# US 9,050,777 B2 · Contendered nonwoven/pulp composite fabric and method for making the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,050,777 B2 - Document ID: US9050777B2 - Status: Granted - Kind: B2 - Application number: 12/226,090 - Filed: 2007-04-10 - Published: 2010-02-25 - Granted: 2015-06-09 - Earliest claimed: 2006-04-10 - Assignees: First Quality Nonwovens, Inc. - Applicants: Michael Kauschke; Mordechai Turi - Inventors: Michael Kauschke; Mordechai Turi - Web page: https://patentgrep.com/patent/US9050777B2 ## CPC - B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} - A47L 13/16: Cloths; Pads; Sponges (metal scraping sponges A47L13/07) - A61F 13/15203: {Properties of the article, e.g. stiffness or absorbency (chemical aspects A61L15/00)} - A61F 13/15617: {Making absorbent pads from fibres or pulverulent material with or without treatment of the fibres} - A61F 13/15731: {Treating webs, e.g. for giving them a fibrelike appearance, e.g. by embossing} - A61F 13/534: having an inhomogeneous composition through the thickness of the pad (A61F13/538, A61F13/539 take precedence) - A61F 13/535: inhomogeneous in the plane of the pad, e.g. core absorbent layers being of different sizes ({A61F13/5323,} A61F13/537 take precedence) - A61F 13/537: characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer {(A61F13/538 takes precedence)} - A61F 13/539: characterised by the connection of the absorbent layers with each other or with the outer layers - B32B 5/022: {Non-woven fabric} - B32B 5/06: characterised by a fibrous {or filamentary} layer {mechanically connected, e.g. by needling} to another layer, e.g. of fibres, of paper - D04H 1/492: by fluid jet (D04H1/49 takes precedence) - D04H 1/498: entanglement of layered webs - D04H 3/14: with bonds between thermoplastic yarns or filaments produced by welding - D04H 5/03: by fluid jet - D04H 13/005: {by needling} - D04H 13/007: {strengthened or consolidated by welding together the various components} - A61F 2013/530248: {being thermosetting fibres} - A61F 2013/53975: {by Hydraulic entanglement} - A61F 2013/53991: {by ultrasonic method} - B32B 2262/0253: Polyolefin fibres - B32B 2262/04: Cellulosic plastic fibres, e.g. rayon - B32B 2262/062: Cellulose fibres, e.g. cotton - B32B 2262/067: Wood fibres - B32B 2307/726: Permeability to liquids, absorption - B32B 2307/728: Hydrophilic - B32B 2432/00: Cleaning articles, e.g. mops or wipes - B32B 2555/02: Diapers or napkins - Y10T 156/1039: Surface deformation only of sandwich or lamina [e.g., embossed panels] - Y10T 428/24355: Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.] - Y10T 428/24612: Composite web or sheet - Y10T 442/10: Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.] - Y10T 442/20: Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer - Y10T 442/667: Needled - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - A47L: DOMESTIC WASHING OR CLEANING (brushes A46B; cleaning quantities of bottles or of other hollow articles of one kind B08B9/00; laundry D06F); SUCTION CLEANERS IN GENERAL (cleaning in general B08) - A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C) - D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## 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. ## Claims ### Claim 1 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. ### Claim 2 (depends on 1) The composite fabric of claim 1 wherein said first nonwoven web has a basis weight of about 11-15 gsm. ### Claim 3 (depends on 1) The composite fabric of claim 1 further comprising a reinforcing scrim. ### Claim 4 (depends on 1) The composite fabric of claim 1 wherein said composite fabric is ultrasonically embossed. ### Claim 5 (depends on 1) The composite fabric of claim 1 wherein said composite fabric is embossed by a heated calender. ### Claim 6 (depends on 1) The composite fabric of claim 1 wherein said composite fabric is embossed by an unheated calender. ### Claim 7 (depends on 1) The composite fabric of claim 1 wherein said continuous fibers comprise spunbond fibers. ### Claim 8 (depends on 1) The composite fabric of claim 1 further comprising a second nonwoven web. ### Claim 9 (depends on 8) The composite fabric of claim 8 wherein said composite fabric is ultrasonically embossed. ### Claim 10 (depends on 8) The composite fabric of claim 8 wherein said second nonwoven web comprises continuous fibers; and has one or more elements selected from the group consisting of (a) a heat set three-dimensional relief structure; and (b) a hydroengorged fiber structure. ### Claim 11 (depends on 10) The composite fabric of claim 10 wherein said first and second nonwoven webs have a hydroengorged fiber structure. ### Claim 12 (depends on 10) The composite fabric of claim 10 wherein said first nonwoven web has a bonding pattern comprising a graphic design. ### Claim 13 (depends on 10) The composite fabric of claim 10 wherein said first and second nonwoven webs are calendered with a superposing pattern. ### Claim 14 (depends on 13) The composite fabric of claim 13 wherein said superposing pattern comprises a graphic design. ### Claim 15 The composite fabric of 14 wherein said graphic design comprises graphic elements having an average size greater than 0.25 square centimeters. ### Claim 16 (depends on 10) The composite fabric of claim 10 wherein said composite fabric comprises a color graphic design. ### Claim 17 The composite fabric of 13 wherein said bonding pattern is anisotropic and biased in the machine direction. ### Claim 18 (depends on 1) A wipe comprising the composite fabric of claim 1. ### Claim 19 (depends on 18) The wipe of claim 18 wherein said wipe is a hygienic wipe. ### Claim 20 (depends on 18) The wipe of claim 18 wherein said wipe is an industrial wipe. ### Claim 21 (depends on 1) An absorbent article comprising the composite fabric of claim 1. ### Claim 22 (depends on 21) The absorbent article of claim 21 wherein said absorbent article is a sanitary napkin. ### Claim 23 (depends on 21) The absorbent article of claim 21 wherein said absorbent article is a diaper. ### Claim 24 (depends on 21) The absorbent article of claim 21 comprising an acquisition distribution layer comprising said composite fabric. ### Claim 25 (depends on 1) An absorbent sheet comprising the composite fabric of claim 1. ### Claim 26 (depends on 25) The absorbent sheet of claim 25 wherein said absorbent sheet is a laminate of said composite fabric and at least one nonwoven web. ### Claim 27 (depends on 1) A fenestration drape comprising the composite fabric of claim 1. ### Claim 28 (depends on 1) A garment comprising the composite fabric of claim 1. ### Claim 29 (depends on 1) A desiccant comprising the composite fabric of claim 1. ### Claim 30 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. ### Claim 31 (depends on 30) The method of claim 30 further comprising the steps of: depositing a second layer substantially comprised of pulp onto said first layer; forming a third layer substantially comprised of continuous fibers; and hydroentangling said first, second and third layers. ### Claim 32 The method of 31 further comprising the step of hydroengorging said third layer. ### Claim 33 (depends on 1) The composite fabric of claim 1 wherein said fabric comprises a first surface substantially free of pulp. ### Claim 34 (depends on 8) The composite fabric of claim 8 wherein said fabric comprises a first surface substantially free of pulp. ### Claim 35 (depends on 33) The composite fabric of claim 33 wherein said fabric comprises a second surface having a rough surface profile. ### Claim 36 (depends on 34) The composite fabric of claim 34 wherein said fabric comprises a second surface having a rough surface profile. ### Claim 37 (depends on 35) The composite fabric of claim 35 wherein said second surface has features extending beyond the plane of said second surface wherein said features have a peak height of at least 20% of the caliper of said composite fabric. ### Claim 38 (depends on 30) The method of claim 30 further comprising the step of: embossing said composite fabric using a cold calender.