Three-dimensional nonwoven materials and methods of manufacturing thereof
Three dimensional nonwoven materials and methods of manufacturing such materials are disclosed. In one embodiment, a method can include providing a precursor web that includes a plurality of fibers and transferring the precursor web to a forming surface having a plurality of forming holes. The method can also include directing a plurality of pressurized fluid streams of entangling fluid in a direction towards the precursor web on the forming surface to move at least some of the fibers into the plurality of forming holes to create a fluid entangled web. The method can further include removing the fluid entangled web from the forming surface such that the at least some of the fibers moved into the plurality of forming holes provide a plurality of nodes. The plurality of nodes can have an anisotropy value greater than 1.0 as determined by the Node Analysis Test Method.
1 . A method for manufacturing a three-dimensional nonwoven material, the method comprising:
providing a precursor web, the precursor web comprising a plurality of fibers;
transferring the precursor web to a forming surface, the forming surface having a plurality of forming holes;
providing a fluid entangling device having a plurality of fluid jets capable of emitting a plurality of pressurized fluid streams of entangling fluid from the plurality of fluid jets in a direction towards the forming surface;
directing the plurality of pressurized fluid streams of the entangling fluid from the plurality of fluid jets in a direction towards the precursor web on the forming surface to move at least some of the fibers into the plurality of forming holes to create a fluid entangled web comprising a first surface and a second surface opposite the first surface;
removing the fluid entangled web from the forming surface such that the at least some of the fibers moved into the plurality of forming holes provide a plurality of nodes extending away from a base plane on the first surface of the fluid entangled web, the plurality of nodes having an anisotropy value greater than 1.0 as determined by the Node Analysis Test Method; and
drying the fluid entangled web to provide a three-dimensional nonwoven material.
2 . The method of claim 1 , wherein the forming surface further comprises a plurality of projections extending away from an outer surface of the forming surface, wherein directing the plurality of pressurized fluid streams of the entangling fluid from the plurality of fluid jets in a direction towards the precursor web on the forming surface moves at least some of the fibers around the projections on the forming surface such that when the fluid entangled web is removed from the forming surface the at least some of the fibers moved around the projections on the forming surface create a plurality of connecting ligaments interconnecting the plurality of nodes and a plurality of openings formed between the plurality of connecting ligaments and the plurality of nodes.
3 . The method of claim 1 , wherein the forming holes of the forming surface include a depth, a major dimension, and an aspect ratio of the depth to the major dimension, and wherein the aspect ratio is greater than 1.0.
4 . The method of claim 3 , wherein the depth of the forming holes is between 1 mm to 10 mm.
5 . The method of claim 4 , wherein the major dimension of the forming holes is less than 10 mm.
6 . The method of claim 1 , wherein providing the precursor web is completed by a process selected from the group consisting of: a wet-laying process, a foam-laying process, and a carding process.
7 . The method of claim 1 , further comprising:
providing a support web;
transferring the support web to the forming surface along with the precursor web; and
directing the plurality of pressurized fluid streams of the entangling fluid at the support web and the precursor web at the same time.
8 . The method of claim 1 , wherein the plurality of fibers comprises synthetic fibers and binder fibers, and wherein drying the fluid entangled web activates the binder fibers.