Hydro-patterned nonwoven and method of making the same
AssigneesPfnonwovens LLC, Pfnonwovens Holding S.R.O
InventorsKarthik Ramaratnam, Peter Zajaczkowski, John C. Parsons, Pavlina Kasparkova
Life of this patent
Estimating the term…
Abstract
A method of forming a hydro-patterned nonwoven web including the steps of forming a nonwoven batt comprising continuous spunmelt fibers, calender bonding the nonwoven batt to form a thermobonded precursor nonwoven web with a bond pattern that defines bond impressions and unbonded areas between the individual bond impressions, and hydraulically treating the thermobonded precursor nonwoven by a plurality of steps of water injection as the thermobonded nonwoven web passes over a screen. The bond pattern has specific features that provide advantages in terms of mechanical properties and visual appearance of the final nonwoven product.
Claims42
A method of forming a hydro-patterned nonwoven web, comprising:
- forming a nonwoven batt comprising continuous spunmelt fibers;
- calender bonding the nonwoven batt to form a thermobonded precursor nonwoven web with a bond pattern that defines bond impressions and unbonded areas between the individual bond impressions;
- and
- hydraulically treating the thermobonded precursor nonwoven by a plurality of steps of water injection as the thermobonded nonwoven web passes over a screen, wherein
- the bond pattern has a percentage bond area of 10% to 25%,
- an imaginary circle C is defined as the largest circle that can be drawn among the unbonded areas and which has a perimeter that intersects with a single point on perimeters of each of at least two adjacent bond impressions within the bond pattern, and the circle C has a radius in the unbonded area of at least 0.5 mm, and
- the bond pattern comprises large-bold bonding impressions with a bond impression area of at least 1 mm2.
A method of forming a hydro-patterned nonwoven web, comprising:
- forming a nonwoven batt comprising continuous spunmelt fibers;
- calender bonding the nonwoven batt to form a thermobonded precursor nonwoven web with a bond pattern that defines bond impressions and unbonded areas between the individual bond impressions;
- and
- hydraulically treating the thermobonded precursor nonwoven by a plurality of steps of water injection as the thermobonded nonwoven web passes over a screen, wherein
- the bond pattern has a percentage bond area of 10% to 25%,
- the bond pattern comprises small bonding impressions with a bond impression area less than 1 mm2, and
- the bond pattern comprises large bonding impressions with a bond impression area of at least 1 mm2.
A method of forming a hydro-patterned nonwoven web, comprising:
- forming a nonwoven batt comprising continuous spunmelt fibers;
- calender bonding the nonwoven batt to form a thermobonded precursor nonwoven web with a bond pattern that defines bond impressions and unbonded areas between the individual bond impressions;
- and
- hydraulically treating the thermobonded precursor nonwoven by a plurality of steps of water injection as the thermobonded nonwoven web passes over a screen, wherein
- the regular bond pattern has a percentage bond area of 10% to 25%,
- the bond pattern comprises large bonding impressions with a bond impression area of at least 1 mm2,
- the bonding impression has the shape of a line with irregular width, the maximum line width (W) of maximum 0.6 mm, and
- bonding impression has the shape of a line with a length (L) of at least 30 mm and a maximum of 25 mm.
Dependencies are inferred from the claim text.