SE412777B - PROCEDURE FOR THE PREPARATION OF A TUFFATED NON-WOVEN WATER-MADE FIBROST COAT MATERIAL USING A WATER-CONTAINING FIBER DISPERSIBLE MEDIUM AND FITTING FIBER COLLECTING ELEMENT - Google Patents

Description

7403106-3 2 to "fall" like fabric. Typical examples of this fiber rearrangement technique are found in U.S. Pat. Nos. 2,862,251, 3,042,576 and 3,081,515.

Other techniques for imparting to the nonwoven fibrous materials some of the properties of the woven fabrics include the use of a needle punching process which forms "pins" of fibers, which increases the structural integrity of the web while improving flexibility and feel. According to yet another technique, the surface is lightly brushed in order to give a raised roughened surface, which shows improved softness, see for example U.S. Pat. No. 3,101,520, or electrostatic fiber flocculation is used to achieve a comparable roughened surface. According to further technology, a creep- or loop-shaped method is used either alone or in combination with needle punching. The nonwoven fabrics, which contain the loop-shaped fibers, tend to mimic the properties of the loop configuration in woven terry cloth and exhibit improved softness as well as high height.

In almost all known techniques, it is necessary to first form a web which is then subjected to further structure-changing treatment in order to achieve the desired properties. In addition, in many cases the originally non-woven materials are not produced according to the more economical wet paper production technique, thereby further increasing the cost of the finished product. Some advances have been made in the manufacture of patterned webs using wet paper papermaking techniques, with reference to the double-wire technique described in U.S. Pat. No. 3,322,617 and techniques disclosed in U.S. Pat. No. 2,940,891.

Despite these previous attempts, it appears that a wet paper making technique has not previously been used to give a tufted nonwoven towel product exhibiting height, softness, mass, absorption property and "fall", such as Turkish towel fabric. A key factor in the difficulty of producing such materials according to the prior art has been the inability of the wet process to produce materials of high height and with a high concentration of absorbent relatively loose and flexible yet strong and strong fibers extending outwardly from the web main mass. .

The object of the present invention is thus to provide, by means of wet technology for papermaking, pile-provided or tufted non-woven fibrous web materials with high height and exhibiting softness, fall, feeling, mass and absorbency corresponding to woven loop materials such as terry towel fabric or so-called Turkish towel cloth. The invention is characterized in that the aqueous fiber dispersing medium in the initially indicated web material is given a controlled fluid viscosity of 3cP or more, that the average hollow surface of the openings in the fiber collecting element in the web material is given a size of at least twice the x 10-4 cm2 large area of the openings is 7¿f03106-3 a flat wire, that in the viscous medium a sufficient amount of water-dispersible fibers is dispersed to give a fiber concentration of at least approx. 0.02% by weight and that the fibers from the dispersion are deposited on the fiber collecting element to form a tufted nonwoven fibrous web with the tufts formed by bundles of loosely bonded individual fibers extending through the openings in the element.

A better understanding of the invention is obtained by the following detailed description and accompanying drawings, in which Fig. 1 is a flow chart of some steps used in the manufacture of web materials of the present invention; Fig. 2 illustrates the progressive manner in which the tufted web material is formed; Fig. 3 is a photograph of the surface of the present web material at a magnification of 10X and Fig. 4 is a photograph of a section through the web material of Fig. 2 with approximately the same magnification.

The tufted nonwoven aqueous fibrous web material is produced according to the invention by a papermaking process which involves the use of a coarse web-forming element and coupled to a viscosity controlled fiber dispersing medium. This technique results in a non-woven material with a high concentration of separate nonwovens or nonwovens extending from the surface of the web material at substantially red angles thereto as they are formed. This tufted nonwoven fabric can be better understood by first considering the structure of both towel material and nonwoven looped and pile woven fabrics.

Turkish towel fabric or terry towel material is a loosely woven fabric characterized by a pile comprising a large number of individual loops of thread extending outwardly from the main mass of the fabric. These individual loops give a flexible or resilient mattressed effect and bend or change shape easily when used not only to give the soft feeling of large mass or high height but also to have a larger thread surface in order to perform the desired absorbent and drying function.

