Cotendered nonwoven/pulp fabric and method for making the same
AssigneeFirst Quality Nonwovens, Inc.
InventorsMichael Kauschke, Mordechai Turi
Life of this patent
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Abstract
The present invention is directed to a nonwoven fabric made from a composite of nonwoven and pulp where the nonwoven has a high loft derived from a heat set three-dimensional relief structure and/or hydroengorged fiber structure. A nonwoven web is hydraulically treated to create a hydroengorged material having an increased loft. Alternatively a nonwoven web is treated to have a heat set three-dimensional relief structure. The treated web is then hydroentangled with pulp to form a cotendered nonwoven/pulp composite fabric.
Claims38
1-48. (canceled)
A fabric comprising:
- a first nonwoven web comprising continuous fibers;
- and
- a first pulp layer substantially comprised of pulp,
- said first pulp layer being entangled with said first nonwoven web;
- wherein, said first nonwoven web has
- (a) a heat set three-dimensional relief structure;
- and
- (b) a repeating bonding pattern.
A method of manufacturing a composite fabric comprising the steps of:
- forming a first nonwoven web substantially comprised of continuous fibers;
- applying a repeating bonding pattern to said first nonwoven web;
- treating said first nonwoven web to create a three-dimensional relief structure in said first nonwoven web;
- hydroengorging said first nonwoven web;
- depositing a first pulp layer substantially comprised of pulp on said first nonwoven web;
- and
- hydroentangling said first nonwoven web and said first pulp layer.
A method of manufacturing a fabric comprising the steps of:
- forming a bonded first nonwoven web substantially comprised of continuous fibers;
- deforming said first nonwoven web to create a heat set three-dimensional relief structure;
- hydroengorging said nonwoven web;
- depositing a first pulp layer substantially comprised of pulp onto said first nonwoven web;
- and
- hydroentangling said first nonwoven web and said first pulp layer after the step of deforming the first nonwoven web.
A hydraulically entangled composite structure comprising:
- a first nonwoven web comprising continuous fibers;
- and
- a first pulp layer substantially comprised of pulp;
- wherein said first nonwoven web has one or more elements selected from the group consisting of (a) a frangibly bonded fiber structure;
- and (b) an initially unbonded hydraulically entwined fiber structure.
Dependencies are inferred from the claim text.