Method of making a filamentary laminate and the products thereof

Abstract

The present invention is directed to a method of making a laminate nonwoven fabric which entails integration of a continuous filament web with a web of cellulosic fiber material, typically wood pulp. In order to abate loss of cellulosic fiber material during integration by hydroentanglement, the present invention contemplates that the continuous filament web is first subjected to hydroentanglement, with the cellulosic fibrous material thereafter integrated, by hydroentangling, into the partially entangled continuous filament web.

1 . A method of making a laminate nonwoven fabric, comprising the steps of: 
 providing a continuous filament web;    hydroentangling said continuous filament web to form a partially entangled web;    juxtaposing a cellulosic fiber web with said partially entangled web;    hydroentangling said juxtaposed partially entangled web and cellulosic fiber web; and    drying said hydroentangled webs to form said nonwoven fabric.    
   
   
       2 . A method of making a laminate nonwoven fabric in accordance with  claim 1 , wherein said continuous filament web may be selected from the group consisting of polyolefins, polyamides, polyesters, and the blends thereof.  
   
   
       3 . A method of making a laminate nonwoven fabric in accordance with  claim 2 , wherein said polyolefins may be selected from the group consisting of polypropylene, polyethylene, and combinations thereof.  
   
   
       4 . A method of making a laminate nonwoven fabric in accordance with  claim 1 , wherein said step of hydroentangling said juxtaposed webs comprises first directing high-pressure liquid streams against a first expansive surface of said juxtaposed webs, and thereafter directing high-pressure liquid streams against an opposite expansive surface of said juxtaposed web.  
   
   
       5 . A method of making a laminate nonwoven fabric in accordance with  claim 1 , wherein said laminate comprises additional wood pulp layers, continuous or discontinuous filaments layers, film layers, or a combination thereof.  
   
   
       6 . A method of making a laminate nonwoven fabric, comprising the steps of: 
 providing a continuous filament web;    providing a foraminous surface;    hydroentangling said continuous filament web to form a partially entangled web;    juxtaposing a cellulosic fiber web with said partially entangled web;    advancing said juxtaposed partially entangled web and cellulosic fiber web onto said foraminous surface and hydroentangling said webs on said surface so as to impart at least one three-dimensional image into said laminate; and    drying said hydroentangled webs to form said nonwoven fabric.    
   
   
       6 . A method of making a laminate nonwoven fabric in accordance with  claim 6 , wherein said foraminous surface is a three-dimensional image transfer device.  
   
   
       7 . A method of making a laminate nonwoven fabric in accordance with  claim 6 , wherein: 
 said step of hydroentangling said juxtaposed partially entangled web and paper web comprises first directing high-pressure liquid streams against a first expansive surface of the juxtaposed webs, and thereafter directing high-pressure liquid streams against an opposite expansive surface of said juxtaposed web.    
   
   
       8 . A method of making a laminate nonwoven fabric as in  claim 1 , wherein said laminate is a wipe.  
   
   
       9 . A method of making a laminate nonwoven fabric as in  claim 6 , wherein said laminate is a wipe.