US5240764A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process for making spunlaced nonwoven fabrics
Assignee: EIDP Inc
•
Filing: 1992-05-13
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Granted: 1993-08-31
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Expires: 2012-05-13
Abstract
Abstract A process for making spunlaced nonwoven fabrics comprised of fusible fibers and non-fusible staple length fibers. The preferred process comprises wet-laying a mixture of fusible and non-fusible staple length fibers into a nonwoven web and then lightly bonding the web to melt the fusible fibers. Optionally, the bonded web is then wound on a roll so the web can be easily transported. Thereafter, the lightly bonded web is hydraulically needled to entangle the fibers in a three-dimensional state. The hydraulically needled web is then optionally dried to remelt the fusible fibers and improve durability and abrasion resistance. The resulting spunlaced nonwoven fabrics made by the inventive process are useful in apparel and wiper applications.
Inventors
- 👤 Joseph W. Haid
- 👤 James R. Vincent
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 17:05
CPC Classifications
D; D04; D04H; D04H1/00; D04H1/40; D04H1/44; D04H1/46; D04H1/48; A; A47; A47L; A47L13/00; A47L13/10; A47L13/16; D04H1/49; D21; D21H; D21H13/00; D21H13/02; D21H13/08; D21H13/10; D21H13/12; D21H13/14; D21H13/20; D21H13/24; D21H13/26; D21H25/00; D21H25/005; D21H25/04; Y; Y10; Y10T; Y10T442/00; Y10T442/60; Y10T442/689
Claims Analysis
Total Claims: 14
Claim 1
Independent Claim
109 words
A process for making a spunlaced nonwoven fabric comprising the steps of: (a) blending a mixture of fusible fibers and non-fusible staple length fibers and forming a nonwoven web from the mixture of fibers, the fusible fibers present in an amount of from 5 to 50 wt. % and the non-fusible fibers present in an amount of from 50 to 95 wt. %; (b) lightly bonding the nonwoven web by heating the web at a temperature sufficient to melt the fusible fibers but insufficient to degrade or melt the non-fusible fibers; and (c) hydraulically needling the lightly bonded web so that the fibers are entangled in a three-dimensional state.
Claim 2
Dependent Claim
109 words
A process for making a spunlaced nonwoven fabric comprising the steps of: (a) blending a mixture of fusible fibers and non-fusible staple length fibers and forming a nonwoven web from the mixture of fibers, the fusible fibers present in an amount of from 5 to 50 wt. % and the non-fusible fibers present in an amount of from 50 to 95 wt. %; (b) lightly bonding the nonwoven web by heating the web at a temperature sufficient to melt the fusible fibers but insufficient to degrade or melt the non-fusible fibers; and (c) hydraulically needling the lightly bonded web so that the fibers are entangled in a three-dimensional state.
Claim 3
Dependent Claim
16 words
The process according to claim 1 wherein the nonwoven web is formed by a dry-lay process.
Claim 4
Dependent Claim
16 words
The process according to claim 1 wherein the nonwoven web is formed by a wet-lay process.
Claim 5
Dependent Claim
38 words
The process according to claim 1 wherein the fusible fibers are present in an amount of from 10 to 30 wt. % and the non-fusible fibers are present in an amount of from 70 to 90 wt. %.
Claim 6
Dependent Claim
15 words
The process according to claim 1 wherein the fusible fibers are all staple length fibers.
Claim 7
Dependent Claim
15 words
The process according to claim 1 wherein the fusible fibers are all non-staple length fibers.
Claim 8
Dependent Claim
21 words
The process according to claim 1 wherein the fusible fibers comprise both staple length fusible fibers and non-staple length fusible fibers.
Claim 9
Dependent Claim
22 words
The process according to claim 1 wherein the lightly bonded web is wound onto a roll before the web is hydraulically needled.
Claim 10
Dependent Claim
25 words
The process according to claim 1 further comprising the step of drying the hydraulically needled web at a temperature sufficient to remelt the fusible fibers.
Claim 11
Dependent Claim
30 words
The process according to claim 1 wherein the lightly bonded web is hydraulically needled using a plurality of columnar water streams at a pressure of from 200 to 2,000 psi.
Claim 12
Dependent Claim
23 words
The process according to claim 1 wherein the fusible fibers are selected from the group consisting of polyamides, polyesters, polyolefins and copolymers thereof.
Claim 13
Dependent Claim
23 words
The process according to claim 1 wherein the non-fusible fibers are selected from the group consisting of polyamides, polyesters, polyolefins and cellulosic fibers.
Claim 14
Dependent Claim
13 words
A spunlaced nonwoven fabric made by the process of any of claims 1-12.
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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) | 1996-08-30 | 1997-03-01 | 1997-08-31 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2000-08-30 | 2001-03-01 | 2001-08-31 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2004-08-30 | 2005-03-01 | 2005-08-31 | $7700.00 | Window Closed / Lapsed |