Method for manufacturing soft, resistant and bulky nonwoven and nonwoven thus obtained

Abstract

Methods for manufacturing nonwovens and nonwovens obtained by such methods are provided. Particularly, nonwovens are provided with improved tactile and absorbent characteristics, which make them suitable for use in the field of surface cleaning, personal hygiene, or formation of garments. The methods are based on the use of lobed spunbonded filaments which have been treated by a thickening apparatus.

1 . A mono- or multi-layer nonwoven obtained by a method comprising the following sequential steps;
 a) extruding continuous thread filaments or microfilaments through spinnerets to produce spunbonded continuous filaments or microfilaments having a lobed cross-section,   b) laying at least one layer (T 1 ) of spunbonded lobed filaments or microfilaments on a suitable three dimensional support having a surface with ribs in contact with said filaments or microfilaments, and   c) effecting a pre-consolidation of said layer T 1  by passing the layer T 1 , supported by said three dimensional support, between two rollers, one of the rollers facing the layer T 1 ,   wherein the ribs of said surface of said support have a height between 0.3 and 5 mm, said ribs being distributed to cover less than 14% of said surface, and   wherein said roller facing the layer T 1  is provided with a metal outer surface and is subject to heating.   
     
     
         2 . The nonwoven according to  claim 1 , further comprising a step of laying at least one layer (T 3 ) of absorbent material fibres on the nonwoven layer (T 1 ) subsequent to said step c). 
     
     
         3 . The nonwoven according to  claim 2 , further comprising a step of laying at least one further layer (T 2 ) of spunbonded lobed filaments or microfilaments or carded staple fibres on the at least one layer (T 3 ) of fibres of absorbent material. 
     
     
         4 . The nonwoven according to  claim 3 , further comprising, subsequent to the step of laying said at least one layer (T 1 ), a step of treating said at least one further layer (T 2 ) to obtain an increase in the thickness thereof, said step being performed by thickening means which comprises the two rollers and a support (S) having the surface with ribs in contact with said filaments. 
     
     
         5 . The nonwoven according to  claim 3 , wherein at least one of the layers (T 1 ) and (T 2 ) has a thickness ranging from 0.54 mm to 0.9 mm, a cotton wool-like appearance and is soft and smooth to the touch. 
     
     
         6 . The nonwoven according to  claim 3 , wherein said at least one of the layers (T 1 ) and (T 2 ) is a lobed spunbonded layer. 
     
     
         7 . The nonwoven according to  claim 3 , further comprising a step of consolidating the layer (T 2 ) after step c) of treatment to obtain an increase in the thickness thereof. 
     
     
         8 . A method for manufacturing single-layer or bi-layer of lobed spunbonded nonwoven comprising the steps of:
 i) providing at least one layer of lobed spunbonded nonwoven which has been subjected to swelling treatment by passing a layer T 1  through means of thickening which comprises two rollers and at least one surface provided with ribs having an height comprised between 0.3 and 5 mm, a free head with a contact surface for the fibres or microfibres having an extension of less than 0.80 mm 2 , said ribs being distributed so that to cover less than 14% of said at least one surface; and   ii) consolidating said layer through hydro-entanglement.   
     
     
         9 . The method according to  claim 8 , wherein said step i) comprises providing at least one layer of fibres (T 3 ) of absorbent material. 
     
     
         10 . The method according to  claim 9 , wherein said step i) further comprises providing at least one second layer (T 2 ) of lobed spunbonded or staple fibres carded nonwoven, which has been subjected to swelling treatment. 
     
     
         11 . The method according to  claim 8 , wherein the contact surface is about 0.50 mm 2 , and the distribution of said ribs covering from 7-9% of the contact surface.