Process For Producing Deformed Nonwoven

Abstract

A process for producing a deformed nonwoven is described. The process includes the steps of: adjusting a water content of a nonwoven such that the nonwoven has at least one area having a water content of at least about 12% by weight of the nonwoven in the area, and subjecting the nonwoven to a mechanical deformation process. The deformation process is a mechanical deformation of the nonwoven and dewatering of the nonwoven to obtain a deformed nonwoven.

What is claimed is: 
     
         1 . A process for producing a deformed nonwoven comprising cellulose-based fibers, the process comprising;
 (a) adjusting a water content of a nonwoven such that the nonwoven comprises at least one area having a water content of at least about 12% by weight of the nonwoven in the area, and   (b) subjecting the nonwoven to a mechanical deformation process, the deformation process comprising mechanical deformation of the nonwoven and dewatering of the nonwoven to obtain a deformed nonwoven.   
     
     
         2 . The process of  claim 1 , wherein the dewatering is conducted by introducing heat to the nonwoven. 
     
     
         3 . The process of  claim 1 , wherein the mechanical deformation and the dewatering are carried out simultaneously. 
     
     
         4 . The process of  claim 1 , wherein the cellulosed-based fibers are fibers selected from the group consisting of cotton fibers, regenerated cellulose fibers and a combination thereof. 
     
     
         5 . The process of  claim 1 , wherein the mechanical deformation of the nonwoven is carried out by a process comprising:
 (i) subjecting the nonwoven to a deformation apparatus, the deformation apparatus comprising a first forming member and a second forming member, wherein the first forming member comprises first forming elements on its surface, wherein at least one of the first forming member and the second forming member is heated, and   (ii) moving the nonwoven through a nip that is formed between the first and second forming members so that deformations are formed in the nonwoven as the first forming member and the second forming member are engaged.   
     
     
         6 . The process of  claim 5 , wherein the deformation apparatus comprises a pair of rolls. 
     
     
         7 . The process of  claim 5 , wherein the nonwoven contacts the first and second forming members for sufficient time the deformations are formed and dewatering of the nonwoven occurs. 
     
     
         8 . The process of  claim 1 , wherein the dewatering of the nonwoven produces a deformed nonwoven having a water content less than 20% by weigh to the deformed nonwoven. 
     
     
         9 . The process of  claim 1 , wherein the mechanical deformation is conducted prior to the dewatering. 
     
     
         10 . The process of  claim 2 , wherein the heat is introduced by a source selected from the group consisting of a heated roller, oven, burner, infrared radiation, and combinations thereof. 
     
     
         11 . The process of  claim 1 , wherein the nonwoven comprises cellulose-based fibers at least 50 wt % of the nonwoven. 
     
     
         12 . The process of  claim 1 , wherein the nonwoven comprises a spunlace web. 
     
     
         13 . The process of  claim 1 , wherein the mechanical deformation process is a process selected from the group consisting of an aperture forming process, a protrusion forming process, an embossing forming process and combinations thereof. 
     
     
         14 . The process of  claim 1 , wherein the water content of a nonwoven is adjusted by applying moisture to the nonwoven. 
     
     
         15 . The process of  claim 1 , wherein the water content of a nonwoven is adjusted by applying moisture to a pre-determined area in the nonwoven. 
     
     
         16 . The process of  claim 8 , wherein the water content of a nonwoven is adjusted by drying the nonwoven. 
     
     
         17 . The process according to  claim 1 , wherein the process further comprises the step of (c) drying the deformed nonwoven, so that the deformed nonwoven has a water content of less than about 12% by weight of the deformed nonwoven. 
     
     
         18 . The process of  claim 1 , wherein the nonwoven comprises a first layer comprising cellulose-based fibers and a second layer comprising thermoplastic fibers. 
     
     
         19 . A process for producing a deformed nonwoven comprising;
 (a) subjecting a fibrous web to an entanglement process to obtain a nonwoven,   (b) adjusting a water content of the nonwoven such that the nonwoven comprises at least one area having a water content of at least about 12% by weight of the nonwoven, and   (c) subjecting the nonwoven to a mechanical deformation process, the deformation process comprising mechanical deformation of the nonwoven, and dewatering of the nonwoven.   
     
     
         20 . The process according to  claim 19 , wherein the entanglement process is a hydroentanglement process or a needle punching process. 
     
     
         21 . The process according to  claim 19 , wherein the mechanical deformation and the dewatering are carried out simultaneously.