Launderable and durable mechanically bonded nonwoven fabric

Abstract

In at least one aspect of the present disclosure, a field durable, repeatably launderable nonwoven fabric is provided including a cross-lapped and needle punched nonwoven fabric that is bonded together by entangling fibers with hydroentanglement.

What is claimed is: 
     
         1 . A field durable, repeatably launderable nonwoven fabric comprising:
 a plurality of fibers formed into a cross-lapped and needle punched nonwoven fabric, said fabric being bonded together by entangling said plurality of fibers with hydroentanglement,   said fabric capable of being laundered at least 25 times per AATCC 135 standard testing method using a home laundering machine with substantially no fabric damage and pilling.   
     
     
         2 . The nonwoven fabric of  claim 1 , wherein said plurality of fibers are inherently fire resistant without chemical treatment. 
     
     
         3 . The nonwoven fabric of  claim 2 , wherein said plurality of fibers are not bonded by thermal or chemical means for retention of textile drape for apparel use. 
     
     
         4 . The nonwoven fabric of  claim 1 , wherein the reduction in tear strength of said fabric is less than 40% after 25 home launderings when tested per ASTM D-5734. 
     
     
         5 . A field durable, repeatably launderable nonwoven fabric comprising:
 a plurality of fire resistant fibers formed into a cross-lapped and needle punched nonwoven fabric,
 said fabric being bonded together by entangling said plurality of fire resistant fibers with hydroentanglement, 
 said fabric capable of being laundered at least 25 times per AATCC 135 standard testing method using a home laundering machine with substantially no fabric damage and pilling. 
   
     
     
         6 . The nonwoven fabric of  claim 5 , wherein said plurality of fire resistant fibers are inherently fire resistant without chemical treatment. 
     
     
         7 . The nonwoven fabric of  claim 5 , wherein said plurality of fire resistant fibers are not bonded by thermal or chemical means for retention of textile drape for apparel use. 
     
     
         8 . The nonwoven fabric of  claim 5 , wherein the reduction in tear strength of said fabric is less than 40% after 25 home launderings when tested per ASTM D-5734. 
     
     
         9 . A process for preparing a field durable, repeatably launderable nonwoven fabric comprising:
 carding a plurality of fibers to form a series of fibrous webs;   cross-lapping said series of fibrous webs;   needle punching said series of cross-lapped fibrous webs; and   bonding together said plurality of fibers with hydroentanglement to form a nonwoven fabric,
 wherein said fabric is capable of being laundered at least 25 times per AATCC 135 standard testing method using a home laundering machine with substantially no fabric damage and pilling.