US2004117916A1PendingUtilityA1

Non-destructive treatment process with uniform coverage

47
Priority: Dec 23, 2002Filed: Dec 23, 2002Published: Jun 24, 2004
Est. expiryDec 23, 2022(expired)· nominal 20-yr term from priority
Inventors:Braulio PolancoChristopher Fenwick
D04H 13/00D06B 23/24D06B 15/04A61F 13/51305A61F 13/15577
47
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Claims

Abstract

A non-destructive method of treating a nonwoven web resulting in uniform coverage throughout the web. The method includes saturating the nonwoven web in a treatment bath including at least one surfactant in an aqueous solution at a concentration between about 0.2% and about 8%, using one or more vacuums to extract excess bath from the nonwoven web, and using a dryer to evaporate water from the web. Add-on level of the treatment can be controlled through the vacuum air velocity, treatment concentration, and line speed. The invention further includes apparatus for carrying out the non-destructive treatment method.

Claims

exact text as granted — not AI-modified
What is claimed is:  
     
         1 . A method of treating a nonwoven web, comprising: 
 saturating the nonwoven web in a treatment bath having a concentration between about 0.2% and about 8%;    using at least one vacuum to extract excess bath from the nonwoven web; and    using a dryer to evaporate water from the nonwoven web.    
     
     
         2 . The method of  claim 1 , wherein the treatment bath comprises at least one surfactant in an aqueous solution.  
     
     
         3 . The method of  claim 2 , wherein the treatment bath further comprises a dye.  
     
     
         4 . The method of  claim 2 , wherein the treatment bath comprises between about 0.2% and about 8% of the at least one surfactant in the aqueous solution.  
     
     
         5 . The method of  claim 2 , wherein the treatment bath comprises between about 0.5% and about 4% of the at least one surfactant in the aqueous solution.  
     
     
         6 . The method of  claim 1 , further comprising transporting the nonwoven web from the treatment bath to the at least one vacuum at a line speed up to 2000 feet per minute.  
     
     
         7 . The method of  claim 1 , further comprising transporting the nonwoven web from the treatment bath to the at least one vacuum at a line speed between about 50 and about 200 feet per minute.  
     
     
         8 . The method of  claim 1 , further comprising using the at least one vacuum to control the percent add-on level to between about 0.5% and about 4% weight by solids.  
     
     
         9 . The method of  claim 1 , wherein the at least one vacuum has an air velocity between about 100 and about 3000 feet per minute.  
     
     
         10 . The method of  claim 1 , comprising using a plurality of vacuums to extract excess bath from the nonwoven web.  
     
     
         11 . The method of  claim 1 , further comprising pulsing the at least one vacuum to create zone treatment.  
     
     
         12 . The method of  claim 11 , wherein the zone treatment is in one of a cross direction, a machine direction, and a combination thereof.  
     
     
         13 . The method of  claim 1 , wherein the dryer is set at a temperature between about 200 and about 250 degrees Fahrenheit.  
     
     
         14 . The method of  claim 1 , further comprising winding the nonwoven web onto a spool.  
     
     
         15 . The method of  claim 1 , wherein the nonwoven web has between about 25% and about 300% wet pick-up of the treatment bath.  
     
     
         16 . The method of  claim 1 , wherein the nonwoven web has a thickness of at least 0.08 inches.  
     
     
         17 . The method of  claim 1 , wherein the nonwoven web has a thickness of between about 0.1 and about 1.5 inches.  
     
     
         18 . The method of  claim 1 , wherein the nonwoven web has a basis weight between about 34 and about 500 grams per square meter.  
     
     
         19 . The method of  claim 1 , wherein the nonwoven web has a density of less than about 0.08 grams per cubic centimeter.  
     
     
         20 . The method of  claim 1 , wherein the nonwoven web has a density of less than about 0.06 grams per cubic centimeter.  
     
     
         21 . The method of  claim 1 , wherein the nonwoven web has a density of less than about 0.04 grams per cubic centimeter.  
     
     
         22 . A method of treating a hydrophobic nonwoven web, comprising: 
 saturating the nonwoven web in a treatment bath including at least one surfactant in an aqueous solution at a concentration between about 0.2% and about 8%;    using at least one vacuum to extract excess bath from the nonwoven web and to control percent add-on level of the treatment to between about 0.5% and about 4% weight by solids;    using a dryer to evaporate water from the nonwoven web.    
     
