength, typically by thermal calendering, mechanical needling, through-air bonding, or chemical binders. Spunbonded fabrics are notable for their combination of strength, softness, and permeability.

Polypropylene is the dominant material, but other polymers such as polyester, polylactic acid, and polyethylene are also used, including bicomponent or multicomponent fibers to tailor properties. The resulting fabrics can be produced in a wide range of weights, from light films around a few gsm to heavy fabrics exceeding 100 gsm, depending on the application and desired durability.

Bonding methods influence performance: thermal point bonding creates discrete fused areas that reinforce strength while preserving breathability; through-air bonding provides uniform bonding with high softness; chemical bonding uses binders to alter stiffness and integrity.

Applications are diverse. Spunbonded fabrics are widely used in disposable hygiene products (diapers, sanitary napkins), medical gowns and drapes, and filtration media for air and liquids. They are also used in geotextiles for erosion control, crop covers in agriculture, wipes, packaging, and automotive interiors.

Compared with meltblown fabrics, spunbonded materials offer greater tensile strength and durability at a lower cost, but generally provide lower filtration efficiency unless combined with other nonwoven layers. Environmental considerations include recyclability of polyolefin-based spunbonded fabrics where facilities exist.