Method for making a fibruous absorbent material

Abstract

An absorbent material including a fibrous material having a plurality of individual fibers forming a fiber matrix, a plurality of absorbent fibers, wherein the plurality of absorbent fibers are impregnated within the fiber matrix by means of a needlepunch process.

What is claimed: 
     
         1 . A method for making an absorbent material comprising the steps of:
 providing a fibrous material including a plurality of individual fibers forming a fiber matrix;   depositing a plurality of absorbent fibers on a top surface of the fibrous material; and   impregnating the plurality of absorbent fibers into the fiber matrix by means of a needlepunch process.   
     
     
         2 . The method according to  claim 1 , wherein each of the plurality of individual fibers has fiber diameter within the range of between about 11 μm and 100 μm. 
     
     
         3 . The method according to  claim 2 , wherein each of the plurality of absorbent fibers has fiber diameter with the range of between about 10 μm and 40 μm. 
     
     
         4 . The method according to  claim 3 , wherein each of the plurality of individual fibers has a fiber diameter that is at least 1 μm greater than a fiber diameter of each of the absorbent fibers. 
     
     
         5 . The method according to  claim 1 , wherein the fibrous material has a thickness prior to the plurality of absorbent fibers being impregnated within the fibrous material and wherein the absorbent material has a thickness after the absorbent fibers have been impregnated within the fibrous material. 
     
     
         6 . The method according to  claim 5 , wherein a percent change between the thickness of the fibrous material prior to the plurality of absorbent fibers being impregnated therein and a thickness of the absorbent material after the absorbent fibers have been impregnated within the fibrous material is less than 50%. 
     
     
         7 . The method according to  claim 6 , wherein the percent change is less than 30%. 
     
     
         8 . The method according to  claim 7 , wherein the percent change is less than 15%. 
     
     
         9 . The method according to  claim 1 , wherein the fibrous material is a fibrous non-woven material. 
     
     
         10 . The method according to  claim 9 , wherein the fibrous non-woven material is formed from a plurality of fibers selected from the group consisting of polyester, nylon, co-polyester, polyethylene, polypropylene, polylactic acid and combinations thereof. 
     
     
         11 . The method according to  claim 10 , wherein the fibrous non-woven is made by one of an airlaid process, a card and bind process or a resin and adhesive bond process. 
     
     
         12 . The method according to  claim 11 , wherein the plurality of absorbent fibers are selected from the group consisting of hard wood pulp, soft wood pulp, rayon, cotton, and combinations thereof. 
     
     
         13 . The method according to method according to  claim 4 , wherein the needlepunch process is carried out by means a plurality of individual pins adapted to impregnate the absorbent fibers within the fiber matrix. 
     
     
         14 . (canceled)