Hydraulically entangled nonwoven material and method for making it

Abstract

A wetlaid or foam formed hydraulically entangled nonwoven material containing at least 30%, by weight, pulp fibres and at least 20%, by weight, man-made fibres or filaments. The material has a basis weight variation in a non-random pattern in that it comprises a plurality of higher basis weight cushions protruding from one major surface of the material. The cushions as a main component comprise pulp fibres and are surrounded by a lower basis weight network which as a main component comprises the man-made fibres or filaments. The invention further refers to a method for making the material.

1 . A method of producing a nonwoven material comprising wetlaying or foamforming a fiber dispersion to form a fibrous web containing at least 30%, by weight, pulp fibres and at least 20%, by weight, man-made fibres or filaments, calculated on the total weight of the fibres in said fibrous web, and hydroentangling the fibrous web followed by subsequent dewatering and drying, 
 wherein at least part of the hydroentangling step is performed on a foraminous support member in the form of a moulded, close-meshed screen of a thermoplastic material, said screen having apertures of cross-dimensional size 0.2-4 mm and the distance between the apertures being between 0.2-4 mm.    
     
     
         2 . The method as claimed in  claim 1 , 
 wherein the cross-dimensional size of the apertures in said screen is 0.5-2 mm and the distance between the apertures is between 0.5-2 mm.    
     
     
         3 . The method as claimed in  claim 1 , 
 wherein the fibrous web is formed on a formation wire and is subjected to a first hydroentangling while supported on said formation wire, and is then transferred to said moulded, close-meshed screen where it is subjected to a further hydroentangling.    
     
     
         4 . The method as claimed in  claim 3 , 
 wherein said further hydroentangling is performed from an opposite side of the fibrous web as compared to the first hydroentangling.    
     
     
         5 . The method as claimed in  claim 1 , 
 wherein the web after dewatering is subjected to non-compacting drying.    
     
     
         6 . The method as claimed in  claim 5 , 
 wherein the non-compacting drying is selected from through air drying and IR drying.    
     
     
         7 . The method as claimed in  claim 5 , 
 wherein no pressing of the fibrous web takes place during dewatering and drying.