Method of making a filamentary laminate and the products thereof

Abstract

The present invention is directed to a nonwoven composite fabric comprising one or more layers of discontinuous filaments or nano-fiber filaments positioned between at least one continuous filament web and one cellulosic fiber web that are subsequently hydroentangled, wherein the discontinuous filaments or nano-fiber filaments provide a barrier to prevent the loss of the cellulosic fibrous material through the highly porous continuous filament web.

1 . A method of making a composite nonwoven fabric, comprising the steps of: 
 providing a continuous filament web;    providing a discontinuous filament web, wherein said web has a basis weight less than about 2 grams per square meter;    providing a cellulosic fiber web;    hydroentangling said webs to form a 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.  
   
   
       10 . A method of making a composite nonwoven fabric, comprising the steps of: 
 providing a continuous filament web;    providing a discontinuous filament web, wherein said web has a basis weight less than about 2 grams per square meter;    providing a cellulosic fiber web;    juxtaposing said webs;    hydroentangling said webs; and    drying said hydroentangled webs to form said nonwoven fabric.    
   
   
       11 . A method of making a laminate nonwoven fabric in accordance with  claim 10 , 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.