# US 2013/0157537 A1 · Nonwoven composite including regenerated cellulose fibers > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2013/0157537 A1 - Document ID: US20130157537A1 - Status: Published application - Kind: A1 - Application number: 13/330,504 - Filed: 2011-12-19 - Published: 2013-06-20 - Earliest claimed: 2011-12-19 - Inventors: David M. Jackson; Donald E. Waldroup; Keyur M. Desai; Jeffrey F. Jurena; Deborah J. Calewarts; Jian Qin - Web page: https://patentgrep.com/patent/US20130157537A1 ## CPC - D04H 1/492: by fluid jet (D04H1/49 takes precedence) - D04H 1/498: entanglement of layered webs - D04H 5/03: by fluid jet - Y10T 428/249924: Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity - Y10T 442/681: Spun-bonded nonwoven fabric - Y10T 442/689: Hydroentangled nonwoven fabric - 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) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract The present invention provides a soft, bulky, and absorbent hydroentangled nonwoven including regenerated cellulose fibers and staple or wood pulp fibers and a method of making the same that includes the steps of a) placing regenerated cellulose fibers on a forming surface; b) depositing staple or wood pulp fibers on the regenerated cellulose fibers; c) hydroentangling the regenerated cellulose fibers and the staple or wood pulp fibers together to form a hydroentangled composite; d) drying the hydroentangled composite; then, e) creping the hydroentangled composite with a frothed creping solution or dispersion. ## Claims ### Claim 1 A direct-formed nonwoven comprising regenerated cellulose fibers and staple or wood pulp fibers, the nonwoven being formed by the steps of: placing the regenerated cellulose fibers on a forming surface; depositing the staple or wood pulp fibers on the regenerated cellulose fibers; hydroentangling the regenerated cellulose fibers and the staple or wood pulp fibers together to form a hydroentangled composite; drying the hydroentangled composite; then, creping the hydroentangled composite with a frothed creping solution or dispersion. ### Claim 2 (depends on 1) The direct-formed nonwoven of claim 1 wherein the regenerated cellulose fibers have a basis weight from about 10 to about 20 grams per square meter. ### Claim 3 (depends on 1) The direct-formed nonwoven of claim 1 wherein the regenerated cellulose fibers are continuous fibers. ### Claim 4 (depends on 1) The direct-formed nonwoven of claim 1 wherein the staple or wood pulp fibers have a basis weight from about 30 to about 150 grams per square meter. ### Claim 5 (depends on 1) The direct-formed nonwoven of claim 1 wherein the creping step includes the steps of: positioning an additive composition applicator adjacent to a hot non-permeable dryer surface; applying the frothed dispersion or frothed solution comprising an additive composition to the dryer surface; allowing the frothed dispersion or frothed solution to convert to an adhesive film; directly bonding the hydroentangled composite to the adhesive film; and scraping the bonded hydroentangled composite and adhesive film from the dryer surface. ### Claim 6 (depends on 5) The direct-formed nonwoven of claim 5 wherein the additive composition further comprises a foaming agent. ### Claim 7 (depends on 6) The direct-formed nonwoven of claim 6 wherein the additive composition comprises a hydroxypropyl cellulose solution. ### Claim 8 (depends on 5) The direct-formed nonwoven of claim 5 wherein the hot non-permeable dryer surface has a temperature exceeding about 300 degrees Fahrenheit, optionally between about 500 and about 550 degrees Fahrenheit. ### Claim 9 An integrated composite fabric comprising greater than about 5 weight percent and less than about 30 weight percent continuous regenerated cellulose filaments and greater than about 70 weight percent and less than about 95 weight percent wood pulp fibers. ### Claim 10 (depends on 9) The integrated composite fabric of claim 9 having an absorbent capacity of greater than 5.6 g/g. ### Claim 11 (depends on 9) The integrated composite fabric of claim 9 having a softness of 4 logs or better than a similar integrated composite fabric with polypropylene filaments instead of regenerated cellulose filaments. ### Claim 12 (depends on 9) The integrated composite fabric of claim 9 wherein the wood pulp fibers are discontinuous fibers. ### Claim 13 (depends on 9) The integrated composite fabric of claim 9 wherein the continuous regenerated cellulose filaments are Lyocell filaments. ### Claim 14 (depends on 9) The integrated composite fabric of claim 9 where in the continuous regenerated cellulose filaments are spunbond filaments. ### Claim 15 A method of making a direct-formed nonwoven comprising regenerated cellulose fibers and wood pulp fibers, the method comprising the steps of: placing the regenerated cellulose fibers on a forming surface; depositing the wood pulp fibers on the regenerated cellulose fibers; hydroentangling the regenerated cellulose fibers and the wood pulp fibers together to form a hydroentangled composite; drying the hydroentangled composite; then, creping the hydroentangled composite with a frothed creping solution or dispersion. ### Claim 16 (depends on 15) The method of claim 15 wherein the regenerated cellulose fibers are continuous fibers. ### Claim 17 (depends on 15) The method of claim 15 wherein the creping step includes the steps of: positioning an additive composition applicator adjacent to a hot non-permeable dryer surface; applying the frothed dispersion or frothed solution comprising an additive composition to the dryer surface; allowing the frothed dispersion or frothed solution to convert to an adhesive film; directly bonding the hydroentangled composite to the adhesive film; and scraping the bonded hydroentangled composite and adhesive film from the dryer surface. ### Claim 18 (depends on 17) The method of claim 17 wherein the additive composition further comprises a foaming agent. ### Claim 19 (depends on 18) The method of claim 18 wherein the additive composition comprises a hydroxypropyl cellulose solution. ### Claim 20 (depends on 17) The method of claim 17 wherein the hot non-permeable dryer surface has a temperature exceeding about 300 degrees Fahrenheit, optionally between about 500 and about 550 degrees Fahrenheit.