Multilayered nonwoven fabric containing micron fibers, a method of manufacture, an apparatus, and articles made from multilayered nonwoven fabrics

Abstract

This document presents a novel method of manufacturing multilayered nonwoven fabrics consisting of micron fibers, hydroentangled, meltfibrillated, and/or spunlaid web layers. The composite multilayered webs contain one or more micron fiber web layers (fibers with a diameter from 1-10 microns) placed between inner and outer layers of hydroentangled, meltfibrillated, and/or spunlaid web, forming a fabric that may be utilized in the manufacture of articles which serve as barriers, wipes or sorbent materials, or may have other potential applications. The created novel composite multilayered fabric may have increased loft, softness and bending length, and may be formed from a broad selection of natural, synthetic, and recycled polymers, including petroleum- and plant-based, allowing polymer selection based on article lifecycle.

What is claimed is: 
     
         1 . An apparatus comprising:
 one or more laydown stations, two or more layer feeders, and a moving conveyor belt;   said one or more laydown stations, the two or more layer feeders having at least a guide and/or roller, and the moving conveyor belt forming a multilayered nonwoven fabric having a base layer, at least one working fiber layer where each fiber has a diameter of one to ten microns, and an upper layer;   where a first layer feeder mechanism is positioned at an initial start position of the moving conveyor belt and is located prior to a position of said one or more laydown stations and moves said multilayered nonwoven fabric physically past said one or more laydown stations;   where said one or more laydown stations further comprise one or more melt fibrillation nozzles;   where any of said two or more layer feeders places said base layer of said multilayered nonwoven fabric onto said conveyor belt;   where at least one of said one or more laydown stations creates a polymeric fiber web layer of said multilayered nonwoven fabric by extruding a polymeric melt through at least one of said one or more melt fibrillation nozzles and an associated fluid stream emanating from an orifice of said at least one or more melt fibrillation nozzles;   where said extruded polymeric melt is then subjected to an entraining fluid to form the at least one working fiber web layer comprising fibers with diameters of one to ten microns formed on an upper surface of said base layer by said at least one of the one or more melt fibrillation nozzles;   where a second layer feeder mechanism is positioned at an end position of the moving conveyor belt and beyond a physical location of said one or more laydown stations;   where said conveyer belt then moves said multilayered nonwoven fabric physically out of the laydown apparatus;   where the moving conveyor belt moves said multilayered nonwoven fabric through the apparatus to create said multilayered nonwoven fabric containing the working fibers with diameters of one to ten microns.   
     
     
         2 . The apparatus according to  claim 1 , where any of said one or more laydown stations comprises said one or more melt fibrillation nozzles and said one or more fluid streams to extrude an elongated hollow tube of the polymeric melt that is subject to the entraining fluid to create said working fiber web layer material comprised of fibers with diameters of one to ten microns as one layer of said multilayered nonwoven fabric. 
     
     
         3 . The apparatus according to  claim 2 , where said one or more laydown stations further comprises utilizing said entraining fluid to form the microfibers and submicron fibers ranging from about 0.1 to about 50 microns to create one or more layers of said multilayered nonwoven fabric. 
     
     
         4 . The apparatus according to  claim 1 , where said first layer feeder mechanism introduces a pre-formed individual base layer such that the moving conveyor belt carries the individual base layer beneath the one or more laydown stations. 
     
     
         5 . The apparatus according to  claim 1 , where said second layer feeder mechanism introduces an individual pre-formed top layer such that the individual top layer is positioned vertically above said working fiber web layer comprised of fibers with diameters of one to ten microns and previously created by said one or more laydown stations. 
     
     
         6 . The apparatus according to  claim 2 , further comprising a consolidation device bonding said multilayered nonwoven fabric containing said working fiber web layer to said base layer after said working fiber web layer is formed. 
     
     
         7 . The apparatus according to  claim 6 , where the consolidation device is a calender. 
     
     
         8 . The apparatus according to  claim 6 , where the consolidation device is an ultrasonic welder.