Non-woven looped fabrics of high height are similar in any of the materials mentioned above but have a flexible adhesive backing with fibers which are individually loop-shaped and outwardly directed from the backing and adhesively embedded in the backing. The fabric can be formed by first producing a dry-shaped grooved substrate web of fibers arranged in a straight line with a fiber length of about 5 to 7.6 cm. The web is then provided with a lattice-like pattern of adhesive and stretched to maintain the grouping of rectilinear fibers. The adhesive is vulcanized and the fibers in the fabric are looped by feeding the web to a collection sheet.

In the past, textile fabrics have been given improved softness by lightly brushing their surfaces to raise a fibrous pile or mat of individual fibers.

This technique has also been applied to nonwoven web materials, but has often resulted in significant loss of strength. It has been reported that by proper adhesion the strength of the material is maintained while the brushed fibers are allowed to individually extend outwards from the main mass of the material to give the desired softness.

The tufted nonwoven fabric made according to the invention has a characteristic surface which differs considerably from both loop material and conventional webs with a brushed or pileed surface. Instead, the surface, as shown in Figs. 3 and 4, is characterized by a large number and high concentration of separate fiber bundles or tufts extending outwardly from the main fibrous main portion of the web. The many fibers in each tuft end in free fiber ends, which are randomly separated by different distances from the fibrous main mass. Despite the random location of the free fiber ends, the fiber tufts have a slightly tapered appearance very reminiscent of a lock of hair, in that they are firmly attached to the main body of the web and taper to their greatest length near the center of the bundle or tuft. As best seen in Fig. 3, the long tufts tend to show a waviness along their length and rest loosely on the surface of the web material. Since each tuft consists of a plurality of loosely assembled or bundle-shaped fibers, yet each fiber is substantially arranged in a straight line with and fairly independent of other fibers within the tuft, and the tufts show significant flexibility, flexibility, flexibility and softness, which also imparts the web material. great height, mass and absorption property. Unlike "pins", which are made by needle punching methods, the fibers in the tufts are not bent or interrupted and the tufts do not have a pronounced central pore or cavity. As can be seen from the following description, the number of fibers in each tuft varies and the concentration of tufts mainly depends on the process conditions used in the production of the web material.

The fibers that form the tufts receive their extensive orientation during web formation by regulating a number of factors associated with wet paper production. The main factor included in this technique, however, is the production of suitable fluid dynamics in the system at the time when the fibers are first precipitated on the fiber collecting element and formed into the nonwoven web. Although all the factors associated with the fluid dynamics of the system are not fully understood due to their complicated interrelationships, it has been noted that best results are obtained by laminar flow through the paper-shaped element under controlled fluid-drained conditions. The laminar flow apparently tends to orient the fibers in their perpendicular, substantially straight positions relative to the web without at the same time causing the fibers to pass completely through the collecting element.

Two of the factors considered important for achieving the optimum fluid flow conditions required for a tufted nonwoven fabric made in accordance with the present invention are (1) the use of a relatively coarse papermaking element such as a wire sorter or perforated plate with thicker entire areas. and larger open areas relative to a standard planar paper wire and (2) controlled viscosity in the fiber dispersion used to form the nonwoven material. Other factors, which are interrelated to the two stated significant properties, also affect the formation of the desired tufted nonwoven material. Thus, mention may be made, inter alia, of the consistency or fiber concentration of the dispersion, the vacuum required to effect the removal of dispersion medium, the type and composition of fibers used, and the denier and length of the fibers and the basis weight of the resulting product.

As stated, one of the primary and necessary factors in connection with the new and improved technology of the present invention is the use of fiber collecting or papermaking elements which are much coarser than normal in the papermaking industry used elements to obtain basis weights exhibited by the products. prepared according to the present invention. As is known, standard planar wires normally consist of fine wire elements and have the same approx. 60 - 100 threads per 2.5 cm in each direction, the threads having a thickness or diameter of approx. 0.014 cm. The sorting elements used in the present invention are well much larger than normal 0.795 mm for flat wires; they are in fact about 0.35 mm or more and preferably about 1.41 to 0.71 mm. In addition, the thickness of the entire areas is at least twice that of a flat wire and can be four or five times thicker or wider. Thus, suitably apertured plates or sorting machines can be used with good results.

