Method for improved aperture clarity in three-dimensional nonwoven fabrics and the products thereof

Abstract

The present invention is directed a nonwoven fabric which is imparted with a three-dimensional image or pattern, and apertures essentially devoid of fiber, during the fabrication stage. The nonwoven fabric exhibits a fibrous extension out of the plane of the material, while apertures are present that have a pronounced uniformity and a significant reduction in fibrous occlusion.

What is claimed is:  
     
         1 . A nonwoven fabric, comprising; 
 a prebond fibrous matrix of staple length fibers,    a three-dimensional transfer device,    hydroentangling the prebond fibrous matrix on the three-dimensional transfer device so as to impart a three-dimensional and at least one aperture into the resultant nonwoven fabric, and    the three-dimensional nonwoven fabric exhibiting a bulk of at least 1.5 millimeters and a clarity of aperture of at least 0.06.    
     
     
         2 . A nonwoven fabric, comprising; 
 a prebond fibrous matrix of staple length fibers,    a three-dimensional transfer device,    hydroentangling the prebond fibrous matrix on the three-dimensional transfer device so as to impart a three-dimensional and at least one aperture into the resultant nonwoven fabric, and    the three-dimensional nonwoven fabric exhibiting a bulk of at least 1.5 millimeters and a clarity of aperture wherein the area of the apex of a graphical projection is greater than 50% of the area at the base of the projection when measured in a Photometric Analysis.