Imaged nonwoven fabrics including meltblown fibers

Abstract

A nonwoven fabrics and composite nonwoven fabrics having a three-dimensional (3D) image imparted therein are provided. The nonwoven fabrics and composite nonwoven fabrics include a plurality of meltblown fibers physically entangled together either alone or in combination with a plurality of cellulosic fibers, and/or a plurality of spunbond fibers.

What is claimed is: 
     
         1 . A nonwoven fabric, comprising: a plurality of meltblown fibers consolidated together via physical entanglement of the plurality of meltblown fibers, and wherein the nonwoven fabric includes a three-dimensional (3D) image imparted therein. 
     
     
         2 . The nonwoven fabric of  claim 1 , wherein the plurality of meltblown fibers has an average diameter from about 5 to about 15 microns. 
     
     
         3 . The nonwoven fabric of  claim 1 , wherein the plurality of meltblown fibers comprise a polymer component and optionally an additive component, wherein the polymer component comprises at least one polyolefin, a propylene-containing copolymer, a polyethylene, an ethylene-containing copolymer, or any combinations thereof. 
     
     
         4 . The nonwoven fabric of  claim 3 , wherein the polymer component comprises from about 50% to about 100% by weight of at least one polyolefin. 
     
     
         5 . The nonwoven fabric of  claim 1 , further comprising a plurality of cellulosic fibers physically entangled with the plurality of meltblown fibers, wherein the plurality of cellulosic fibers comprise natural cellulose, synthetic cellulose, or a combination thereof. 
     
     
         6 . The nonwoven fabric of  claim 5 , wherein the plurality of meltblown fibers comprise from about 30% to 100% by weight of a total fiber weight of the nonwoven fabric. 
     
     
         7 . The nonwoven fabric of  claim 1 , wherein the nonwoven fabric is devoid of staple fibers. 
     
     
         8 . The nonwoven fabric of  claim 1 , wherein the 3D image comprises a 3D pattern on a first side of the nonwoven fabric and includes a plurality of recessed portions in a z-direction relative to an imaginary central plane extending through the nonwoven fabric in an x-y plane that is perpendicular to the z-direction. 
     
     
         9 . The nonwoven fabric of  claim 1 , wherein the 3D image comprises a 3D pattern on a first side of the nonwoven fabric and includes a plurality of elevated portions in a z-direction relative to an imaginary central plane extending through the nonwoven fabric in an x-y plane that is perpendicular to the z-direction. 
     
     
         10 . The nonwoven fabric of  claim 1 , further comprising one or more apertures extending completely through the nonwoven fabric. 
     
     
         11 . The nonwoven fabric of  claim 1 , wherein the plurality of meltblown fibers comprise a polymer component and optionally an additive component, wherein the additive component includes one or more fillers, one or more surfactants, one or more slip additives, or any combinations thereof. 
     
     
         12 . A composite nonwoven fabric, comprising:
 (i) a first layer comprising a nonwoven fabric according to  claim 1 ;   (ii) a second layer comprising a first meltspun nonwoven comprising a first plurality of spunbond fibers;   wherein the first plurality of spunbond fibers are physically entangled with the plurality of meltblown fibers, and wherein the composite nonwoven fabric includes a three-dimensional (3D) image imparted therein.   
     
     
         13 . The composite nonwoven fabric of  claim 12 , further comprising a third layer comprising a second meltspun nonwoven comprising a second plurality of spunbond fibers; wherein the second plurality of spunbond fibers are physically entangled with the plurality of meltblown fibers, the first plurality of spunbond fibers, or both. 
     
     
         14 . The composite nonwoven fabric of  claim 12 , wherein the 3D image comprises a 3D pattern on a first side of the composite nonwoven fabric and includes a plurality of recessed portions in a z-direction relative to an imaginary central plane extending through the composite nonwoven fabric in an x-y plane that is perpendicular to the z-direction. 
     
     
         15 . The composite nonwoven fabric of  claim 12 , further comprising one or more apertures extending completely through the composite nonwoven fabric. 
     
     
         16 . The composite nonwoven fabric of  claim 12 , wherein the composite nonwoven fabric comprises a basis weight from about 15 to about 200 grams-per-square-meter (gsm). 
     
     
         17 . A method of making a nonwoven fabric according to  claim 1 , comprising:
 (i) providing or forming a meltblown nonwoven web comprising a plurality of meltblown fibers;   (ii) hydroentangling the plurality of meltblown fibers together to form the nonwoven fabric, wherein hydroentangling the plurality of meltblown fibers together comprises applying at least one jet of fluid directly or indirectly onto the meltblown nonwoven web to consolidate the meltblown web and to impart a three-dimensional (3D) image into the nonwoven fabric.   
     
     
         18 . The method of  claim 17 , further comprising a first consolidation step to form an intermediate nonwoven fabric prior to imparting the 3D image into the nonwoven fabric. 
     
     
         19 . A method of making a hydroentangled composite nonwoven fabric, comprising:
 (i) providing or forming a composite nonwoven of juxtaposed webs or a composite nonwoven fabric both of which comprising (a) a first layer comprising a nonwoven web or fabric including a plurality of meltblown fibers alone or in combination with a plurality of cellulosic fibers, and (b) a second layer comprising a first meltspun nonwoven web or fabric comprising a first plurality of spunbond fibers;   (ii) hydroentangling the first layer and the second layer together to form the hydroentangled composite nonwoven fabric, wherein hydroentangling the first layer and the second layer together comprises applying at least one jet of fluid directly or indirectly onto the first layer, the second layer, or both to consolidate the first layer and the second layer together and to impart a three-dimensional (3D) image into the composite nonwoven fabric.   
     
     
         20 . The method of  claim 18 , further comprising a first consolidation step bonding the first layer and the second layer together to form an intermediate hydroentangled composite nonwoven fabric prior to imparting the 3D image into the hydroentangled composite nonwoven fabric.