US5389202A
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Process for making a high pulp content nonwoven composite fabric
Assignee: Kimberly Clark Worldwide Inc
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Filing: 1993-06-09
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Granted: 1995-02-14
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Expires: 2013-06-09
Abstract
Abstract A high pulp content nonwoven composite fabric is disclosed. The composite fabric contains more than about 70 percent, by weight, pulp fibers which are hydraulically entangled into a continuous filament substrate. This high pulp content composite nonwoven fabric may be used as a heavy duty wiper or as a fluid distribution material, cover material, and/or absorbent material in an absorbent personal care product. Also disclosed is a method of making the high pulp content nonwoven composite fabric.
Inventors
- 👤 Cherie H. Everhart
- 👤 Daniel O. Fischer
- 👤 Fred R. Radwanski
- 👤 Henry Skoog
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 10:54
CPC Classifications
A; A61; A61F; A61F13/00; A61F13/15; A61F13/53; A61F13/534; A61F13/537; D; D04; D04H; D04H1/00; D04H1/40; D04H1/407; D04H1/42; D04H1/425; D04H1/44; D04H1/46; D04H1/492; D04H1/498; D04H5/00; D04H5/02; D04H5/03; A61F13/15203; A61F2013/15284; A61F2013/15406; Y; Y10; Y10S; Y10S428/00; Y10S428/913; Y10T; Y10T428/00; Y10T428/25; Y10T428/252; Y10T428/253; Y10T442/00; Y10T442/60; Y10T442/681; Y10T442/689; Y10T442/695
Claims Analysis
Total Claims: 26
Claim 1
Independent Claim
93 words
A method of making a high pulp content nonwoven composite fabric having from about 10 to about 25 percent, by weight, of a nonwoven continuous filament substrate; and more than about 70 percent, by weight, of a fibrous component consisting of pulp fibers, said method comprising: superposing a pulp fiber layer over a nonwoven continuous filament substrate having a bond density greater than about 100 pin bonds per square inch and a total bond area less than about 30 percent; hydraulically entangling said layers to form a composite material; and drying said composite.
Claim 2
Independent Claim
93 words
A method of making a high pulp content nonwoven composite fabric having from about 10 to about 25 percent, by weight, of a nonwoven continuous filament substrate; and more than about 70 percent, by weight, of a fibrous component consisting of pulp fibers, said method comprising: superposing a pulp fiber layer over a nonwoven continuous filament substrate having a bond density greater than about 100 pin bonds per square inch and a total bond area less than about 30 percent; hydraulically entangling said layers to form a composite material; and drying said composite.
Claim 3
Dependent Claim
25 words
The method of claim 1 wherein the layers are superposed by depositing pulp fibers onto the nonwoven continuous filament substrate by dry forming or wet-forming.
Claim 4
Dependent Claim
25 words
The method of claim 1 wherein the layers are superposed by combining a coherent sheet of pulp fibers with the nonwoven continuous filament substrate layer.
Claim 5
Dependent Claim
34 words
The method of claim 1 wherein the coherent sheet of pulp fibers is selected from the group consisting of a re-pulpable paper sheet, a re-pulpable tissue sheet, and a batt of wood pulp fibers.
Claim 6
Dependent Claim
45 words
The method of claim 1 wherein the pulp fiber layer is superposed over a continuous filament substrate having a bond density from about 250 to about 450 pin bonds per square inch and an overall bond area from about 5 percent to about 25 percent.
Claim 7
Dependent Claim
20 words
The method of claim 1 wherein the pulp fiber layer is superposed over a nonwoven web of continuous spunbonded filaments.
Claim 8
Dependent Claim
31 words
The method of claim 1 further comprising the step of adding a material selected from clays, activated charcoals, starches, particulates, and superabsorbent particulates to the superposed layers prior to hydraulic entangling.
Claim 9
Dependent Claim
30 words
The method of claim 1 further comprising the step of adding a material selected from clays, activated charcoals, starches, particulates, and superabsorbent particulates to the superposed, hydraulically entangled composite material.
Claim 10
Dependent Claim
41 words
The method of claim 2 further comprising the step of adding a material selected from clays, activated charcoals, starches, particulates, and superabsorbent particulates to a suspension of pulp fibers used to form the pulp fiber layer on the continuous filament substrate.
