Contendered nonwoven/pulp composite fabric and method for making the same
View Patent ↗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.
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.
2. The composite fabric of claim 1 wherein said first nonwoven web has a basis weight of about 11-15 gsm.
3. The composite fabric of claim 1 further comprising a reinforcing scrim.
4. The composite fabric of claim 1 wherein said composite fabric is ultrasonically embossed.
5. The composite fabric of claim 1 wherein said composite fabric is embossed by a heated calender.
6. The composite fabric of claim 1 wherein said composite fabric is embossed by an unheated calender.
7. The composite fabric of claim 1 wherein said continuous fibers comprise spunbond fibers.
8. The composite fabric of claim 1 further comprising a second nonwoven web.
9. The composite fabric of claim 8 wherein said composite fabric is ultrasonically embossed.
10. 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.
11. The composite fabric of claim 10 wherein said first and second nonwoven webs have a hydroengorged fiber structure.
12. The composite fabric of claim 10 wherein said first nonwoven web has a bonding pattern comprising a graphic design.
13. The composite fabric of claim 10 wherein said first and second nonwoven webs are calendered with a superposing pattern.
14. The composite fabric of claim 13 wherein said superposing pattern comprises a graphic design.
15. The composite fabric of 14 wherein said graphic design comprises graphic elements having an average size greater than 0.25 square centimeters.
16. The composite fabric of claim 10 wherein said composite fabric comprises a color graphic design.
17. The composite fabric of 13 wherein said bonding pattern is anisotropic and biased in the machine direction.
18. A wipe comprising the composite fabric of claim 1 .
19. The wipe of claim 18 wherein said wipe is a hygienic wipe.
20. The wipe of claim 18 wherein said wipe is an industrial wipe.
21. An absorbent article comprising the composite fabric of claim 1 .
22. The absorbent article of claim 21 wherein said absorbent article is a sanitary napkin.
23. The absorbent article of claim 21 wherein said absorbent article is a diaper.
24. The absorbent article of claim 21 comprising an acquisition distribution layer comprising said composite fabric.
25. An absorbent sheet comprising the composite fabric of claim 1 .
26. The absorbent sheet of claim 25 wherein said absorbent sheet is a laminate of said composite fabric and at least one nonwoven web.
27. A fenestration drape comprising the composite fabric of claim 1 .
28. A garment comprising the composite fabric of claim 1 .
29. A desiccant comprising the composite fabric of claim 1 .
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.
31. 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.
32. The method of 31 further comprising the step of hydroengorging said third layer.
33. The composite fabric of claim 1 wherein said fabric comprises a first surface substantially free of pulp.
34. The composite fabric of claim 8 wherein said fabric comprises a first surface substantially free of pulp.
35. The composite fabric of claim 33 wherein said fabric comprises a second surface having a rough surface profile.
36. The composite fabric of claim 34 wherein said fabric comprises a second surface having a rough surface profile.
37. 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.
38. The method of claim 30 further comprising the step of: embossing said composite fabric using a cold calender.