The coarse paper-forming sorting machines or wires, such as the type known as "wired" or "twisted cable" or the recently developed plastic sorting machines, are usually preferred. These have wire thicknesses of at least 0.030 cm, preferably 0.045 to 0.089 cm, resulting in drainage openings which usually have an average hollow surface area which is about 2 to 60 times larger than the approximate 5.9 x 10 'cm 2 surface area of the plant. wire openings. It is understood that the exact type of sorting machine and the size used will vary depending on the products desired, the type, denier and length of fibers used in the stock, the consistency of the stock as well as the viscosity of the suspension fluid and the degree of vacuum applied to the web. -3 6 formation. Of course, and in fact preferably, the open or coarse sorting machines tend to give an undulated web structure and waviness of the tufts, which also increases the visible mass and height of the nonwoven material and is believed to impart improved feel, fall and appearance to the resulting product. . The open and coarse structure of the sorting machine or plate allows greater laminar flow of dispersing fluid through the openings in the perforated fiber collecting member during web formation so that the fibers are driven into the orientation required to give the desired tufted structure. At the same time, the size of the openings in the sorting machine or plate should not be so large that the fibers in the fiber dispersion are not retained or "suspended" on the sorting machine during the web forming process and the size of the closed areas should not be so large as to affect drainage of the fiber dispersion. The exact size required is that which is large enough to provide the desired fluid flow during drainage but at the same time small enough to allow the required fiber collection when the fiber dispersion medium passes rapidly through the sorting machine.

According to the present invention, advantage is gained in that a non-woven mesh fabric or gauze fabric can be used as the first fiber collecting element.

In this case, the sorting machine and the openings in the gauze facilitate tuft formation while at the same time the gauze is embedded in the nonwoven fibrous web which is deposited thereon. Such an arrangement greatly strengthens the web without undue loss of the softness of the tufted material.

As previously stated, the web-shaped element preferably consists of a sorting wire with a dimension of about 0.35 mm or higher constructed of plastic wires or of twisted cable wires. According to the present invention, it has been found that sorting machines with as few as 8 threads per 2.5 cm and containing openings with an average hole area which is as much as sixty times larger than with conventional web-shaped elements can be used effectively. Although threads from different sources vary, a few typical examples of thread sizes are listed in Table I along with some of their physical properties. In general, the size of the hollow surface relates to the fiber diameter, since the thicker fibers more effectively form tufts on the coarser lower mesh machines. For most uses, an average hollow surface area between about 18.75 x 10-4 and 125 x 10_4 cm 2 is preferred, although the exact degree of hollow surface used or the exact sorting machine size varies considerably depending on numerous other considerations of the process.

A second important feature of the papermaking technique of the present invention involves the use of a viscous dispersing fluid for the fibers. This means that the dispersing fluid has a higher viscosity than water. The high viscosity allows the advantageous use of innumerable fibers and mixtures thereof, which have not previously been used for papermaking according to the wet method, including mixtures of textile staple fibers with fibers of considerably shorter length. The viscous solution used to disperse the fibers prevents the formation of fiber clumps in the dispersion and reduces the tendency of the dispersed fibers to entangle. In addition, the dispersing medium maintains the fibers in their dispersed state during drainage and ensures a more uniform fiber distribution in the resulting web material, whereby properties of improved flexibility, softness and fall are obtained in the produced material. In fact, the viscous medium of the present invention greatly widens the number and type of fibers that can be used. At present, only dispersions in which all the fibers consist of very short wood fibers are inefficient for forming a well-tufted web. However, this is mainly due to the openings in the sorting machine used for the short fibers and cannot be entirely attributed to the viscosity of the dispersing medium. On the other hand, the dispersing medium allows the use of 100 percent natural or synthetic papermaking or textile staple fibers or suitable mixtures thereof.

As a general rule, the dispersing medium should have a viscosity greater than approx. three cP. Although some tufting can be obtained even at this low viscosity level, when other process properties are suitably controlled and where selected fibers are used, a viscosity higher than ten cP is required to achieve good results. Preferably, a viscosity level of 30 cP and higher is used to achieve best results. The viscosity actually used varies and for practical applications it can be as high as 250 -300 cP. As is to be understood, certain practical considerations determine the upper limit, since extremely high viscosities can tend to adversely affect the drainage properties of the system. Other practical limitations relating to the operability of the paper machine include the vacuum available to remove the dispersion medium without breaking through the web, the extractability of the medium and the effect of its residual presence in the web as well as the economy associated with the system.

