Hydraulically treated nonwoven fabrics and method of making the same
AssigneeFirst Quality Nonwovens, Inc.
InventorsPeter Zajaczkowski, John C. Parsons, Karthik Ramaratnam
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Abstract
A nonwoven laminate having a SMS structure is hydraulically treated by particular process parameters to improve softness and tactile feel. The nonwoven laminate may also be imparted with one or more regular aperture patterns by additional hydraulic treatment processes, where the initial hydraulic treatment provides for improved aperture definition.
Claims24
A nonwoven laminate, comprising:
- a first nonwoven web comprising continuous polymeric fibers, the continuous polymeric fibers of the first nonwoven web having a first average diameter;
- and
- a second nonwoven web comprising continuous polymeric fibers, the continuous polymeric fibers of the second nonwoven web having a second average diameter that is less than the first average diameter,
- the nonwoven laminate is hydraulically treated,
- the nonwoven laminate is apertured with a regular aperture pattern, and
- the nonwoven laminate has an abrasion rating of 3.0 or higher.
The nonwoven laminate of claim 6, wherein at least one of the differing types of continuous polymeric fibers comprises polyethylene.
The nonwoven laminate of claim 6, wherein the one or more layers of continuous polymeric fibers of the first nonwoven web comprise bicomponent fibers.
A method of making an apertured nonwoven laminate, comprising:
- forming a first nonwoven web comprising continuous spunbond fibers;
- forming a second nonwoven web comprising continuous meltblown fibers;
- forming a third nonwoven web comprising continuous spunbond fibers;
- calender bonding the first, second and third nonwoven webs at a pressure of between 20 newtons per meter (N/m) and 60 N/m to form a laminate with a regular bond pattern;
- and
- hydraulically imparting one or more aperture patterns to the laminate.
A nonwoven laminate, comprising:
- first and second outer nonwoven layers comprising spunbond fibers, and
- a third inner nonwoven layer comprising meltblown fibers,
- wherein the nonwoven laminate is thermally bonded with a regular bond pattern having a percentage bond area of 10% or greater, and
- the nonwoven laminate includes a plurality of apertures arranged in a regular pattern.
A nonwoven laminate, comprising:
- first and second outer nonwoven layers comprising spunbond fibers;
- and
- a third inner nonwoven layer comprising meltblown fibers,
- wherein the nonwoven laminate is thermally bonded with a regular bond pattern having a percentage bond area of 10% or greater,
- the nonwoven laminate is hydraulically treated,
- the basis weight of the third inner layer is at least 5 grams per square meter (gsm);
- and
- the nonwoven laminate has an abrasion rating of 4.0 or higher and an average Hand-O-Meter measurement (HOM) of 6.0 grams (g) or lower.
Dependencies are inferred from the claim text.