Cotendered nonwoven/pulp fabric and method for making the same
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 fabric comprising:
a hydroengorged first nonwoven web comprising continuous fibers, the first nonwoven web having a repeating bonding pattern; and
a first pulp layer comprising cotton linter hydroentangled with the first nonwoven web.
2. The fabric of claim 1 , wherein the first pulp layer is disposed on top of the nonwoven web.
3. The fabric of claim 1 , wherein the first nonwoven web has a basis weight of 11-15 gsm.
4. The fabric of claim 1 , further comprising a reinforcing scrim.
5. The fabric of claim 1 , wherein the fabric is ultrasonically embossed.
6. The fabric of claim 1 , wherein the fabric is embossed by a heated calender.
7. The fabric of claim 1 , wherein the fabric is embossed by an unheated calender.
8. The fabric of claim 1 , wherein the continuous fibers comprise spunbond fibers.
9. The fabric of claim 1 , further comprising a second nonwoven web.
10. The fabric of claim 9 , wherein the second nonwoven web is hydroengorged and comprises continuous fibers.
11. The fabric of claim 9 , wherein the repeating bonding pattern of the first nonwoven web has a graphic design.
12. The fabric of claim 9 , wherein the first and second nonwoven webs are calendered with a superposing pattern.
13. The fabric of claim 12 , wherein the superposing pattern comprises a graphic design.
14. The fabric of claim 13 , wherein the graphic design comprises graphic elements having an average size greater than 0.25 square centimeters.
15. The fabric of claim 9 , wherein the fabric comprises a color graphic design.
16. The fabric of claim 11 , wherein the repeating bonding pattern is anisotropic and biased in the machine direction.
17. The fabric of claim 1 , wherein the fabric comprises closed-end apertures.
18. The fabric of claim 1 , wherein the fabric is apertured by a needling process.
19. The fabric of claim 18 , wherein the needling is a cold needling process.
20. A wipe comprising the fabric of claim 1 .
21. The wipe of claim 17 , wherein the wipe is a hygienic wipe.
22. The wipe of claim 17 , wherein the wipe is an industrial wipe.
23. An absorbent article comprising the fabric of claim 1 .
24. The absorbent article of claim 23 , wherein the absorbent article is a sanitary napkin.
25. The absorbent article of claim 23 , wherein the absorbent article is a diaper.
26. The absorbent article of claim 23 comprising an acquisition distribution layer comprising the fabric.
27. An absorbent sheet comprising the fabric of claim 1 .
28. The absorbent sheet of claim 27 , wherein the absorbent sheet is a laminate of the fabric and at least one nonwoven web.
29. A fenestration drape comprising the fabric of claim 1 .
30. A garment comprising the fabric of claim 1 .
31. A desiccant comprising the fabric of claim 1 .
32. The fabric of claim 1 , wherein the fabric comprises a first surface substantially free of pulp.
33. The fabric of claim 32 , wherein the fabric comprises a second surface having a rough surface profile.
34. The fabric of claim 33 , wherein the second surface has features extending beyond the plane of the second surface wherein the features have a peak height of at least 20% of the caliper of the composite fabric.