Technical Textile Innovations in Japan

The Japanese textile industry is well known for its innovativeness. Asahi Kasei's Precisé fine polyester nonwoven is ""very thin, like paper"" and has a fine and even structure. Kuraray's new Vancool tent and awning material helps to block heat while its Clarino synthetic leather is being used for baseballs and lightweight shoes. Kuraray has also developed towable polyacrylate water bags made from Vectran, and Flextar fabrics made from Kuralon K-II polyvinyl alcohol (PVA). Mitsubishi Rayon Engineering's steam-jet entanglement process opens up new end uses for nonwovens. Fabrics made from Omikenshi's Sundia viscose fibres are able to deodorise on exposure to sunlight. Crabyon activates the lysozyme enzyme in the body which gives protection from germs. Kishu Binchotan particles are said to create a sense of well-being, absorb odours and humidity and release far-infrared radiation to aid blood circulation. Other fibres contain the health-giving compounds squalene and squalane. Daiwabo is using artificial enzymes to create odour-free fabrics. Ingenious nonwovens containing photocatalysts are used for filtration by Kurashiki Textile. Teijin Twaron's rubber additive based on a para-aramid fibre increases the durability of tyres and reduces rolling resistance.

Health and safety considerations are also prominent. Asahi Kasei, Teijin and Toyobo have developed polyester cushioning materials to compete with PU foam in public transport seating and household furniture. Also, a number of developments are directed towards environmental protection. Teijin Fibers has developed Ecocircle, a system for recycling synthetic fibres from discarded garments. Other companies have developed new processes for recycling polyester terephthalate (PET) bottles into polyester fibre.

Biofibres are also growing in importance. Teijin has a heat-stable polylactic alternative to traditional polyesters, and Toray has a biofibre car mat, also based on polylactic acid. Other plant-derived fibres include polybutylene succinate and natural fibres such as bamboo and kenaf. Fujitsu has a biopolymer derived from castor oil and Honda has a plant-based fabric for car interiors.

Teijin's new monofilament Morphotex mimics butterfly wings by using interference to produce colour without pigments or dyes. Teijin also has a polyester alternative to high grade merino wool and a polyester fabric for sportswear which absorbs and releases moisture rapidly.