Granted Patent B2

US 11,441,252 · App. 16/702,748 · Granted Sep 13, 2022

Inventors: Dionne Pots ('s-Hertogenbosch, NL); Matthijs Van Hunen (Arhem, NL); James Taylor (Chelmsford, GB)

Assignee: Berry Global, Inc.

D04H5/02A47L13/16A47L13/22D04H13/001D04H13/002D10B2331/04

Abstract

Claims (31)

1. A nonwoven fabric, comprising:

(i) continuous fibers; and

(ii) a blend of staple fibers comprising (a) polyester staple fibers, (b) bicomponent staple fibers substantially devoid of micro-pores, micro-channels, or both, (c) microfiber staple fibers having a plurality of micro-pores and/or micro-channels defined by a plurality of split portions having a decitex (dtex) value of less than 1 dtex, and (d) wettable staple fibers;

wherein the continuous fibers are mechanically entangled with the blend of staple fibers to define the nonwoven fabric.

2. The nonwoven fabric of claim 1 , wherein the continuous fibers comprise spunbond fibers; wherein the spunbond fibers comprise a polyolefin.

3. The nonwoven fabric of claim 1 , wherein the continuous fibers comprise from 3% to 30% by weight of the nonwoven fabric, and the blend of staple fibers comprises from 70% to 97% by weight of the nonwoven fabric.

4. The nonwoven fabric of claim 1 , wherein the polyester staple fibers comprise from 10% to 40% by weight of the nonwoven fabric, the bicomponent staple fibers comprise from 10% to 40% by weight of the nonwoven fabric, the microfiber staple fibers comprise from 10% to 40% by weight of the nonwoven fabric, and the wettable staple fibers comprise from 10% to 40% by weight of the nonwoven fabric.

5. The nonwoven fabric of claim 1 , wherein the blend of staple fibers comprise a component weight ratio between the polyester staple fibers, the bicomponent staple fibers, the microfiber staple fibers, and the wettable staple fibers according to the formula A:B:C:D, wherein ‘A’, ‘B’, ‘C’, and ‘D’ each comprises a value from 0.75 to 1.25.

6. The nonwoven fabric of claim 1 , wherein the polyester staple fibers comprise at least 70% by weight of one or more polyester polymers.

7. The nonwoven fabric of claim 1 , wherein the bicomponent staple fibers comprise a sheath/core configuration, a side-by-side configuration, a pie configuration, an islands-in-the-sea configuration, a multi-lobed configuration, or any combinations thereof.

8. The nonwoven fabric of claim 7 , wherein the bicomponent fibers comprise crimps; wherein the crimps increase a loft of the nonwoven fabric.

9. The nonwoven fabric of claim 1 , wherein the microfiber staple fibers comprise natural fibers, synthetic fibers, or combinations thereof.

10. The nonwoven fabric of claim 1 , wherein wettable staple fibers comprise viscose.

11. The nonwoven fabric of claim 1 , wherein the wettable staple fibers comprise hydrophilic-modified polyester staple fibers; wherein the hydrophilic-modified polyester staple fibers comprise a hydrophilic finish coated thereon.

12. The nonwoven fabric of claim 1 , wherein the nonwoven fabric comprises a first surface and a second surface, and a first quantity of the continuous fibers is located at the first surface and a second quantity of the continuous fibers is located at the second surface; wherein the first quantity is greater than the second quantity.

13. The nonwoven fabric of claim 1 , wherein the nonwoven fabric comprises a three-dimensional pattern on at least one surface of the nonwoven fabric; wherein the three-dimensional pattern comprises a plurality of recessed portions having an average depth from 1.5 mm to 3 mm.

14. The nonwoven fabric of claim 1 , wherein the nonwoven fabric comprises a cleaning ability to dust and/or disinfect an area of at least 900 to 3000 m 2 per 1 m 2 of the nonwoven fabric as determined by the ratio between a surface area cleaned to a macroscopic area of the nonwoven fabric.

15. A cleaning system, comprising:

(i) a cleaning implement including a mop frame; and

(ii) a nonwoven fabric comprising (a) continuous fibers; and (b) a blend of staple fibers;

wherein the blend of staple fibers comprises (1) of polyester staple fibers, (2) bicomponent staple fibers substantially devoid of micro-pores, micro-channels, or both, (3) microfiber staple fibers having a plurality of micro-pores and/or micro-channels defined by a plurality of split portions having a decitex (dtex) value of less than 1 dtex, and (4) wettable staple fibers;

wherein the continuous fibers are mechanically entangled with the blend of staple fibers to define the nonwoven fabric.

16. The cleaning system of claim 15 , wherein the nonwoven fabric is releasably engaged by the mop frame and the cleaning implement further comprises a liquid reservoir and spraying mechanism configured to controllably dispense a liquid housed within the liquid reservoir.

17. The cleaning system of claim 16 , wherein the cleaning implement further comprises a handle directly or indirectly attached to the mop frame, and wherein the liquid reservoir is mounted directly or indirectly onto the handle.

18. A method of forming a nonwoven fabric, comprising:

(i) forming or providing a web of continuous fibers having a top surface;

(ii) forming or providing a carded web comprising a blend of staple fibers comprising (a) polyester staple fibers, (b) bicomponent staple fibers, (c) microfiber staple fibers, and (d) wettable staple fibers;

(iii) positioning the carded web directly or indirectly onto the top surface of the web of continuous filaments; and

(iii) mechanically entangling the carded web with the continuous fibers to define a nonwoven fabric.

19. The method of claim 18 , wherein the step of mechanically entangling comprises hydroentangling the carded web with the continuous fibers to form a hydroentangled nonwoven fabric.

20. The method of claim 18 , further comprises positioning a first surface of the nonwoven fabric directly or indirectly onto an image transfer device having a three-dimensional pattern and applying jets of fluid directly or indirectly to a second surface of the nonwoven fabric to impart a three-dimensional pattern onto the nonwoven fabric.

Assignments (34)