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US 2002/0177378 A1Published application
Acquisition/distribution layer and method of making same
AssigneeFirst Quality Nonwovens, Inc.
InventorHassan Bodaghi
Life of this patent
Estimating the term…
Abstract
A nonwoven fabric comprised of a self-sustaining pre-bonded web formed by carding together first relatively thin monocomponent fibers, second relatively thicker monocomponent fibers, and 1-5% bicomponent fibers with the low softening point component thereof bonding together the first, second and bicomponent fibers to form the self-sustaining web. Six to ten percent by weight of cured latex particles are disposed within the fabric and smeared on the outer surfaces of the fabric, the particles being cured in situ to provide enhanced tensile strength to the fabric.
Claims27
A method of manufacturing a nonwoven fabric comprising the steps of:
- (A) forming a supported carded web including:
- (i) 75-89% by weight, based on the carded web, first monocomponent fibers having a first denier of 3 to 7,
- (ii) 10-20% second monocomponent fibers having a second denier of 8 to 20, the second denier being substantially higher than the first denier, and
- (iii) 1-5% bicomponent fibers having a denier generally similar to the first denier;
- (B) heating the supported carded web to a temperature where one component of the bicomponent fibers softens;
- (C) cooling the heated supported carded web to a temperature where the softened one component binds together the first, second and bicomponent fibers to form a self-sustaining pre-bonded web;
- (D) depositing 6-10% by weight latex particles, based on the total fiber of the self-sustaining pre-bonded web, in the interior and on the exterior of the self-sustaining pre-bonded web;
- (E) concurrently smearing and curing the associated latex particles in the interior and on the exterior of the self-sustaining pre-bonded web to form a bonded web of acceptable tensile strength, and
- (F) removing excess moisture from the bonded web to form the nonwoven fabric.
6 more elements
A nonwoven fabric comprising:
- (A) a self-sustaining pre-bonded web formed by carding together
- (i) 75-89% by weight, based on the total fiber, first monocomponent fibers having a first denier of 5-6,
- (ii) 10-20% second monocomponent fibers having a second denier of 10-12, said second denier being substantially higher than said first denier, and
- (iii) 1-5% bicomponent fibers having a denier generally similar to said first denier, said bicomponent fibers having a first component with low softening point and a second component with a relatively higher softening point, said first component binding together said first, second and bicomponent fibers to form said self-sustaining pre-bonded web;
- and
- (B) 6-10% by weight cured latex particles, based on the total fiber of said self-sustaining pre-bonded web, disposed within the interior of said fabric and smeared on the outer surfaces of said fabric, said particles being cured in situ to provide enhanced tensile strength to said fabric.
3 more elements
A method of manufacturing a nonwoven fabric comprising the steps of:
- (a) forming a supported carded web including:
- (i) 75-89% by weight, based on the carded web, first fibers having a first denier of 3 to 7 and a first softening temperature,
- (ii) 10-20% second fibers having a second denier of 8 to 20 and a second softening temperature, the second denier being substantially higher than the first denier, and
- (iii) 1-5% third fibers having a denier generally similar to the first denier and a softening temperature lower than the first and second softening temperatures;
- (B) heating the supported carded web to a temperature where the third fibers soften;
- (C) cooling the heated supported carded web to a temperature where the third fibers bind together the first, second and the third fibers to form a self-sustaining pre-bonded web;
- (D) depositing 6-10% by weight latex particles, based on the total fiber of the self-sustaining pre-bonded web, in the interior and on the exterior of the self-sustaining pre-bonded web;
- (E) concurrently smearing the associated latex particles over the exterior of the self-sustaining pre-bonded web and curing the associated latex particles in the interior and on the exterior of the self-sustaining pre-bonded web to form a bonded web of acceptable tensile strength;
- and
- (F) removing excess moisture from the bonded web to form the nonwoven fabric.
7 more elements
A nonwoven fabric comprising:
- (A) a self-sustaining pre-bonded web formed by carding together
- (i) 75-89% by weight, based on the total fiber, first fibers having a first denier of 3 to 7 and a first softening temperature,
- (ii) 10-20% second fibers having a second denier of 8 to 20 and a second softening temperature, said second denier being substantially higher than said first denier, and
- (iii) 1-5% third fibers having a denier generally similar to said first denier and a softening temperature less than the first and second softening temperatures, said third fibers binding together said first, second and third fibers to form said self-sustaining pre-bonded web;
- and
- (B) 6-10% by weight cured latex particles, based on the total fiber of said self-sustaining pre-bonded web, disposed within said fabric and smeared on the outer surfaces of said fabric, said particles being cured in situ to provide enhanced tensile strength to said fabric.
3 more elements
Dependencies are inferred from the claim text.