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

0026] The nonwoven materials of the invention are useful in a wide variety of applications. For example, the nonwoven material is useful as a component of absorbent products such as disposable diapers, feminine hygiene products, adult incontinence products; medical products which contact the human skin such as surgical gowns and masks; disposable dry or wet wipes (both plain and impregnated dry wipes); industrial garments; filtration media; etc. The nonwoven material of the invention is in particularly well suited for those applications requiring both high strength and soft hand feel. The nonwoven material is also suitable for use as a barrier layer for retaining solids within a desired location, e.g., SAPs in diapers, adult incontinence products and feminin...

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...

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