Method for making a hydroentangled nonwoven fabric and the fabric made thereby

Abstract

A process for making a single layer or multi-layer nonwoven material having improved cross-directional strength and feel, and the nonwoven material made thereby, is described. The process provides a nonwoven material including at least one layer formed of polymeric continuous filaments. The layer(s) are formed in a continuous sequential manner, i.e., a subsequent layer being formed on top of a preceding layer or layers. Thereafter, in the absence of any prebonding, the layer(s) are subjected to hydroentanglement. The basis weight of the nonwoven material is from about 17 to 150 gsm. The nonwoven material has improved properties based on treating the layer(s) by hydroentanglement. Varying the number of water jets and the pressure of the water allows variance in the properties obtained in the final product. Other physical properties can also be imparted to or changed in the nonwoven material by inclusion of an additive in a polymer melt during formation of the filaments, or by topical treatment following treatment of the layers of the nonwoven material by hydroentanglement.

Description

[0001] The invention is directed to a method for making a nonwoven material including forming at least one layer of continuous filaments and subjecting the layer(s) to hydroentanglement in the absence of any prebonding of the continuous filaments in the layer(s) prior to being subjected to hydroentanglement, as well as the nonwoven material made thereby. The nonwoven material has improved physical properties such as increased tensile and elongation properties, hand and drape, very low surface linting, etc. The nonwoven material provided is preferably spunlaid or meltblown or is a composite and can be present as a single layer or as one or more layers in a multi-layer nonwoven material. The material of the invention is in particular useful in personal care absorbent products, such as feminine hygiene products, diapers, adult incontinence products, etc., as well as for dry or wet wipes, medical products which come in contact with skin, and the like.[0002] Hydroentangled nonwoven webs ...

AI Technical Summary

Benefits of technology

[0014] Accordingly, a primary object of the present invention is to provide a method for making a nonwoven material utilizing hydroentanglement as a means of bonding thereby eliminating the need for thermal bonding or chemical bonding agents, and a nonwoven material having improved strength.

[0015] More particularly, it is an object of the invention to provide a single layer or multi-layer nonwoven material having improved cross-directional strength made in a continuous in-line process wherein at least one layer of spunlaid or meltblown continuous filaments are bonded together by hydroentanglement in the absence of any prebonding such as by chemical, thermal compression, needling, calendering or the like.

Problems solved by technology

This adds to the time and cost of the process, but also affects the properties of the resulting nonwoven material, in particular as to the softness and durability of the material.

When the material is pulled in a cross-direction, the material will stretch and ultimately tear.

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