Method of making a filamentary laminate and the products thereof
The present invention is directed to a nonwoven composite fabric comprising one or more layers of discontinuous filaments or nano-fiber filaments positioned between at least one continuous filament web and one cellulosic fiber web that are subsequently hydroentangled, wherein the discontinuous filaments or nano-fiber filaments provide a barrier to prevent the loss of the cellulosic fibrous material through the highly porous continuous filament web.
1 . A method of making a composite nonwoven fabric, comprising the steps of:
providing a continuous filament web;
providing a discontinuous filament web, wherein said web has a basis weight less than about 2 grams per square meter;
providing a cellulosic fiber web;
hydroentangling said webs to form a partially entangled web;
hydroentangling said juxtaposed partially entangled web and cellulosic fiber web; and
drying said hydroentangled webs to form said nonwoven fabric.
2 . A method of making a laminate nonwoven fabric in accordance with claim 1 , wherein said continuous filament web may be selected from the group consisting of polyolefins, polyamides, polyesters, and the blends thereof.
3 . A method of making a laminate nonwoven fabric in accordance with claim 2 , wherein said polyolefins may be selected from the group consisting of polypropylene, polyethylene, and combinations thereof.
4 . A method of making a laminate nonwoven fabric in accordance with claim 1 , wherein said step of hydroentangling said juxtaposed webs comprises first directing high-pressure liquid streams against a first expansive surface of said juxtaposed webs, and thereafter directing high-pressure liquid streams against an opposite expansive surface of said juxtaposed web.
5 . A method of making a laminate nonwoven fabric in accordance with claim 1 , wherein said laminate comprises additional wood pulp layers, continuous or discontinuous filaments layers, film layers, or a combination thereof.
6 . A method of making a laminate nonwoven fabric, comprising the steps of:
providing a continuous filament web;
providing a foraminous surface;
hydroentangling said continuous filament web to form a partially entangled web;
juxtaposing a cellulosic fiber web with said partially entangled web;
advancing said juxtaposed partially entangled web and cellulosic fiber web onto said foraminous surface and hydroentangling said webs on said surface so as to impart at least one three-dimensional image into said laminate; and
drying said hydroentangled webs to form said nonwoven fabric.
6 . A method of making a laminate nonwoven fabric in accordance with claim 6 , wherein said foraminous surface is a three-dimensional image transfer device.
7 . A method of making a laminate nonwoven fabric in accordance with claim 6 , wherein:
said step of hydroentangling said juxtaposed partially entangled web and paper web comprises first directing high-pressure liquid streams against a first expansive surface of the juxtaposed webs, and thereafter directing high-pressure liquid streams against an opposite expansive surface of said juxtaposed web.
8 . A method of making a laminate nonwoven fabric as in claim 1 , wherein said laminate is a wipe.
9 . A method of making a laminate nonwoven fabric as in claim 6 , wherein said laminate is a wipe.
10 . A method of making a composite nonwoven fabric, comprising the steps of:
providing a continuous filament web;
providing a discontinuous filament web, wherein said web has a basis weight less than about 2 grams per square meter;
providing a cellulosic fiber web;
juxtaposing said webs;
hydroentangling said webs; and
drying said hydroentangled webs to form said nonwoven fabric.
11 . A method of making a laminate nonwoven fabric in accordance with claim 10 , wherein said step of hydroentangling said juxtaposed webs comprises first directing high-pressure liquid streams against a first expansive surface of said juxtaposed webs, and thereafter directing high-pressure liquid streams against an opposite expansive surface of said juxtaposed web.