Nonwoven fabric having three-dimensional printed surface and method for producing the same

Abstract

The present invention relates to a nonwoven fabric having a three-dimensional printed surface which is achieved by screen printing the fabric with a puff pigment to create an inexpensive, textured fabric. The fabric is preferably printed with a puff pigment of contrasting color, when compared with the color of the base fabric, so that an aesthetically pleasing two-tone fabric is produced. The fabric is primarily comprised of continuous multi-component fibers that are at least partially split along their length. The fabric may be manufactured into such end-use products as automotive interior fabric, apparel, drapery, cleaning cloths, upholstery, and office panels. Also encompassed within this invention is a method for producing a nonwoven fabric having a three-dimensional printed surface.

We claim:  
     
         1 . A spun-bonded nonwoven fabric having a three-dimensional printed surface, wherein the spun-bonded nonwoven fabric is comprised of continuous multi-component fibers that are at least partially split along their length into individual filament fibers by mechanical or chemical action.  
     
     
         2 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is comprised of multi-component fibers, and wherein the multi-component fibers are characterized by having a fiber size of less than 5 denier.  
     
     
         3 . The spun-bonded nonwoven fabric of  claim 1 , wherein the multi-component fibers are at least partially split along their length into individual filament fibers by mechanical or chemical action, and wherein the individual filament fibers are characterized by having a fiber size of less than 1 denier.  
     
     
         4 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is comprised of fibers selected from the group consisting of polyester, polyamide, polyolefin, polyaramide, polyurethane, polylactic acid, and combinations thereof.  
     
     
         5 . The spun-bonded nonwoven fabric of  claim 4 , wherein the fiber is polyester, and wherein the polyester is selected from the group consisting of polyethylene terephthalate, polytriphenylene terephthalate, polybutylene terephthalate, and combinations thereof.  
     
     
         6 . The spun-bonded nonwoven fabric of  claim 4 , wherein the fiber is polyolefin, and wherein the polyolefin is selected from the group consisting of polypropylene, polyethylene, and combinations thereof.  
     
     
         7 . The spun-bonded nonwoven fabric of  claim 4 , wherein the fiber is polyamide, and wherein the polyamide is selected from the group consisting of nylon 6, nylon 6,6, and combinations thereof.  
     
     
         8 . The spun-bonded nonwoven fabric of  claim 7 , wherein the spun-bonded nonwoven fabric is comprised of polyester and nylon 6,6.  
     
     
         9 . The spun-bonded nonwoven fabric of  claim 8 , wherein the spun-bonded nonwoven fabric is comprised of polyester and nylon 6,6, wherein the polyester comprises approximately 65% of the spun-bonded nonwoven fabric, and wherein the nylon 6,6 comprises approximately 35% of the spun-bonded nonwoven fabric.  
     
     
         10 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into a composite material.  
     
     
         11 . The spun-bonded nonwoven fabric of  claim 10 , wherein the composite material further comprises one or more layers of foam material, wherein the foam material is polyurethane, polystyrene, polyether, polyester, or combinations thereof; one or more layers of nonwoven, woven, or knitted fabric; one or more layers of film; and one or more layers of adhesive material.  
     
     
         12 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is dyed.  
     
     
         13 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is undyed.  
     
     
         14 . The spun-bonded nonwoven fabric of  claim 1 , wherein the three-dimensional printed surface imparts between about 2 and about 60 percent print coverage on the surface of the spun-bonded nonwoven fabric.  
     
     
         15 . The spun-bonded nonwoven fabric of  claim 1 , wherein the three-dimensional printed surface imparts between about 5 and about 30 percent print coverage on the surface of the spun-bonded nonwoven fabric.  
     
     
         16 . The spun-bonded nonwoven fabric of  claim 1 , wherein the three-dimensional printed surface imparts less than about 2 percent print coverage on the surface of the spun-bonded nonwoven fabric.  
     
     
         17 . The spun-bonded nonwoven fabric of  claim 1 , wherein the three-dimensional printed surface imparts more than about 60 percent print coverage on the surface of the spun-bonded nonwoven fabric.  
     
     
         18 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article of automotive interior fabric.  
     
     
         19 . The spun-bonded nonwoven fabric of  claim 18 , wherein the spun-bonded nonwoven fabric is incorporated into an article of automotive headliner fabric.  
     
     
         20 . The spun-bonded nonwoven fabric of  claim 18 , wherein the spun-bonded nonwoven fabric is incorporated into an article of automotive upholstery.  
     
     
         21 . The spun-bonded nonwoven fabric of  claim 18 , wherein the spun-bonded nonwoven fabric is incorporated into an article for automotive package trays.  
     
     
         22 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article of automotive trunk lining.  
     
     
         23 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article of apparel.  
     
     
         24 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article of drapery.  
     
     
         25 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article of residential upholstery.  
     
     
         26 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article of commercial upholstery.  
     
     
         27 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article for cleaning cloths.  
     
     
         28 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article for office panels.  
     
     
         29 . A spun-bonded nonwoven fabric having a three-dimensional screen printed surface, wherein the spun-bonded nonwoven fabric is comprised of continuous multi-component fibers that are at least partially split along their length into individual filament fibers by mechanical or chemical action.  
     
     
         30 . A spun-bonded nonwoven fabric having a three-dimensional screen printed surface, wherein, the spun-bonded nonwoven fabric is comprised of continuous multi-component fibers that are at least partially split along their length into individual filament fibers by mechanical or chemical action, and wherein puff pigment is used to create the three-dimensional screen printed surface.