Environmentally friendly nonwoven fabrics can be formed through thermal bonding of cotton and cellulose acetate fiber blends at reduced bonding temperature with the aid of a plasticizer. Water has been introduced as an external plasticizer to lower the softening temperature of cellulose acetate fibers and to enhance the tensile strength of cotton/cellulose acetate web. It has been found that water can significantly increase the tensile strength of cotton/cellulose acetate thermally-bonded webs at reasonable bonding temperatures. In addition, water can enhance web bonding to essentially the same degree as an acetone treatment does. The mechanisms of water effect are considered and optimal processing conditions are proposed.
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