The viscosity control material may be a natural or synthetic material or mixtures thereof. However, the preferred viscosity control materials are high molecular weight plastics, such as water-soluble polymers formed by the polymerization of acrylamide. These polymers are preferably used because dilute aqueous solutions thereof can be easily controlled to achieve the desired viscosity at the drainage area of the system. The preferred acrylamide polymer used is a material sold by the Dow Chemical Company under the name "Separan AP-30".

Other materials such as polyethylene oxide sold by Union Carbide Corporation under the name "Polyox WSR 310", as well as selected viscosity-giving carboxymethylcellulose solutions may also be used. In addition, other conventionally used materials which provide controlled viscosity in aqueous solutions containing water-soluble synthetic polymer electrolytes of methacrylic acid and their copolymer as well as natural viscosity-giving materials such as decomposable enzymes, mixtures of natural and synthetic rubber materials and inorganic salts can be used. According to the preferred embodiment, however, the viscosity regulating material is a material which is stable to shear forces, which can be added to the headbox and which maintains its viscosity up to and through the drainage area of the system.

As previously stated, the particular type of web-shaped elements used and the particular viscosity used for the dispersing medium depend on other interrelated factors such as the type, denier and length of fibers used in the fiber dispersion. It is particularly advantageous that tufted webs can be manufactured from a large number of different natural and synthetic papermaking and textile fibers. For example, synthetic or man-made papermaking or textile staple fibers can be used, e.g. Rayon, nylon, polyesters or vinyl polymers or copolymers are used either alone or in combination with natural fibers such as bleached or unbleached kraft pulp, manilla hemp, jute and similar papermaking fibers. In addition, inorganic fibers such as glass, quartz, ceramics, mineral wool, asbestos and similar materials can be used.

The synthetic fibers can vary in both denier and length, although fibers with lower denier numbers are generally preferred. Fibers with about 1 to 1.5 denier per thread (dpt) to about 15 dpt and more have been used successfully and have given excellent results. However, with materials having higher denier numbers, it is usually necessary to use a lower fiber concentration and a more viscous dispersant medium. As can be seen, the highest and lowest denier numbers used depend on many other related factors such as product requirements, machine operating conditions, consistency, size of the sorting machine or wire, etc.

The length of synthetic fibers used depends largely on the particular wire or sorting machine used, and ranges from about 0.31 cm or higher up to several cm and may be of the straight cut-taw type used in papermaking or of shrinkage. or straight textile staple fibers.

As stated, the finer denier material having a length of about 1.25 to 1.90 cm or higher is preferably used in order to impart improved softness to the material, while maintaining the desired height and absorbent properties of the material. Mixtures using natural and synthetic papermaking fibers with lengths down to 0.16 cm or less can also be used depending on the special properties and characteristics required in the final product. 9 7aoz1oe-3 In addition to the length and denier of fibers used, the fiber consistency or concentration in the dispersion must be carefully controlled before web formation takes place to facilitate the formation of the tufted structure. As a general rule, the lowest fiber concentration or consistency consistent with good release of the resulting product from the web-forming wire is most desirable for best tufting. Thus, a fiber concentration in the range of from about 0.02 to about 1.0 percent may be used, with the preferred range being between about 0.05 and 0.5 percent fiber concentration. In standard laboratory operations, a fiber concentration of about 0.1 per cent has been found to give uniformly good results. The consistency of large paper machines varies, of course, with the machine conditions.

The fiber concentration and the viscosity of the dispersant medium also affect the degree of vacuum or suction that must be applied to the underside of the paper-shaped element during web forming in order to achieve the desired tufted effect. Although good tufting can be obtained under suitable conditions even in the absence of vacuum, it is generally preferred that vacuum be applied to the underside of the web-forming wire in order to ensure proper fluid dynamics of the system. However, these variations depend not only on the fiber concentration and the viscosity of the dispersant but also on other factors associated with these systems, such as the roughness of the wire and the type and length of fibers used.

