IP Library › Granted Patent US 6,905,524
Granted Patent B2
US 6,905,524 · App. 10/289,554 · Granted Jun 14, 2005

Method of continuously dyeing nonwoven fabrics and the products thereof

Assignee: Polymer Group, Inc.
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Quick Facts
Patent No.
US 6,905,524
App. No.
10/289,554
Granted
Jun 14, 2005
Kind
B2
Abstract

It is the objective of the present invention to disclose a method of continuously dyeing durable nonwoven fabrics, and more specifically, nonwoven fabrics comprising a cellulosic fibrous material dyed with indigo dyestuffs. It is in accordance with the present invention, to utilize synthetic fibers in combination with natural or cellulosic fibers in the formation of a nonwoven web. The natural fibers, preferably cotton, make up at least 10% of the fibrous nonwoven fabric.

Claims (23)

1. A process of continuously dyeing a nonwoven fabric, comprising the steps of:

a. providing a nonwoven fabric comprising staple length fibers, the staple length fibers including at least 10% natural fiber;

b. wetting said nonwoven fabric;

c. dyeing said wetted nonwoven fabric with a leuco indigo vat dye;

d. skying said dyed nonwoven fabric;

e. rinsing said dyed nonwoven fabric;

f. drying said nonwoven fabric;

g. said indigo dyed nonwoven fabric having a crock fastness, per AATCC TM 8-1988, of at least 5.

2. A process of continuously dyeing a nonwoven fabric as in claim 1 , wherein said fibrous blend comprises synthetic and natural fibers.

3. A process of continuously forming and dyeing a nonwoven fabric as in claim 2 , wherein said synthetic fibers are selected from the group consisting of polyamides, polyester, polyolefins, and the combinations thereof.

4. A process of continuously dyeing a nonwoven fabric as in claim 2 , wherein said natural fibers are selected from the group consisting of cotton, wood pulp, rayon and the combinations thereof.

5. A process of continuously dyeing a nonwoven fabric as in claim 4 , wherein said natural fiber is cotton.

6. A process of continuously dyeing a nonwoven fabric, comprising the steps of:

a. providing a fibrous blend comprising staple length fibers, the staple length fibers including at least 10% natural fibers;

b. carding said fibrous blend;

c. forming said fibrous blend into a fibrous batt;

d. bonding said fibrous web to form a nonwoven fabric;

e. wetting said nonwoven fabric;

f. dyeing said wetted nonwoven fabric with a leuco state indigo vat dye;

g. skying said dyed nonwoven fabric;

h. rinsing said dyed nonwoven fabric;

i. drying said nonwoven fabric; and

j. said indigo dyed nonwoven fabric having a crock fastness, per AATCC TM 48 -1988, of at least 5.

Assignments (8)
RELEASE OF SECURITY INTEREST IN PATENTS Recorded Dec 6, 2005
From: CITICORP NORTH AMERICA, INC., AS FIRST LIEN COLLATERAL AGENT
To: BONLAM (S.C.), INC.; CHICOPEE, INC.; DOMINION TEXTILE (USA) INC.; FABPRO ORIENTED POLYMERS, INC.; FABRENE CORP.; FABRENE GROUP L.L.C.; FIBERGOL CORPORATION; FIBERTECH GROUP, INC.; FNA ACQUISITION, INC.; FNA POLYMER CORP.; LORETEX CORPORATION; PGI EUROPE, INC.; PGI POLYMER, INC.; PNA CORPORATION; POLY-BOND INC.; POLYLONIX SEPARATION TECHNOLOGIES, INC.; POLYMER GROUP, INC.; PRISTINE BRANDS CORPORATION; TECHNETICS GROUP, INC.
Reel/Frame 016851/0436 →
RELEASE OF SECURITY INTEREST IN PATENTS Recorded Dec 6, 2005
From: WILMINGTON TRUST COMPANY, AS SECOND LIEN COLLATERAL AGENT
To: BONLAM (S.C.), INC.; CHICOPEE, INC.; DOMINION TEXTILE (USA) INC.; FABPRO ORIENTED POLYMERS, INC.; FABRENE CORP.; FABRENE GROUP L.L.C.; FIBERGOL CORPORATION; FIBERTECH GROUP, INC.; FNA ACQUISITION, INC.; FNA POLYMER CORP.; LORETEX CORPORATION; PGI EUROPE, INC.; PGI POLYMER, INC.; PNA CORPORATION; POLY-BOND INC.; POLYLONIX SEPARATION TECHNOLOGIES, INC.; POLYMER GROUP, INC.; PRISTINE BRANDS CORPORATION; TECHNETICS GROUP, INC.
Reel/Frame 016851/0471 →
SECURITY AGREEMENT Recorded Dec 6, 2005
From: POLYMER GROUP, INC.; CHICOPEE, INC.; FIBERTECH GROUP, INC.; PGI POLYMER, INC.; POLY-BOND INC.
To: CITICORP NORTH AMERICA, INC., AS COLLATERAL AGENT
Reel/Frame 016851/0624 →
SECURITY AGREEMENT Recorded Aug 12, 2004
From: CHICOPEE, INC.; FIBERTECH GROUP, INC.; POLY-BOND, INC.; POLYMER GROUP, INC.
To: WILMINGTON TRUST COMPANY, AS SECOND LIEN COLLATERAL AGENT
Reel/Frame 015778/0311 →
SECURITY AGREEMENT Recorded Aug 10, 2004
From: CHICOPEE, INC.; FIBERTECH GROUP, INC; POLY-BOND, INC.; POLYMER GROUP, INC.
To: CITICORP NORTH AMERICA, INC. AS FIRST LIEN COLLATERAL AGENT
Reel/Frame 015732/0080 →
RELEASE OF SECURITY INTEREST Recorded May 13, 2004
From: JPMORGAN CHASE BANK, AS ADMINISTRATIVE AGENT
To: FIBERTECH GROUP, INC.; POLYMER GROUP, INC.
Reel/Frame 015380/0798 →
SECURITY AGREEMENT Recorded Jun 26, 2003
From: POLYMER GROUP, INC.
To: JPMORGAN CHASE BANK
Reel/Frame 014192/0001 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Feb 20, 2003
From: HARTGROVE, HERBERT; DE LEON, SERGIO DIAZ
To: POLYMER GROUP, INC.
Reel/Frame 013764/0129 →
Continuity (2)
Provisional Application 6034537700 · Nov 9, 2001
Related Publication 20030115688A1 · Jun 26, 2003