Patent ID: 6669799
Filing Date: 2003-12-30
Classification: D04H,D06C,Y10T

Abstract:
A process for making a highly durable, hydroentangled nonwoven fabric, consisting of the steps of;a) providing a nonwoven first fibrous matrix comprising a blend of thermoplastic fusible fibers and base fibers, b) providing a nonwoven second fibrous matrix comprising a blend of thermoplastic fusible fibers and base fibers, wherein said base fibers of said first and second fibrous matrices are selected from the group consisting of thermoplastic and rayon fibers, c) layering one or more first fibrous matrices with one or more second fibrous matrices, wherein the thermoplastic fusible fibers of said first and second fibrous matrices have a melt temperature less than the melt temperature or the decomposition temperature of the base fibers of said fibrous matrices, d) consolidating only the layered fibrous matrices into a precursor web, e) hydroentangling the precursor web into a nonwoven fabric using a three-dimensional image transfer device, the three-dimensional image transfer device imparting the layered fibrous matrices into a three-dimensional spatial arrangement, said hydroentangling step being effected prior to thermal-bonding of said thermoplastic fusible fibers, f) elevating the temperature of the imaged nonwoven fabric subsequent to said hydroentangling step such that said fusible fibers are softened or melted and act to thermally bond the fusible fibers and base fibers of the fibrous blend together, thus securing the three-dimensional spatial arrangement of the fibrous matrices.