Nonwoven fabric for buffing applications

Abstract

A method of forming a nonwoven fabric suitable for metal-finishing buffing operations includes providing a precursor web comprising polyester, staple length fibers, with hydroentanglement of the web effected to impart desired physical characteristics. Hydroentanglement is effected on a three-dimensional, image transfer device having an array of three-dimensional surface elements for patterning the fabric which is formed. Application of a binder composition lends desired durability to the fabric, with the binder composition preferably including a melamine polymeric composition to achieve the desired strength and abrasion resistance.

What is claimed is:  
     
         1 . A method of making a nonwoven fabric for buffing applications, comprising the steps of: 
 providing a precursor web comprising polyester staple length fibers;    providing a foraminous, three-dimensional image transfer device having an array of three-dimensional surface elements;    positioning said precursor web on said image transfer device, and hydroentangling said precursor web to form an imaged nonwoven fabric, and    applying a polymeric binder composition to said imaged nonwoven fabric to provide said fabric with a Combined Tensile Strength of at least about 800 grams/ounce of fabric.    
     
     
         2 . A method of making a nonwoven fabric in accordance with  claim 1 , including: 
 pre-entangling said precursor web on a foraminous forming surface prior to said step of hydroentangling said precursor web on said image transfer device.    
     
     
         3 . A method of making a nonwoven fabric in accordance with  claim 1 , wherein: 
 said imaged nonwoven fabric has a Taber Abrasion of at least about 1000 cycles after application of said binder composition.    
     
     
         4 . A method of making a nonwoven fabric in accordance with  claim 1 , wherein: 
 said binder composition comprises a melamine polymeric compound.    
     
     
         5 . A method of making a nonwoven fabric in accordance with  claim 1 , wherein: 
 said step of hydroentangling said precursor web on said image transfer device includes forming a pattern of surface irregularities in the nonwoven fabric formed thereby.    
     
     
         6 . A method of making a nonwoven fabric in accordance with  claim 5 , wherein: 
 said pattern of surface irregularities include apertures.    
     
     
         7 . A method of making a nonwoven fabric in accordance with  claim 5 , wherein: 
 said pattern of surface irregularities include raised portions.    
     
     
         8 . A method of making a nonwoven fabric for buffing applications, comprising the steps of: 
 providing a precursor web comprising polyester staple length fibers; pre-entangling said precursor web on a foraminous forming surface;    providing a three-dimensional image transfer device having an array of three-dimensional surface elements;    positioning said precursor web on said image transfer device, and hydroentangling said precursor web to form an imaged nonwoven fabric having a pattern of apertures therein; and    applying a polymeric binder composition to said imaged fabric, said binder composition comprising a melamine polymeric compound, said resultant fabric having combined tensile strength of at least about 800 grams/ounce of fabric.    
     
     
         9 . A method of making a nonwoven fabric in accordance with  claim 8 , wherein: 
 said nonwoven fabric has a Taber Abrasion of at least about 1000 cycles after application of said binder composition.    
     
     
         10 . A method of making a nonwoven fabric in accordance with  claim 8 , wherein: 
 said step of providing said three-dimensional image transfer device includes providing said image transfer device with an array of three-dimensional surface elements having an octagon-and-square configuration.    
     
     
         11 . A method of making a nonwoven fabric in accordance with  claim 8 , wherein: 
 said step of providing said three-dimensional image transfer device includes providing said image transfer device with an array of three-dimensional surface elements having a herringbone configuration.    
     
     
         12 . A method of making a nonwoven fabric in accordance with  claim 8 , wherein: 
 said step of applying said binder composition includes applying a binder composition further comprising an acrylic/copolymer composition.    
     
     
         13 . A nonwoven fabric for buffing applications formed in accordance with the method of  claim 8 .  
     
     
         14 . A nonwoven fabric for buffing applications comprising: 
 an imaged, apertured fibrous matrix comprising polyester staple length fibers, and a polymeric binder,    said nonwoven fabric having a combined tensile strength of at least about 800 grams/ounce of fabric, and a Taber Abrasion of at least about 1000 cycles.    
     
     
         15 . A nonwoven fabric in accordance with  claim 14 , wherein: 
 said binder composition comprises a melamine composition.    
     
     
         16 . A nonwoven fabric in accordance with  claim 15 , wherein: 
 said binder composition further comprises an acrylic/copolymer composition.    
     
     
         17 . A nonwoven fabric in accordance with  claim 14 , wherein: 
 said fabric has an image imparted thereto by a three-dimensional image transfer device having an array of three-dimensional surface elements having an octagon-and-square configuration.    
     
     
         18 . A nonwoven fabric in accordance with  claim 14 , wherein: 
 said fabric has an image imparted thereto by a three-dimensional image transfer device having an array of three-dimensional surface elements having a herringbone configuration.    
     
     
         19 . A nonwoven fabric for buffing applications comprising: 
 a fibrous matrix comprising staple length fibers,    said fibrous matrix being hydroentangled into a nonwoven fabric,    said nonwoven fabric has an image imparted thereto by a three-dimensional image transfer device having an array of three-dimensional surface elements,    said image imparting the ability of the nonwoven fabric to retain compounds applied thereto.