Claim 11
Dependent Claim
24 words
The method of claim 1 wherein the hydraulically entangled composite is subjected to a finishing step selected from mechanical softening, pressing, creping, and brushing.
Claim 12
Dependent Claim
21 words
The method of claim 1 wherein the hydraulically entangled composite is subjected to a chemical post-treatment selected from dyes and adhesives.
Claim 13
Independent Claim
70 words
A method of making a high pulp content nonwoven composite fabric having from about 10 to about 25 percent, by weight, of a nonwoven continuous filament substrate; and more than about 70 percent, by weight, of a fibrous component consisting of pulp fibers, said method comprising: superposing a pulp fiber layer over a nonwoven continuous filament substrate; hydraulically entangling said layers to form a composite material; and drying said composite.
Claim 14
Independent Claim
70 words
A method of making a high pulp content nonwoven composite fabric having from about 10 to about 25 percent, by weight, of a nonwoven continuous filament substrate; and more than about 70 percent, by weight, of a fibrous component consisting of pulp fibers, said method comprising: superposing a pulp fiber layer over a nonwoven continuous filament substrate; hydraulically entangling said layers to form a composite material; and drying said composite.
Claim 15
Dependent Claim
25 words
The method of claim 12 wherein the layers are superposed by depositing pulp fibers onto the nonwoven continuous filament substrate by dry forming or wet-forming.
Claim 16
Dependent Claim
25 words
The method of claim 12 wherein the layers are superposed by combining a coherent sheet of pulp fibers with the nonwoven continuous filament substrate layer.
Claim 17
Dependent Claim
34 words
The method of claim 12 wherein the coherent sheet of pulp fibers is selected from the group consisting of a re-pulpable paper sheet, a re-pulpable tissue sheet, and a bart of wood pulp fibers.
Claim 18
Dependent Claim
40 words
The method of claim 12 wherein the pulp fiber layer is superposed over a continuous filament substrate having a bond density greater than about 100 pin bonds per square inch and a total bond area less than about 30 percent.
Claim 19
Dependent Claim
20 words
The method of claim 12 wherein the pulp fiber layer is superposed over a nonwoven web of continuous spunbonded filaments.
Claim 20
Dependent Claim
31 words
The method of claim 12, further comprising the step of adding a material selected from clays, activated charcoals, starches, particulates, and superabsorbent particulates to the superposed layers prior to hydraulic entangling.
Claim 21
Dependent Claim
29 words
The method of claim 12 further comprising the step of adding a material selected from clays, activated charcoals, starches, particulates, and superabsorbent particulates to the hydraulically entangled composite material.
Claim 22
Dependent Claim
41 words
The method of claim 13 further comprising the step of adding a material selected from clays, activated charcoals, starches, particulates, and superabsorbent particulates to a suspension of pulp fibers used to form the pulp fiber layer on the continuous filament substrate.
Claim 23
Dependent Claim
24 words
The method of claim 12 wherein the hydraulically entangled composite is subjected to a finishing step selected from mechanical softening, pressing, creping, and brushing.
Claim 24
Dependent Claim
21 words
The method of claim 12 wherein the hydraulically entangled composite is subjected to a chemical post-treatment selected from dyes and adhesives.
Claim 25
Independent Claim
68 words
A method of improving the abrasion resistance of a high pulp content nonwoven composite fabric having from about 10 to about 25 percent, by weight, of a nonwoven continuous filament substrate; and more than about 70 percent, by weight, of a fibrous component consisting of pulp fibers, said method comprising adding up to about 3 percent of a de-bonding agent to the high pulp content nonwoven composite fabric.
Claim 26
Independent Claim
68 words
A method of improving the abrasion resistance of a high pulp content nonwoven composite fabric having from about 10 to about 25 percent, by weight, of a nonwoven continuous filament substrate; and more than about 70 percent, by weight, of a fibrous component consisting of pulp fibers, said method comprising adding up to about 3 percent of a de-bonding agent to the high pulp content nonwoven composite fabric.
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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) | 1998-02-13 | 1998-08-15 | 1999-02-14 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2002-02-13 | 2002-08-15 | 2003-02-14 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2006-02-13 | 2006-08-15 | 2007-02-14 | $7700.00 | Window Closed / Lapsed |