Multi-layer nonwoven having a printed layer and products made therefrom

Abstract

A multi-layered nonwoven having a printed layer comprises a pair of outer layers, with each of the outer layers comprising a carded web. An inner layer is disposed between the outer layers and includes printed indicia, which may be in the form of text, graphics, colors, or other suitable indicia. The inner layer is bonded to each of the outer layers by hydroentanglement. A method of making such a nonwoven may include the steps of providing a pair of outer layers comprising carded webs, providing a pulp inner layer having printed indicia, positioning the inner layer between the outer layers, passing the outer layers and the inner layer together through a hydroentangling system to secure the inner layer to each of the outer layers to form a web, and drying the web.

1 . A nonwoven formed from multiple layers and having a printed layer and comprising:
 a fibrous layer;   a printed layer disposed adjacent the fibrous layer, the printed layer having indicia; and   wherein the printed layer is bonded to the fibrous layer by hydroentanglement.   
   
   
       2 . The nonwoven of  claim 1 , wherein the printed layer comprises a pulp material. 
   
   
       3 . The nonwoven of  claim 1 , wherein the indicia includes text or graphics. 
   
   
       4 . The nonwoven of  claim 1 , wherein at least a portion of the printed layer is colored. 
   
   
       5 . The nonwoven of  claim 1 , wherein the printed layer is hydroentangled to the fibrous layer in a first direction and in a second direction. 
   
   
       6 . The nonwoven of  claim 1 , wherein the nonwoven forms a web, and wherein the web is dried. 
   
   
       7 . The nonwoven of  claim 6 , wherein the web is moistened. 
   
   
       8 . The nonwoven of  claim 1 , wherein the fibrous layer comprises synthetic fibers formed of staple fibers. 
   
   
       9 . The nonwoven of  claim 1 , wherein the fibrous layer is formed of spun fibers. 
   
   
       10 . The nonwoven of  claim 1 , wherein the fibrous layer is formed of continuous fibers. 
   
   
       11 . The nonwoven of  claim 1 , wherein the fibrous layer comprises polypropylene fibers and rayon fibers in a ratio of about 3:2. 
   
   
       12 . A nonwoven formed from multiple layers and having a printed layer and comprising:
 a fibrous layer;   a printed layer disposed adjacent the fibrous layer, wherein the printed layer is colored; and   wherein the printed layer is bonded to the fibrous layer by hydroentanglement.   
   
   
       13 . A nonwoven having a printed layer and comprising:
 a pair of outer layers, at least one of the outer layers comprising a fibrous layer;   an inner layer disposed parallel to the outer layers and having printed indicia; and   wherein the inner layer is secured to each of the outer layers by hydroentanglement.   
   
   
       14 . The nonwoven of  claim 13 , wherein the second layer is disposed immediately adjacent to the first layer and comprises a pulp material. 
   
   
       15 . The nonwoven of  claim 13 , wherein the indicia includes at least one of text, graphics, or colors. 
   
   
       16 . The nonwoven of  claim 13 , wherein the inner layer is hydroentangled to the outer layers in a first direction and in a second direction. 
   
   
       17 . The nonwoven of  claim 13 , wherein the fibrous layer comprises carded fibers. 
   
   
       18 . The nonwoven of  claim 13 , wherein the fibrous layer comprises continuous fibers. 
   
   
       19 . The nonwoven of  claim 13 , wherein the synthetic web comprises high opacity polypropylene fibers and rayon fibers. 
   
   
       20 . An absorbent product having indicia and comprising:
 a wearable garment having an absorbent layer;   a fibrous layer;   a printed layer disposed adjacent the fibrous layer, the printed layer having indicia;   wherein the printed layer is bonded to the fibrous layer by hydroentanglement; and   wherein the hydroentangled layers are coupled to the garment.   
   
   
       21 . A nonwoven wipe having indicia and comprising:
 a nonwoven substrate comprising a fibrous layer;   a printed layer disposed adjacent the fibrous layer, the printed layer having indicia;   wherein the printed layer is bonded to the fibrous layer by hydroentanglement to form the wipe.   
   
   
       22 . The nonwoven wipe of  claim 21 , including a second nonwoven substrate comprising a fibrous layer, the printed layer disposed between the fibrous layers, and wherein the printed layer is bonded to both of the fibrous layers by hydroentanglement to form the wipe. 
   
   
       23 . A wipe product having indicia and comprising:
 a wearable mitt having a fibrous layer;   a printed layer disposed adjacent the fibrous layer, the printed layer having the indicia;   wherein the printed layer is bonded to the fibrous layer by hydroentanglement; and   wherein the hydroentangled layers form at least a portion of the wearable mitt.   
   
   
       24 . A bib product having indicia and comprising:
 a bib having a fibrous layer;   a printed layer disposed adjacent the fibrous layer, the printed layer having the indicia;   wherein the printed layer is bonded to the fibrous layer by hydroentanglement; and   wherein the hydroentangled layers form at least a portion of the bib.   
   
   
       25 . An absorbent diaper having indicia and comprising:
 an absorbent layer;   a fibrous layer;   a fastener securable to a landing zone;   a printed layer disposed adjacent the fibrous layer, the printed layer having indicia, at least a portion of the indicia disposed in the landing zone; and   wherein the printed layer is bonded to the fibrous layer by hydroentanglement.   
   
   
       26 . A method of manufacturing a nonwoven comprising the steps of:
 providing a fibrous layer;   providing a pulp layer having printed indicia;   positioning the pulp layer adjacent the fibrous layer;   passing the layers together through a hydroentangling system to secure the layers to one another.   
   
   
       27 . The method of  claim 26 , including the step of drying the layers. 
   
   
       28 . The method of  claim 26 , including the steps of providing a second fibrous layer, and positioning the printed layer between the fibrous layers prior to hydroentangling. 
   
   
       29 . The method of  claim 26 , including the step of passing the layers through the hydroentangling system multiple times. 
   
   
       30 . The method of  claim 29 , wherein the step of passing the layers through the hydroentangling system comprises directing water jets in a first direction, then a second direction different than the first direction.