Nonwoven Fabric Including Fibers Formed from Post-Consumer Recycled Plastic
AssigneeBerry Global, Inc.
InventorDianne B. Ellis
Life of this patent
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Abstract
Nonwoven fabrics are provided that include a mechanically entangled blend of fibers comprising (a) post-consumer recycled polymer staple fibers (PCR-staple fibers) and (b) one or more additional fibers, in which the one or more additional fibers are different than the PCR-staple fibers. The PCR-staple fibers are mechanically entangled with the one or more additional fibers to define the nonwoven fabric.
Claims20
A nonwoven fabric, comprising:
- a mechanically entangled blend of fibers comprising (a) post-consumer recycled polymer staple fibers (PCR-staple fibers) and (b) one or more additional fibers;
- wherein the one or more additional fibers are different than the PCR-staple fibers, and the PCR-staple fibers are mechanically entangled with the one or more additional fibers to define the nonwoven fabric.
The nonwoven fabric of 5, wherein the one or more additional fibers comprise a plurality of wettable staple fibers and a plurality of cellulosic fibers, and wherein the nonwoven fabric comprises a component weight ratio between the PCR-staple fibers in grams per square meter of the nonwoven fabric, the plurality of wettable staple fibers in grams per square meter of the nonwoven fabric, and the plurality of cellulosic fibers in grams per square meter of the nonwoven fabric according to the formula A:B:C, wherein
- (i) ‘A’ represents the PCR-staple fibers in grams per square meter of the nonwoven fabric and comprises a value from about 0.2 to about 0.8;
- (ii) ‘B’ represents the plurality of wettable staple fibers in grams per square meter of the nonwoven fabric and comprises a value from about 0.2 to about 0.8;
- and
- (iii) ‘C’ represents the plurality of cellulosic fibers in grams per square meter of the nonwoven fabric and comprises a value from about 0.2 to about 0.8.
A method of forming a nonwoven fabric, comprising:
- (ia) forming or providing a carded web comprising a blend of fibers comprising (a) post-consumer recycled polymer staple fibers (PCR-staple fibers) and (b) one or more additional fibers;
- wherein the one or more additional fibers is different from the PCR-staple fibers;
- or
- (ib) forming or providing a first layer of post-consumer recycled polymer staple fibers (PCR-staple fibers) and forming or providing a second layer of one or more additional fibers;
- wherein the first layer and the second layer are adjacent to provide a multilayer nonwoven web;
- and
- (ii) mechanically entangling the PCR-staple fibers and the one or more additional fibers to define a nonwoven fabric.
Dependencies are inferred from the claim text.