Apertured hydro-patterned nonwoven and method of making the same

Abstract

A method of forming an apertured hydro-patterned nonwoven web including the steps of forming a nonwoven batt comprising continuous spunmelt fibers, calender bonding the nonwoven batt to form a fully bonded precursor nonwoven web with a regular bond pattern that defines individual bond impressions and unbonded areas between the individual bond impressions, the regular bond pattern having a percentage bond area of 10% to 25%, and hydraulically imparting the fully bonded precursor nonwoven web with a plurality of apertures, the step of hydraulically imparting comprising hydraulically treating the fully bonded precursor nonwoven web by a plurality of steps of water injection as the fully bonded nonwoven web passes over a plurality of pins.

1 . A method of forming an apertured hydro-patterned nonwoven web, comprising:
 providing a bonded precursor nonwoven web with a bond pattern that defines individual bond impressions and unbonded areas between the individual bond impressions; and   hydraulically treating the bonded precursor nonwoven web by one or more steps of water injection as the bonded precursor nonwoven web passes over a plurality of pins to form a plurality of apertures in the bonded precursor nonwoven web.   
     
     
         2 . The method of  claim 1 , wherein each of the pins have a base portion and a top portion, where the area of the base portion is larger than the area of the top portion. 
     
     
         3 . The method of  claim 1 , wherein each pin is symmetrical with respect to a longitudinal axis of the pin. 
     
     
         4 . The method of  claim 1 , wherein each pin has a base, and distances between centers of immediately adjacent pins are at least 100% of a diameter of the base. 
     
     
         5 . The method of  claim 1 , wherein the step of hydraulically treating comprises applying water jets applied to the bonded precursor nonwoven web at an angle of 80 to 100° with respect to the bonded precursor nonwoven web. 
     
     
         6 . The method of  claim 1 , wherein the step of hydraulically treating the bonded precursor nonwoven web to form a plurality of apertures comprises at least partially altering the individual bond impressions by application of water pressure. 
     
     
         7 . The method of  claim 6 , wherein the step of at least partially altering results in at least 60% of bonded portions of the individual bond impressions remaining after the step of hydraulically imparting. 
     
     
         8 . The method of  claim 6 , wherein the step of at least partially altering results in at least 70% of bonded portions of the individual bond impressions remaining after the step of hydraulically imparting. 
     
     
         9 . The method of  claim 6 , wherein the step of at least partially altering results in at least 80% of bonded portions of the individual bond impressions remaining after the step of hydraulically imparting. 
     
     
         10 . The method of  claim 6 , wherein the step of at least partially altering results in at least 90% of bonded portions of the individual bond impressions remaining after the step of hydraulically imparting. 
     
     
         11 . The method of  claim 6 , wherein the step of at least partially altering results in separating the individual bond impressions into at least two portions. 
     
     
         12 . The method of  claim 6 , wherein the step of at least partially altering results in fibers in areas around perimeters of the individual bond impressions randomly frayed in and out of a major plane of the f bonded precursor nonwoven web so as to at least partially eliminate three-dimensionality of the individual bond impressions. 
     
     
         13 . Apertured hydro-patterned nonwoven web produced according to  claim 1 . 
     
     
         14 . Apertured hydro-patterned nonwoven web according to  claim 13 , wherein a basis weight of the web is 60 gsm or less. 
     
     
         15 . Apertured hydro-patterned nonwoven web according to  claim 13 , wherein the web has an MD tensile strength of at least 4 N/cm. 
     
     
         16 . Apertured hydro-patterned nonwoven web according to the  claim 13 , wherein the web has a CD tensile strength of at least 2 N/cm. 
     
     
         17 . Apertured hydro-patterned nonwoven web according to  claim 13 , wherein the web has a caliper of at least 12 microns/gsm of fabric. 
     
     
         18 . Apertured hydro-patterned nonwoven web according to  claim 13 , wherein the web does not exhibit two sidedness in terms of abrasion rating. 
     
     
         19 . Apertured hydro-patterned nonwoven web according to  claim 13 , wherein the web does not exhibit two sidedness in terms of coefficient of friction. 
     
     
         20 . Apertured hydro-patterned nonwoven web according to  claim 13 , wherein the web has a visual aperture clarity of at least 3 on a scale of 1 to 5.