     
         23 . The method of  claim 22 , wherein the treatment bath comprises between about 0.5% and about 4% of the at least one surfactant in the aqueous solution.  
     
     
         24 . The method of  claim 22 , wherein the treatment bath further comprises a dye.  
     
     
         25 . The method of  claim 22 , further comprising transporting the nonwoven web from the treatment bath to the at least one vacuum at a line speed up to about 2000 feet per minute.  
     
     
         26 . The method of  claim 22 , further comprising transporting the nonwoven web from the treatment bath to the at least one vacuum at a line speed between about 50 and about 200 feet per minute.  
     
     
         27 . The method of  claim 22 , wherein the at least one vacuum has an air velocity between about 100 and about 3000 feet per minute.  
     
     
         28 . The method of  claim 22 , comprising using a plurality of vacuums to extract excess bath from the nonwoven web.  
     
     
         29 . The method of  claim 22 , further comprising pulsing the at least one vacuum to create zone treatment.  
     
     
         30 . The method of  claim 29 , wherein the zone treatment is in one of a cross direction, a machine direction, and a combination thereof.  
     
     
         31 . The method of  claim 22 , wherein the dryer is set at a temperature between about 200 and about 250 degrees Fahrenheit.  
     
     
         32 . The method of  claim 22 , further comprising winding the nonwoven web onto a spool.  
     
     
         33 . The method of  claim 22 , wherein the nonwoven web has between about 25% and about 300% wet pick-up of the treatment bath.  
     
     
         34 . The method of  claim 22 , wherein the nonwoven web has a thickness of at least 0.08 inches.  
     
     
         35 . The method of  claim 22 , wherein the nonwoven web has a thickness of between about 0.1 and about 1.5 inches.  
     
     
         36 . The method of  claim 22 , wherein the nonwoven web has a basis weight between about 34 and about 500 grams per square meter.  
     
     
         37 . The method of  claim 22 , wherein the nonwoven web has a density of less than about 0.08 grams per cubic centimeter.  
     
     
         38 . The method of  claim 22 , wherein the nonwoven web has a density of less than about 0.06 grams per cubic centimeter.  
     
     
         39 . The method of  claim 22 , wherein the nonwoven web has a density of less than about 0.04 grams per cubic centimeter.  
     
     
         40 . Apparatus for treating a nonwoven web, comprising: 
 a treatment bath having a concentration between about 0.2% and about 8%;    at least one vacuum;    a dryer;    a device for transporting the nonwoven web from the treatment bath to the at least one vacuum to the dryer.    
     
     
         41 . The apparatus of  claim 40 , wherein the treatment bath comprises at least one surfactant in an aqueous solution.  
     
     
         42 . The apparatus of  claim 41 , wherein the treatment bath further comprises a dye.  
     
     
         43 . The apparatus of  claim 41 , wherein the treatment bath comprises between about 0.2% and about 8% of the at least one surfactant in the aqueous solution.  
     
     
         44 . The apparatus of  claim 41 , wherein the treatment bath comprises between about 0.5% and about 4% of the at least one surfactant in the aqueous solution.  
     
     
         45 . The apparatus of  claim 40 , wherein the at least one vacuum has an air velocity between about 100 and about 3000 feet per minute.  
     
     
         46 . The apparatus of  claim 40 , further comprising at least one rotary valve attached to the at least one vacuum.  
     
     
         47 . The apparatus of  claim 40 , comprising a plurality of vacuums.  
     
     
         48 . The apparatus of  claim 40 , wherein the dryer is set at a temperature between about 200 and about 250 degrees Fahrenheit.  
     
     
         49 . The apparatus of  claim 40 , wherein the device for transporting the nonwoven web from the treatment bath to the at least one vacuum to the dryer has a line speed up to about 2000 feet per minute.  
     
     
         50 . The apparatus of  claim 40 , wherein the device for transporting the nonwoven web from the treatment bath to the at least one vacuum to the dryer has a line speed between about 50 and about 200 feet per minute.  
     
     
         51 . The apparatus of  claim 40 , further comprising a spool onto which the nonwoven web can be wound.

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