Granted Patent B2

US 11,105,027 · App. 16/153,160 · Granted Aug 31, 2021

Inventors: Herbert P. Hartgrove (Dunn, NC); Sayanti Basu (Charlotte, NC); Jerry Snider (Mooresville, NC)

Assignee: Berry Global, Inc.

D04H1/492A47L13/16B08B1/006D04H1/43825D04H1/43835D04H1/43838D04H1/43912D04H1/488D04H1/587D04H1/74A61L2/18D10B2321/02D10B2331/04

Abstract

Claims (15)

1. A fabric, comprising:

(i) mono-component staple fibers comprising from about 1 to about 4 decitex (dtex);

(ii) a first group of split staple fibers comprising from about 0.05 to about 0.5 dtex, wherein the first group of split fibers comprise a first polymeric material;

(iii) a second group of split staple fibers comprising from about 0.05 to about 0.5 dtex, wherein the second group of split fibers comprise a second polymeric material that is different than the first polymeric material; and

(iv) a binder comprising a non-ionic acrylic binder and a melamine-formaldehyde copolymer resin, wherein the melamine-formaldehyde copolymer resin comprises a methylated or partially methylated melamine-formaldehyde copolymer resin, and wherein the binder includes a first ratio between (i) the non-ionic acrylic binder and (ii) the melamine-formaldehyde copolymer resin comprises from about 0.75:1 to about 2.5:1;

wherein the mono-component staple fibers, the first group of split staple fibers, and the second group of split staple fibers are physically entangled together to define a consolidated nonwoven being devoid of synthetic and natural cellulosic material, and wherein a total amount of split fibers comprises from about 10% to 40% by weight of a total amount of fibers forming the fabric, wherein the total amount of split fibers is defined by the sum of the first group of split staple fibers and the second group of split staple fibers.

2. The fabric of claim 1 , wherein the consolidated nonwoven comprises a hydroentangled nonwoven.

3. The fabric of claim 1 , wherein the total amount of split fibers comprises from about 10% to 30% by weight of the total amount of fibers forming the fabric.

4. The fabric of claim 1 , wherein the first group of split staple fibers, the second group of split staple fibers, or both comprise a non-round cross-section.

5. The fabric of claim 1 , wherein the mono-component staple fibers comprise a synthetic polymeric material comprising at least one of a polyolefin, a polyester, a polyamide, or any combination thereof.

6. The fabric of claim 1 , wherein the first polymeric material comprises at least one of a polyolefin, a polyester, a polyamide, or any combination thereof, and the second polymeric material also comprises at least one of a polyolefin, a polyester, a polyamide, or any combination thereof.

7. The fabric of claim 1 , wherein the mono-component staple fibers comprise a first polyester, the first polymeric material comprises a second polyester that is the same or different than the first polyester, and the second polymeric material comprises a polyolefin.

8. The fabric of claim 1 , wherein the binder further comprises a polyvinyl acetate and acrylic copolymer.

9. The fabric of claim 8 , further comprising a second ratio between the (i) polyvinyl acetate and acrylic copolymer and (ii) the non-ionic acrylic binder from about 6.75:1 to about 3.25:1.

10. The fabric of claim 1 , wherein the ratio between (i) the non-ionic acrylic binder and (ii) the melamine-formaldehyde copolymer resin comprises from about 1:1 to about 2:1.

Assignments (34)