# US 12,180,628 B2 · Multilayered nonwoven fabric containing submicron fibers, a method of manufacture, an apparatus, and articles made from multilayered nonwoven fabrics

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- Number: US 12,180,628 B2
- Document ID: US12180628B2
- Status: Granted
- Kind: B2
- Application number: 18/395,004
- Filed: 2023-12-22
- Published: 2024-04-18
- Granted: 2024-12-31
- Earliest claimed: 2020-11-17
- Applicants: Applied Materials Group LLC
- Inventors: Morgan Darwin
- Web page: https://patentgrep.com/patent/US12180628B2

## CPC

- D01D 5/0985: {by means of a flowing gas (e.g. melt-blowing)}
- D04H 1/559: the fibres being within layered webs
- B32B 5/067: {characterised by the fibrous or filamentary layer being mechanically connected by hydroentangling}
- B32B 5/266: {next to one or more non-woven fabric layers}
- B32B 5/267: {characterised by at least one non-woven fabric layer that is a spunbonded fabric}
- B32B 37/02: characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
- B32B 37/15: with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
- B32B 37/156: {at least one layer is calendered and immediately laminated}
- D04H 3/16: with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
- B32B 5/022: {Non-woven fabric}
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2262/02: Synthetic macromolecular fibres
- B32B 2262/16: Structural features of fibres, filaments or yarns e.g. wrapped, coiled, crimped or covered
- B32B 2305/20: in the form of a non-woven mat
- B32B 2309/12: Pressure
- B32B 2310/028: using vibration, e.g. sonic or ultrasonic
- B32B 2535/00: Medical equipment, e.g. bandage, prostheses or catheter
- B32B 2555/02: Diapers or napkins
- B32B 2571/00: Protective equipment
- D01D 4/025: {Melt-blowing or solution-blowing dies}
- D01D 5/0023: {the material being a polymer melt}
- D01D 5/08: Melt spinning methods {(D01D5/0023 takes precedence)}
- D04H 1/4374: using different kinds of webs, e.g. by layering webs
- D04H 1/43838: {Ultrafine fibres, e.g. microfibres}
- D04H 1/498: entanglement of layered webs
- D04H 3/14: with bonds between thermoplastic yarns or filaments produced by welding
- D01D: MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

This document presents a novel method of manufacturing multilayered nonwoven fabrics consisting of submicron fibers, hydroentangled, meltfibrillated, and/or spunlaid web layers. The composite multilayered webs contain one or more submicron fiber webs placed between inner and outer layers of hydroentangled, meltfibrillated, and/or spunlaid web, forming a fabric that may be utilized in the manufacture of articles which serve as barriers, wipes or sorbent materials, or may have other potential applications. The created novel composite multilayered fabric may have increased loft, softness and bending length, may not be solely dependent upon an electrostatic charge to repel small particles and microbes, and may be formed from a broad selection of natural, synthetic, and recycled polymers, including petroleum- and plant-based, allowing polymer selection based on article lifecycle.

## Claims

### Claim 1

A process comprising:
creating one or more base layers comprised of pre-formed hydroentangled and/or meltfibrillated nonwoven fabrics and/or comprised of meltfibrillated and/or spunlaid fiber webs, on top of a moving conveyer belt;
creating, through melt fibrillating, one or more submicron fiber web layers on top of said one or more base layers traveling on said moving conveyor belt by extruding a polymeric melt through at least one of one or more melt fibrillation nozzles and a fluid stream associated with said polymeric melt emanating from an orifice of said at least one of one or more fibrillation nozzles;
subjecting said extruded polymeric melt to an entraining fluid flowing from a separate orifice of the at least one of said one or more fibrillation nozzles to form said one or more submicron fiber web layers comprising microfibers and submicron fibers formed on an upper surface of said one or more base layers;
covering the one or more submicron layers with one or more top layers comprised of pre-formed hydroentangled and/or meltfibrillated nonwoven fabrics and/or comprised of meltfibrillated and/or spunlaid fiber webs;
consolidating the one or more base layers, the one or more submicron layers, and the one or more top layers to form a multilayered nonwoven fabric containing the microfibers and submicron fibers in a single continuous process.

### Claim 2 (depends on 1)

The process according to claim 1, where at least one of the one or more base and top layers is created via melt fibrillating or spin laying while traveling on the moving conveyor belt.

### Claim 3 (depends on 1)

The process according to claim 1, where at least one of the one or more base and top layers is created by feeding in a hydroentangled and/or meltfibrillated nonwoven fabric while traveling on the moving conveyor belt.

### Claim 4 (depends on 1)

The process according to claim 1, where at least one of the one or more base layers is overlain by one or more submicron fiber webs and is consolidated by bonding said one or more submicron fiber webs, having been overlain, to said one or more base layers.

### Claim 5 (depends on 1)

The process according to claim 1, where at least one of the one or more top layers is positioned on top of said one or more submicron layers while the multilayered nonwoven fabric is traveling on the moving conveyor belt after melt fibrillating the one or more submicron layers.

### Claim 6 (depends on 1)

The process according to claim 1, where at least one of the one or more top layers positioned on top of said one or more submicron layers is consolidated by bonding to said one or more base layers and said one or more submicron layers.