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AssigneeE. I. Du Pont de Nemours and Company
InventorsHyun S. Lim, Robert H. Peterson, Roger K. Siemionko, James R. Vincent
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A process for hydraulically needling a web of staple fibers into an unbonded flash spun web made of continuous plexifilaments to form a spunlaced nonwoven fabric. The web of staple fibers is positioned against the unbonded flash spun web and then hydraulically needled such that the staple fibers are embedded into and entangled with the unbonded flash spun web to form a spunlaced nonwoven fabric. Optionally, the spunlaced nonwoven fabric can be thermally bonded to maintain or increase the permeability of the fabric. Thermal bonding can be used to control the level of permeability depending on the end-use desired. Spunlaced nonwoven fabrics made by the inventive process are particularly useful in filtration applications (e.g., vacuum cleaner bags) when thermal bonding is employed and as bulky, downproof and featherproof barrier liners for garments, sleeping bags, pillows, comforters and the like when thermal bonding is not employed.
A process for making a spunlaced nonwoven fabric comprising the steps of:
An unbonded, spunlaced nonwoven fabric comprised of an unbonded flash spun web having staple fibers embedded into and entangled therewith, the fabric having a Frazier porosity of at least 4 ft.sup.3 /ft.sup.2 /min.
A thermally bonded, spunlaced nonwoven fabric comprised of an unbonded flash spun web having staple fibers embedded into and entangled therewith, the fabric having a Frazier porosity of at least 4 ft.sup.3 /ft.sup.2 /min.
Dependencies are inferred from the claim text.