Hydroentangled nonwoven composite structures containing recycled synthetic fibrous materials

Abstract

A hydraulically entangled nonwoven composite structure that includes a matrix of substantially continuous filaments; and recycled synthetic fibers and fiber-like materials having at least one thread element composed of synthetic material with at least one irregular distortion generated by hydraulic fracture of the thread element to separate it from a bonded fibrous material while the bonded fibrous material is suspended in a liquid. This nonwoven composite structure may be used as a wiper or an absorbent material. A method of forming the nonwoven composite structure includes the steps of: (a) providing a layer of recycled synthetic fibers and fiber-like materials having at least one thread element composed of synthetic material containing at least one irregular distortion generated by hydraulic fracture of the thread element to separate it from a bonded fibrous material while the bonded fibrous material is suspended in a liquid; (b) superposing the layer of recycled fibers and fiber-like materials over a layer of substantially continuous filaments; (c) hydraulically entangling the layers to form a nonwoven web; and (d) drying the web.

What is claimed is:  
     
         1 . A hydraulically entangled nonwoven composite structure comprising: 
 a matrix of substantially continuous filaments; and    a fibrous material comprising recycled synthetic fibers and fiber-like materials having at least one thread element composed of synthetic material including at least one irregular distortion generated by hydraulic fracture of the thread element to separate it from a bonded fibrous material while the bonded fibrous material is suspended in a liquid.    
     
     
         2 . The hydraulically entangled nonwoven composite structure of  claim 1 , wherein the thread element has a length ranging from about 1 millimeter to about 15 millimeters.  
     
     
         3 . The hydraulically entangled nonwoven composite structure of  claim 2 , wherein the thread element has a length ranging from about 1.5 to about 10 millimeters.  
     
     
         4 . The hydraulically entangled nonwoven composite structure of  claim 3 , wherein the thread element has a length ranging from about 2 to about 5 millimeters.  
     
     
         5 . The hydraulically entangled nonwoven composite structure of  claim 1 , wherein the irregular distortions are in the form of bends in the thread element, flattened segments of thread element, expanded segments of thread element and combinations thereof.  
     
     
         6 . The hydraulically entangled nonwoven composite structure of  claim 1 , wherein the thread elements of the recycled materials have surface areas that are greater than comparable thread elements in the bonded fibrous material prior to hydraulic fracture of the thread element to separate it from the bonded fibrous material.  
     
     
         7 . The hydraulically entangled nonwoven composite structure of  claim 6 , wherein the surface areas of the recycled thread elements are at least about 5 percent greater than comparable thread elements in the bonded fibrous material prior to hydraulic fracture of the thread element to separate it from the bonded fibrous material.  
     
     
         8 . The hydraulically entangled nonwoven composite structure of  claim 1 , wherein the synthetic material is a synthetic thermoplastic material.  
     
     
         9 . The hydraulically entangled nonwoven composite structure of  claim 1 , further comprising pulp fibers.  
     
     
         10 . The hydraulically entangled nonwoven composite structure of  claim 9  comprising: 
 from about 1 to about 85 percent, by weight, recycled synthetic fibers and fiber-like materials;  
 from about 15 to about 99 percent, by weight, pulp fibers; and  
 from about 1 to about 30 percent, by weight, substantially continuous filaments.  
 
     
     
         11 . The hydraulically entangled nonwoven composite structure of  claim 1  having a basis weight of from about 20 to about 200 grams per square meter.  
     
     
         12 . The hydraulically entangled nonwoven composite structure of  claim 1 , wherein the recycled synthetic fibers and fiber-like materials are selected from polyesters, polyamides, polyolefins and combinations thereof.  
     
     
         13 . The hydraulically entangled nonwoven composite structure of  claim 1 , wherein the pulp fibers are selected from the group consisting of virgin hardwood pulp fibers, virgin softwood pulp fiber, secondary fibers, and mixtures of the same.  
     
     
         14 . The hydraulically entangled nonwoven composite structure of  claim 1 , further comprising clays, starches, particulates, and superabsorbent particulates.  
     
     
         15 . The hydraulically entangled nonwoven composite structure of  claim 1 , further comprising up to about 3 percent of a de-bonding agent.  
     
     
         16 . A wiper comprising one or more layers of the hydraulically entangled nonwoven composite structure of  claim 1 , said wiper having a basis weight from about 20 gsm to about 200 gsm.  
     
     
         17 . The wiper according to  claim 16  having a basis weight from about 40 to about 150 gsm.  
     
     
         18 . A method of making a hydraulically entangled nonwoven composite structure, the method comprising: 
 providing a layer of recycled synthetic fibers and fiber-like materials comprising at least one thread element composed of synthetic material having at least one irregular distortion generated by hydraulic fracture of the thread element to separate it from a bonded fibrous material while the bonded fibrous material is suspended in a liquid;    superposing the layer of recycled synthetic fibers and fiber-like materials over a layer of substantially continuous filaments    hydraulically entangling the layers to form a nonwoven web; and    drying the web.    
     
     
         19 . The method of  claim 18  wherein the steps of providing the layer of recycled synthetic fiber and fiber-like materials and superposing the layer of recycled synthetic fibers and fiber-like materials over a layer of substantially continuous filaments comprises depositing a layer of the recycled fibers and fiber-like materials directly on a layer of substantially continuous filaments by dry forming or wet-forming techniques.  
     
     
         20 . The method of  claim 19  wherein pulp fibers are included within the layer of recycled synthetic fiber and fiber-like materials.