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US 12,746,735 B2Granted
Lofty nonwoven fabrics
AssigneeMagnera Corporation
InventorRalph A. Moody, III
Life of this patent
Estimating the term…
Abstract
Nonwoven fabrics are provided that include (i) at least one disposable-high-loft nonwoven layer having a plurality of crimped multi-component fibers and (ii) a scrim. A first side of the scrim may be bonded directly or indirectly to a first disposable-high-loft nonwoven layer and optionally a second side of the scrim may be bonded directly or indirectly to a second disposable-high-loft nonwoven layer. The first disposable-high-loft nonwoven layer has a first density and the scrim has a scrim density, in which the scrim density is larger than the first density.
Claims22
A nonwoven fabric, comprising:
- (i) a first disposable-high-loft (“DHL”) nonwoven layer consisting of a first plurality of crimped multi-component spunbond fibers of continuous length and being consolidated by a plurality of discrete first thermal bond sites having a first average bond site area;
- wherein the first DHL nonwoven layer has a first density and a first bonded area comprising from 7% to 15%, and the first bonded area is defined by the plurality of discrete first thermal bond sites, and wherein the first DHL nonwoven layer has a thickness from 0.2 to 2.75 mm;
- and
- (ii) a scrim comprising one or more spunbond layers including a plurality of monocomponent spunbond fibers of continuous length, wherein the scrim is consolidated by a plurality of discrete scrim thermal bond sites having a second average bond site area, wherein the scrim comprises a first side, a second side, and a scrim density;
- wherein the first side of the scrim is bonded directly to the first DHL nonwoven layer and the scrim density is larger than the first density;
- wherein (a) an average distance between adjacent scrim thermal bond sites is smaller than an average distance between adjacent first thermal bond sites, wherein the average distance between adjacent scrim thermal bond sites is from 0.1 mm to 10 mm, (b) the second average bond site area is larger than the first average bond site area, and (c) at least a portion of the plurality of discrete first thermal bond sites extends entirely through the first DHL nonwoven layer and thermally bonds the first DHL nonwoven layer to the scrim.
3 more elements
A method of forming a nonwoven fabric, comprising:
- (i) forming a first DHL nonwoven layer comprising depositing continuous attenuated filaments from a fiber draw unit and forming a first plurality of crimped multi-component spunbond fibers of continuous length upon removal of an attenuating force from the fiber draw unit followed by consolidation forming a plurality of discrete first thermal bond sites having a first average bond site area;
- wherein the first DHL nonwoven layer has a first density and a first bonded area comprising from 7% to 15%, and the first bonded area is defined by the plurality of discrete first thermal bond sites, and wherein the first DHL nonwoven layer has a thickness from 0.2 to 2.75 mm;
- (ii) forming or providing a scrim comprising one or more spunbond layers including a plurality of monocomponent spunbond fibers of continuous length, wherein the scrim is consolidated by a plurality of discrete scrim thermal bond sites having a second average bond site area, wherein the scrim comprises a first side and a second side;
- wherein the scrim has a scrim density that is larger than the first density;
- and
- (iii) directly bonding the first side of the scrim to the first DHL nonwoven layer to provide the nonwoven fabric;
- wherein (a) an average distance between adjacent scrim thermal bond sites is smaller than an average distance between adjacent first thermal bond sites, wherein the average distance between adjacent scrim thermal bond sites is from 0.1 mm to 10 mm, and (b) the second average bond site area is larger than the first average bond site area.
4 more elements
Dependencies are inferred from the claim text.