Contendered nonwoven/pulp composite fabric and method for making the same
AssigneeFirst Quality Nonwovens, Inc.
InventorsMichael Kauschke, Mordechai Turi
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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
A cotendered composite fabric comprising:
- a bonded first nonwoven web comprising continuous fibers;
- and
- a first pulp layer substantially comprised of pulp hydroentangled with the bonded first nonwoven web;
- wherein, prior to being hydroentangled with the first pulp layer, said bonded first nonwoven web has
- a hydroengorged fiber structure.
The composite fabric of 14 wherein said graphic design comprises graphic elements having an average size greater than 0.25 square centimeters.
The composite fabric of 13 wherein said bonding pattern is anisotropic and biased in the machine direction.
A method of manufacturing a composite fabric comprising the steps of:
- forming a first layer substantially comprised of continuous fibers;
- hydroengorging said first layer;
- depositing a second layer substantially comprised of pulp onto said first layer;
- and
- hydroentangling said first and second layers.
The method of 31 further comprising the step of hydroengorging said third layer.
Dependencies are inferred from the claim text.