IP Library › Granted Patent US 6,905,524
Granted Patent B2
US 6,905,524 · App. 10/289,554 · Granted Jun 14, 2005

Method of continuously dyeing nonwoven fabrics and the products thereof

View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 6,905,524
App. No.
10/289,554
Granted
Jun 14, 2005
Kind
B2
Abstract

It is the objective of the present invention to disclose a method of continuously dyeing durable nonwoven fabrics, and more specifically, nonwoven fabrics comprising a cellulosic fibrous material dyed with indigo dyestuffs. It is in accordance with the present invention, to utilize synthetic fibers in combination with natural or cellulosic fibers in the formation of a nonwoven web. The natural fibers, preferably cotton, make up at least 10% of the fibrous nonwoven fabric.

Claims (23)

1. A process of continuously dyeing a nonwoven fabric, comprising the steps of:

a. providing a nonwoven fabric comprising staple length fibers, the staple length fibers including at least 10% natural fiber;

b. wetting said nonwoven fabric;

c. dyeing said wetted nonwoven fabric with a leuco indigo vat dye;

d. skying said dyed nonwoven fabric;

e. rinsing said dyed nonwoven fabric;

f. drying said nonwoven fabric;

g. said indigo dyed nonwoven fabric having a crock fastness, per AATCC TM 8-1988, of at least 5.

2. A process of continuously dyeing a nonwoven fabric as in claim 1 , wherein said fibrous blend comprises synthetic and natural fibers.

3. A process of continuously forming and dyeing a nonwoven fabric as in claim 2 , wherein said synthetic fibers are selected from the group consisting of polyamides, polyester, polyolefins, and the combinations thereof.

4. A process of continuously dyeing a nonwoven fabric as in claim 2 , wherein said natural fibers are selected from the group consisting of cotton, wood pulp, rayon and the combinations thereof.

5. A process of continuously dyeing a nonwoven fabric as in claim 4 , wherein said natural fiber is cotton.

6. A process of continuously dyeing a nonwoven fabric, comprising the steps of:

a. providing a fibrous blend comprising staple length fibers, the staple length fibers including at least 10% natural fibers;

b. carding said fibrous blend;

c. forming said fibrous blend into a fibrous batt;

d. bonding said fibrous web to form a nonwoven fabric;

e. wetting said nonwoven fabric;

f. dyeing said wetted nonwoven fabric with a leuco state indigo vat dye;

g. skying said dyed nonwoven fabric;

h. rinsing said dyed nonwoven fabric;

i. drying said nonwoven fabric; and

j. said indigo dyed nonwoven fabric having a crock fastness, per AATCC TM 48 -1988, of at least 5.