IP Library › Patent Application 14878198
Patent Application
App. No. 14/878,198

Nonwoven Composite and Method for Making the Same

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Quick Facts
Patent No.
US None
App. No.
14/878,198
Abstract

A nonwoven composite and a method of making a nonwoven composite including lightly bonding and hydroentangling a continuous filament nonwoven web to improve its integrity and fiber mobility for subsequent processing steps, such as adding a first layer to the continuous filament nonwoven web and hydroentangling the first layer and the continuous filament nonwoven web together.

Claims (27)

1 . A method of making a nonwoven composite, comprising the steps of:

providing a continuous filament nonwoven web,

lightly bonding the continuous filament nonwoven web with hot air from a hot air knife to temporarily bond filaments in the continuous filament nonwoven web to each other, wherein the hot air knife is heated to a temperature between about 200° F. and 550° F.,

hydroentangling the lightly bonded continuous filament nonwoven web to controllably break temporary bonds formed in the continuous filament nonwoven web,

providing a first layer on the lightly bonded, hydroentangled continuous filament nonwoven web, and

hydroentangling the first layer with the lightly bonded, hydroentangled continuous filament nonwoven web to form the nonwoven composite.

2 . The method of claim 1 , further comprising the steps of:

winding the lightly bonded continuous filament nonwoven web onto a roll,

transporting the roll of the lightly bonded continuous filament nonwoven web, and unwinding the roll of lightly bonded continuous filament nonwoven web prior to the step of hydroentangling.

3 . The method of claim 1 further comprising the steps of:

winding the lightly bonded, hydroentangled continuous filament nonwoven web onto a roll,

transporting the roll of the lightly bonded, hydroentangled continuous filament nonwoven web, and

unwinding the roll of hydroentangled, lightly bonded continuous filament nonwoven web prior to the step of providing a layer.

4 . The method of claim 1 , wherein the step of providing a first layer includes providing pulp fibers.

5 . The method of claim 1 , wherein the step of providing a first layer includes providing staple fibers.

6 . The method of claim 5 , wherein the step of providing a first layer further includes providing pulp fibers.

7 . The method of claim 1 , wherein the step of providing a first layer includes providing a mixture of pulp fibers and staple fibers.

8 . The method of claim 1 , wherein the step of providing a first layer includes providing a continuous filament nonwoven web.

9 . The method of claim 1 , wherein the step of providing a first layer includes providing a continuous filament nonwoven web and fibers selected from the group consisting of pulp fibers, staple fibers, and a mixture of pulp fibers and staple fibers.

10 . (canceled)

11 . The method of claim 1 , further comprising the step of providing a second layer, and then hydroentangling the second layer and the first layer with the lightly bonded, hydroentangled continuous filament nonwoven web.

12 . The method of claim 11 , wherein the second layer is a continuous filament nonwoven web.

13 . The method of claim 12 , wherein the second layer is lightly bonded with hot air.

14 . The method of claim 12 , the second layer is hydroentangled.

15 - 25 . (canceled)

26 . The method of claim 1 , further comprising the step of:

extracting discontinuous fibers out of the nonwoven composite.