Two-sided hydrophilic/hydrophobic nonwoven and method of manufacturing thereof
AssigneeFirst Quality Nonwovens, Inc.
InventorsW. Andrew Coslett, Lynda A. Kelly, John C. Parsons
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Abstract
A nonwoven fabric comprises: a first layer comprising hydrophilic spunbond fibers including a hydrophilic melt additive, the first layer forming at least one exposed outer surface of the nonwoven fabric; a second layer comprising hydrophobic spunbond fibers, the second layer forming an opposite exposed outer surface of the nonwoven fabric; and a third layer comprising meltblown fibers interposed between the first and second layers; wherein the nonwoven fabric has an absorptive capacity of at least 100%.
Claims34
A nonwoven fabric comprising:
- a first layer comprising hydrophilic spunbond fibers including a hydrophilic melt additive, the first layer forming at least one exposed outer surface of the nonwoven fabric;
- a second layer comprising hydrophobic spunbond fibers, the second layer forming an opposite exposed outer surface of the nonwoven fabric;
- and
- a third layer comprising meltblown fibers interposed between the first and second layers;
- wherein the nonwoven fabric has an absorptive capacity of at least 100%.
A process of manufacturing a nonwoven fabric, the process comprising:
- forming a first layer comprising hydrophilic spunbond fibers including a hydrophilic melt additive;
- forming a second layer comprising hydrophobic meltblown fibers disposed over the first layer;
- forming a third layer comprising hydrophobic spunbond fibers disposed over the second layer;
- and
- calendering the first, second, and third layers between two calender rolls.
The process of claim 24, wherein the nonwoven fabric has an absorbent capacity of about 300 to 500%.
The process of claim 26, wherein the nonwoven fabric has a hydrostatic head of at least 30 to 65 mbar when challenged from the hydrophilic outer surface.
The process of claim 29, wherein nonwoven fabric has a spunbond content of about 72 to 78% and a meltblown content of about 22 to 28%.
The process of claim 31, wherein the basis weight of the nonwoven fabric is between about 34 to 68 gsm.
Dependencies are inferred from the claim text.