CA2491697A1 - Method of forming a nonwoven composite fabric and fabric produced thereof - Google Patents

Method of forming a nonwoven composite fabric and fabric produced thereof Download PDF

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Publication number
CA2491697A1
CA2491697A1 CA002491697A CA2491697A CA2491697A1 CA 2491697 A1 CA2491697 A1 CA 2491697A1 CA 002491697 A CA002491697 A CA 002491697A CA 2491697 A CA2491697 A CA 2491697A CA 2491697 A1 CA2491697 A1 CA 2491697A1
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CA
Canada
Prior art keywords
fibers
layer
composite fabric
jets
splittable
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002491697A
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French (fr)
Other versions
CA2491697C (en
Inventor
Mari-Pat Vonfeldt
Tara Tryphena Steinke
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Kimberly Clark Worldwide Inc
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Individual
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Filing date
Publication date
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Publication of CA2491697A1 publication Critical patent/CA2491697A1/en
Application granted granted Critical
Publication of CA2491697C publication Critical patent/CA2491697C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2432/00—Cleaning articles, e.g. mops, wipes

Abstract

The present invention provides a method of forming a nonwoven composite fabric that includes the steps of a) providing a first layer that includes splittable continuous fibers, b) splitting at least a portion of the splittable continuous fibers into split filaments, c) thereafter superposing a second layer and the first layer, wherein the second layer includes staple fibers, and d) entangling the first and second layers to form a composite fabric.

Claims (31)

1. A method of forming a nonwoven composite fabric comprising the steps of:
providing a first layer comprising splittable continuous fibers;
splitting at least a portion of the splittable continuous fibers into split filaments;
thereafter, superposing a second layer and said first layer, wherein said second layer comprises staple fibers; and entangling the first and second layers to form a composite fabric.
2. The method of claim 1 wherein the splitting step comprises impinging the splittable continuous fibers with high energy jets.
3. The method of claim 2 wherein the jets comprise water.
4. The method of claim 3 further comprising the step of drying the composite fabric.
5. The method of claim 1 wherein the split filaments are substantially continuous in length.
6. The method of claim 1 wherein the entangling step comprises impinging the superposed first and second layers with high energy jets.
7. The method of claim 6 wherein the jets comprise water.
8. The method of claim 6 wherein the jets are directed at the exposed surface of the second layer.
9. The method of claim 7 further comprising the step of drying the composite fabric.
10. The method of claim 1 wherein the composite fabric comprises a staple fiber rich side.
11. The method of claim 1 wherein the staple fibers are entangled substantially uniformly throughout the cross section of the composite fabric.
12. The method of claim 1 wherein the entangling step does not result in substantial additional splitting of the splittable continuous fibers.
13. The method of claim 1 wherein at least about 50% of the splittable continuous fibers are at least partially split.
14. The method of claim 1 wherein at least about 75% of the splittable continuous fibers are at least partially split.
15. The method of claim 1 wherein at least about 90% of the splittable continuous fibers are at least partially split.
16. The method of claim 1 wherein at least a substantial portion of the split filaments have a denier of less than about 0.7.
17. The method of claim 16 wherein a majority of the split filaments have a denier of less than about 0.7.
18. The method of claim 1 wherein at least a substantial portion of the split filaments have a denier of less than about 0.1.
19. The method of claim 1 wherein the splittable continuous fibers comprise spunbond fibers.
20. The method of claim 19 wherein the spunbond fibers comprise a first thermoplastic polymer and a second thermoplastic polymer arranged in distinct zones across the cross-section of the fibers, the first and second thermoplastic polymers being incompatible with each other.
21. The method of claim 1 wherein the staple fibers comprise pulp fibers.
22. A composite fabric made by the method of claim 1.
23. A composite fabric made by the method of claim 14.
24. The method of claim 1 wherein the ratio of the dry weight of the first layer to the dry weight of the second layer ranges from about 0.1 to about 2.
25. The method of claim 1 wherein the ratio of the dry weight of the first layer to the dry weight of the second layer ranges from about 0.2 to about 1.
26. A method of forming a nonwoven composite fabric comprising the steps of:
providing a first layer comprising splittable spunbond fibers, the splittable spunbond fibers comprising a first thermoplastic polymer and a second thermoplastic polymer arranged in distinct zones across the cross-section of the fibers, the first and second thermoplastic polymers being incompatible with each other;
splitting at least a portion of the splittable continuous fibers into split filaments;
thereafter, superposing a second layer and said first layer, wherein said second layer comprises pulp fibers; and entangling the first and second layers to form a composite fabric.
27. The method of claim 26 wherein the splitting step comprises impinging the splittable continuous fibers with first high energy hydraulic jets, and wherein the entangling step comprises impinging the superposed first and second layers with second high energy hydraulic jets.
28. The method of claim 27 wherein the first jets are supplied through first orifices, the hydraulic pressure at the first orifices ranging from about 2,500 kPa to about 21,000 kPa.
29. The method of claim 27 wherein the second jets are supplied through second orifices, the hydraulic pressure at the second orifices ranging from about 1,300 kPa to about 14,000 kPa.
30. The method of claim 27 wherein the first and second jets are supplied through first and second orifices respectively, the hydraulic pressure at the second orifices being lower than the hydraulic pressure at the first orifices.
31. A composite fabric made by the method of claim 26.
CA2491697A 2002-07-18 2003-05-29 Method of forming a nonwoven composite fabric and fabric produced thereof Expired - Lifetime CA2491697C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/197,736 US6739023B2 (en) 2002-07-18 2002-07-18 Method of forming a nonwoven composite fabric and fabric produced thereof
US10/197,736 2002-07-18
PCT/US2003/017147 WO2004009347A1 (en) 2002-07-18 2003-05-29 Method of forming a nonwoven composite fabric and fabric produced thereof

Publications (2)

Publication Number Publication Date
CA2491697A1 true CA2491697A1 (en) 2004-01-29
CA2491697C CA2491697C (en) 2011-07-19

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA2491697A Expired - Lifetime CA2491697C (en) 2002-07-18 2003-05-29 Method of forming a nonwoven composite fabric and fabric produced thereof

Country Status (10)

Country Link
US (1) US6739023B2 (en)
EP (1) EP1551628B1 (en)
KR (1) KR100972896B1 (en)
AU (1) AU2003231932B2 (en)
BR (1) BR0312455B1 (en)
CA (1) CA2491697C (en)
DE (1) DE60332855D1 (en)
MX (1) MXPA04012112A (en)
WO (1) WO2004009347A1 (en)
ZA (1) ZA200500055B (en)

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EP1551628A1 (en) 2005-07-13
AU2003231932A1 (en) 2004-02-09
BR0312455A (en) 2005-04-19
KR100972896B1 (en) 2010-07-28
ZA200500055B (en) 2006-07-26
AU2003231932B2 (en) 2008-05-22
US6739023B2 (en) 2004-05-25
MXPA04012112A (en) 2005-04-19
EP1551628B1 (en) 2010-06-02
BR0312455B1 (en) 2014-04-15
WO2004009347A1 (en) 2004-01-29
KR20050021427A (en) 2005-03-07
DE60332855D1 (en) 2010-07-15
CA2491697C (en) 2011-07-19
US20040010895A1 (en) 2004-01-22

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