Durable, absorbent spunlaced fabric structures

Abstract

This invention relates to making nonwoven fabrics which are durable for machine washing and durable for other wet and hard use or abusive applications. The inventive fabrics comprise two layers of fabric sheet bonded together at closely spaced locations where the bonding includes fibers from both fabrics thoroughly involved with the binder. The inventive fabrics retain the qualities of a spunlaced nonwoven fabric which include low cost, comfort, drapability, softness, absorbency, breathability and others while having the durability comparable to traditional knitted or woven fabrics.

We claim:  
     
         1 . A process of forming an absorbent, durable fabric comprising the steps of: 
 providing a first layer of fabric comprising fibers wherein at least a portion of the fibers have a Z component orientation    providing a second layer of fabric comprising fibers wherein at least a portion of the fibers have a Z component orientation;    positioning adhesive material onto one of the first or second layer;    overlying one layer of fabric over the other to form a sandwich with the adhesive material between the first and second layers; and    activating the adhesive material to form discrete globules encompassing fibers in each of said layers together such that portions of the Z component fibers are substantially surrounded by some of the globules,    dyeing the durable fabric with one of either a direct dye or a reactive dye,    washing the durable fabric under alkaline conditions to increase fibrillation.    
     
     
         2 . The process according to    claim 1    wherein the step of activating the adhesive material comprises heating.  
     
     
         3 . The process according to    claim 1    wherein the step of activating further comprises pressing the fabric layers together while the adhesive material is being heated.  
     
     
         4 . The process according to    claim 1    wherein the step of positioning adhesive material comprises laying a mesh comprising interconnected points of adhesive with fine portions connecting the points in a network.  
     
     
         5 . The process according to    claim 1    wherein the step of positioning adhesive material comprises depositing small drops of adhesive material on one layer.  
     
     
         6 . The process according to claim I wherein the step of activating the adhesive material comprises passing the sandwich through a heated calender to heat and compress the fabric layers into the melting adhesive material.  
     
     
         7 . The process according to    claim 6    further comprising preheating at least one of said fabric layers prior to the heated calender.  
     
     
         8 . The process according to    claim 1    wherein the first fabric layer is a nonwoven hydroentangled fabric sheet.  
     
     
         9 . The process according to    claim 1    wherein the second fabric layer is a nonwoven hydroentangled fabric sheet.  
     
     
         10 . A durable absorbent material made by the process of either of claims  1 - 9 .  
     
     
         11 . The durable absorbent material of    claim 10    wherein the fibers of the first layer and the fibers of the second layer are lyocell.  
     
     
         12 . A chamois-type material made from the material of either    claim 10    or    11   .