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PUL diaper coversPolyurethane laminate (PUL, thermal stretch,[1] fuzzy rubber[1]) is a compound fabric made by laminating a cloth fabric to one or both sides of a thin film of polyurethane.[1][2] Polyurethane laminated fabrics have a wide range of applications in medical, automotive and garment uses.[2]
Most PUL fabric is made by laminating lightweight polyester interlock knit fabric to a 1mm thick film of polyurethane. There are two processes used for lamination: solvent lamination, which fuses the fabric and polyurethane film into a single monolithic fabric, and hot melt, which uses heat-activated glue to adhere the fabrics together.[citation needed] Woven fabric and fleece fabric can also be used,[1] but a stiff fabric will drastically reduce the elasticity of the finished laminate.
Use
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PU laminate cloth is waterproof, breathes and stretches somewhat, and is soft and flexible. It can usually be machine-washed and dried,[1] and cleaned with dilute bleach or alcohol.[2]
PU fabric is useful as a wind and/or water barrier in the construction of fluid-splash protecting garments, shower curtains, and outerwear clothing.[citation needed] It is used for upholstery, especially in cars and restaurants.[2]
It is used in watersports clothing and equipment.[1] PUL is used for tents and waterproofing backpacks.[3]
Because it can be readily cleaned and sterilized, PUL is used for medical bedding, mattress protectors, reusable incontinence products, diapers/nappies, wet bags, and cloth menstrual pads.[4][5]
Materials and degradability
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There are many different polyurethane blends and resin types,[6] which vary in durability, resistance to heat, ambient humidity, and light,[2] and the maximum temperature they will stand (some, for medical use, are autoclavable).[1] Resistance is measured by accelerated aging in a harsh controlled environment; the number of weeks survived is expressed as a hydrolysis resistance in units of years (expected under normal conditions).[7] Apart from heat and humidity, bleach, salt, and chlorine can also shorten coating life.[3]
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If PUL is kept wet for a long time, it disintegrates into the water and sticks to itself, though it will probably go mouldy first.[7] If the polyurethane starts delaminating from the fabric, it may be possible to relaminate it with care and a hot iron. If the PU coating has decayed, it can be replaced.[8][3]
See also
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References
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It is a very durable fabric with many people reporting that they have been able to use nappies made with this material for the nappy wearing duration of at least a couple of children with only the elastic needing updating between children. You can imagine how much they are getting used and washed. I made my son's nappy wraps to go outside his cloth nappies when he was tiny and they stayed in perfect condition despite being used 3 1/12 years constantly between him and his little sister and being washed every other day for that whole time.
Polyurethane is more durable even than thermoplastics, so as a coating it lasts extremely well. Combined with polyester fabrics, which are inherently strong, resistant to tearing and don't damage over time with repeated washes and abrasion, this combination makes for a long-lasting fabric.
If damage occurs to the laminated side of the fabric, then over time and use /repeated washing, the laminate can begin to separate away from the polyester. This is usually only a problem if you have large areas of unsewn laminate without any backing to protect it. For example, this happened to me with a large unlined laundry wash bag that got turned inside out into the washing machine - over time, small damage inside the washing machine where it was rubbing over sharper surfaces such as zips and velcro caused damage. This is simply fixed by using sandwich PUL, or adding a lining layer, or turning the fabric so the polyurethane is inside or within a protective laundry bag, or washing it without other abrasive laundry items. I used a bit of old curtain lining to line my large full load of laundry wet bags for our cloth nappies after that and with the added lining it was happily going for a couple of years with no problems until we stopped using nappies and it became a washable recycling bin liner instead which is still just as good 6+ years after making it.
Yes and No. Polyurethane is much better at biodegrading than many other types of plastics, however, polyester is very poor at biodegrading. However, this fabric is very durable and is very well suited to replacing many single-use plastic products such as sanitary towels, breast pads, continence pads, plastic bags, nappies and much more. In this respect, a small piece of fabric that may last through regular use for 10 years or more will save many many pieces of single-use plastics from going to landfills.
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