US4623575A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Lightly entangled and dry printed nonwoven fabrics and methods for producing the same
Assignee: JPMorgan Chase Bank NA
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Filing: 1985-02-07
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Granted: 1986-11-18
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Expires: 2005-02-07
Abstract
Abstract A strong, durable nonwoven fabric comprising polyester and/or polyolefin fibers arranged in a pattern of high density, lightly entangled fiber regions. Distributed throughout the fibers is an adhesive binder material to provide the final fabric with improved strength characteristics. Entangled nonwoven fabrics are dry print bonded to produce nonwoven fabrics having an excellent combination of strength, softness and durability.
Inventors
- 👤 Berry A. Brooks
- 👤 John W. Kennette
- 👤 Conrad C. Buyofsky
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 12:01
CPC Classifications
D; D04; D04H; D04H1/00; D04H1/40; D04H1/44; D04H1/46; D04H1/48; D04H1/58; D04H1/64; D04H1/66; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1007; Y10T156/1023; Y10T428/00; Y10T428/24; Y10T428/24058; Y10T428/24124; Y10T428/24273; Y10T428/24752; Y10T428/24802; Y10T428/24826; Y10T442/00; Y10T442/60; Y10T442/689
Claims Analysis
Total Claims: 23
Claim 1
Independent Claim
100 words
A method of producing a strong, durable nonwoven fabric comprising: (a) forming a layer of overlapping intersecting polyester or polyolefin or both fibers; (b) supporting said layer on an apertured support member; (c) jetting pressurized fluid through rows of orifices to form essentially columnar jets of fluid and directing said jets of fluid against the surface of the fibrous support layer opposite said support member without impeding or diffusing said jets, to rearrange the fibers into a regular repeating pattern of lightly entangled fiber regions, and; (d) applying an effective amount of an adhesive bonding material to said rearranged layer.
Claim 2
Independent Claim
100 words
A method of producing a strong, durable nonwoven fabric comprising: (a) forming a layer of overlapping intersecting polyester or polyolefin or both fibers; (b) supporting said layer on an apertured support member; (c) jetting pressurized fluid through rows of orifices to form essentially columnar jets of fluid and directing said jets of fluid against the surface of the fibrous support layer opposite said support member without impeding or diffusing said jets, to rearrange the fibers into a regular repeating pattern of lightly entangled fiber regions, and; (d) applying an effective amount of an adhesive bonding material to said rearranged layer.
Claim 3
Dependent Claim
20 words
A method of producing a nonwoven fabric according to claim 1 wherein the apertured support member has a predetermined topography.
Claim 4
Dependent Claim
20 words
A method of producing a nonwoven fabric according to claim 1 wherein the jets of fluid are streams of water.
Claim 5
Dependent Claim
25 words
A method of producing a nonwoven fabric according to claim 1 including drying the fabric at an elevated temperature to cure the adhesive bonding material.
Claim 6
Dependent Claim
43 words
A method of producing a nonwoven fabric according to claim 1 wherein the apertured support member has a predetermined topography, the jets of fluid are streams of water, and the fabric is dried at an elevated temperature to cure the adhesive bonding material.
Claim 7
Dependent Claim
102 words
A strong, durable nonwoven fabric comprising a layer of polyester or polyolefin or both fibers, said fibers being disposed in a regular repeating pattern of lightly entangled fiber regions of higher area density than the average area density of the layer, and interconnecting fibers extending between the lightly entangled fiber regions and being randomly entangled with each other in said regions, and an effective amount of an adhesive binder, said fabric formed by the method of claim 1 and exhibiting a strength greater than the combined strength attributable to the amount of binder and degree of entanglement used to form said fabric.
Claim 8
Dependent Claim
10 words
The fabric of claim 6 wherein the fibers are polyester.
Claim 9
Dependent Claim
10 words
The fabric of claim 6 wherein the fibers are polypropylene.
Claim 10
Dependent Claim
16 words
The nonwoven fabric of claims 6, wherein adhesive binder material is uniformly distributed through the layer.
Claim 11
Dependent Claim
21 words
The nonwoven fabric of claims 6, wherein the adhesive binder material is distributed in an intermittent pattern of spaced binder areas.
Claim 12
Dependent Claim
126 words
Process which comprises: (a) supporting a layer of staple-length fibrous starting material whose individual fibers are in mechanical engagement with one another but which are capable of movement under applied liquid forces, on a liquid pervious support member adapted to move in a predetermined direction; (b) moving the supported layer in said predetermined direction through a zone within which streams of high pressure, fine, essentially columnar jets of water are projected directly onto said layer to produce a web of entangled fibers; (c) drying the web of entangled fibers; (d) applying, by printing, an effective amount of an aqueous resin binder composition to the dried web in an intermittent pattern; and (e) drying said aqueous resin binder composition after it has been applied to said web.
Claim 13
Dependent Claim
126 words
Process which comprises: (a) supporting a layer of staple-length fibrous starting material whose individual fibers are in mechanical engagement with one another but which are capable of movement under applied liquid forces, on a liquid pervious support member adapted to move in a predetermined direction; (b) moving the supported layer in said predetermined direction through a zone within which streams of high pressure, fine, essentially columnar jets of water are projected directly onto said layer to produce a web of entangled fibers; (c) drying the web of entangled fibers; (d) applying, by printing, an effective amount of an aqueous resin binder composition to the dried web in an intermittent pattern; and (e) drying said aqueous resin binder composition after it has been applied to said web.
Claim 14
Dependent Claim
35 words
Process of claim 11 wherein said binder composition is applied to said dried web so as to produce discrete binder areas that extend into said web a distance less than the thickness of said web.
Claim 15
Dependent Claim
18 words
Process of claim 11 wherein said aqueous binder composition is applied to both surfaces of said dried web.
Claim 16
Dependent Claim
51 words
Process of claim 13 wherein said binder composition is applied to each surface of said dried web so as to produce discrete binder areas that extend into said web a distance such that a region free of binder is maintained inside said web between the discrete binder areas on each surface.
Claim 17
Dependent Claim
18 words
Process of claim 14 wherein said fibrous starting material is rayon or a mixture of rayon and polyester.
Claim 18
Dependent Claim
24 words
Process of claim 15 wherein said aqueous resin binder composition has a viscosity of from about 300 to about 2000 centipoises at 72° F.
Claim 19
Dependent Claim
22 words
Process of claim 14 wherein said aqueous resin binder composition has a viscosity of at least about 150 centipoises at 72° F.
Claim 20
Dependent Claim
18 words
Process of claim 13 wherein said fibrous starting material is rayon or a mixture of rayon and polyester.
Claim 21
Dependent Claim
24 words
Process of claim 18 wherein said aqueous resin binder composition has a viscosity of from about 300 to about 2000 centipoises at 72° F.
Claim 22
Dependent Claim
22 words
Process of claim 13 wherein said aqueous resin binder composition has a viscosity of at least about 150 centipoises at 72° F.
Claim 23
Dependent Claim
11 words
The bonded fibrous web produced by the process of claim 11.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1989-11-17 | 1990-05-19 | 1990-11-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-11-17 | 1994-05-19 | 1994-11-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-11-17 | 1998-05-19 | 1998-11-18 | $7700.00 | Window Closed / Lapsed |