Polyester Fiber Cushioning Material

V-Lap Vertically Lapped Nonwoven Fabric Provides Lighter Weight and Superior Cushioning

Among the various cushioning materials used for bedding and mattresses today, urethane foam is the most common. Urethane provides superior cushioning, but it has issues such as absorbing moisture and body heat, yellowing, and creating environmental burden when it is disposed.

Cross-section of V-Lap nonwoven fabric (upper photo); V-Lap nonwoven fabric is lapped vertically, while fibers of conventional nonwoven fabric are lapped horizontally.

Teijin has focused on the polyester nonwoven fabric products business utilizing high-function staple fibers. These efforts have included the development of the high-function polyester fiber cushion material ELK. In 2007, we were the first to introduce V-Lap, production equipment for vertically lapped nonwoven fabric. By combining our vertically lapped fabric production technology with ELK and other high-function staple fibers, Teijin created V-Lap nonwoven fabric, a polyester fiber cushioning material which has cushioning properties similar to urethane foam but can easily be recycled.

Superior Properties of V-Lap Nonwoven Fabric

Because fibers are arranged uniformly in the direction of the fiber thickness (vertically) and combined with high-performance staple fibers, V-Lap nonwoven fabric has greater vertical pressure strength compared with conventional polyester nonwoven fabric and does not sag easily.

Pressure dispersion

Improved pressure dispersion--the shape only changes where weight is placed.

Compared with conventional types, V-Lap nonwoven fabric also provides lighter weight, better breathability, higher flexibility, and it is easier to mold. What is more, V-Lap nonwoven fabric does not easily yellow and it emits little toxic gas when burned. After use, it can be recycled using Teijin´s ECO CIRCLE closed-loop recycling technology.

Light weight

V-Lap nonwoven fabric has less than half the weight of urethane foam.

Flexibility

V-Lap cushioning material is easy to mold because of its superior flexibility.

Development as a Sound-Absorbing Material and for Industrial Uses

Aside from its functions as a cushioning material, V-Lap nonwoven fabric can be fabricated together with other materials to create higher-function nonwoven fabric products. For example, a lightweight material with strong sound-absorption properties can be achieved by laminating the surface of V-Lap nonwoven fabric with film. Development as a sound-absorbing material for automobiles is expected.

Developments for industrial applications are also planned, including uses as a heat-insulation material and in lightweight board.