Another factor that must be considered when using the technique of the present invention is the weight of the material produced. The technology described herein can produce a tufted product with weights as low as about 17 g / m2 and min and with as low as 8.5 g / m2. Dynkq lamtvikfigm material can, however, only be produced with very fine control over other factors associated with the technology and the basis weights of most materials are at least 34 g / m2.

It can be seen that the formation of the tufted structure begins at the beginning of the web forming process and it is in fact assumed that the tuft is the first portion of the web formed when the fibers are draped over the entire area of the web forming element and pulled through the intermediate opening due to system fluid dynamics. This is indicated illustratively in Fig. 2. As the web becomes increasingly thicker, more fibers are precipitated both in the tufts or bundles and in the main mass of the web until the desired basis weight and strength are achieved.

In the case that the precipitation of fibers ends when only the original tuft formation has taken place, it can be noted that even if a network of tufts has formed, the material shows very low strength, is mainly lacking in sheet nature and could not be removed from the web-shaped wire. In addition, it has been found that when the basis weight exceeds about 204 g / m2, few if any further precipitated fibers participate in the tuft formation, but form only a mat at the top of the tufted substrate but in little or no fiber integration 'MÛ3106-3 w with the tufts. Although the many factors set forth herein are all interrelated to give the desired tufted structure, it has been observed that certain generalized governing provisions may be established. In this regard, it has been found that the best results are obtained when using the highest possible fluid viscosity compatible with the operation, the lowest possible fiber consistency consistent with good release from the web-forming element and the lowest fiber denier acceptable for the product requirements. It has also been found that longer fibers not only give longer tufts but also assist in detachment from the wire, due to the stronger web being produced. In addition, it has been observed that coarser wires give better tufts than fine wire structures and that fibers with lower denier give a better tufted product than fibers with higher denier regardless of the length of the fibers used. In this context, and as mentioned before, the fibers with higher denier usually require a coarser wire and also higher viscosity as well as lower consistency than corresponding fibers having finer denier. For example, a fiber with a value of 1.5 dpt provides an acceptable tufted product at a viscosity of 50 cP and a fiber concentration of about 0.2 percent while comparable results can only be obtained with a 15 dpt fiber at a viscosity of 150 cP. cP and a consistency of 0.1 percent. As can also be seen, the lower basis for basis weight of tufted product varies with the thickness of the wire used, so that a material with a lower basis weight can be obtained with a finer forming wire than with a coarser wire.

As shown, the tufts are formed only on one side of the material and products having tufts on both sides can be easily formed by arranging tufted web materials back-to-back. Mutual locking of folds and the incorporation of reinforcing or binding agents can be used in the usual way either during or after the web formation. Subsequent softening or other treatments can also be used.

In order that the present invention may be more readily understood, it will be further described with reference to the following particular embodiments, which are given for illustrative purposes only and are not intended to limit the invention: EXAMPLE I A fiber dispersing medium having a viscosity of 150 cP was prepared as a 0.15% aqueous solution of a water-soluble polyacrylamide ("Separan AP-30"). Sufficient 1.9 cm 15 dpt rayon staple fibers were added to the viscous medium to give a 0.1% fiber dispersion. The fiber dispersion was poured into a hand sheet mold equipped with a 0.71 x 1.19 mm bronze cable wire and having an average hollow surface area of 50.8 x 10-4 cm 2 and drained by means of a vacuum. The resulting fibrous product was an excellent tufted web of basis weight of 86.7 g / m 2.

H 71103106-3 EXAMPLE II According to the general procedure of Example I, a 0.1% fiber dispersion of 1.9 cm 1.5 denier rayon staple fibers dispersed in a polyacrylamide solution ("Separan AP-30") having a viscosity of 50 cP. The fiber dispersion is poured into a hand sheet mold provided with a regular weaving wire with a dimension of 1.19 x 1.19 mm of polyester with openings having an average hollow surface of about 76.25 x 10.4 cm2. Vacuum was applied to the underside of the wire and a nonwoven web material was prepared having excellent tufting properties and a basis weight of about 86 g / m 2.

EXAMPLE III The procedure of Example II was repeated using a 0.05% fiber dispersion of 70% 0.95 cm 1.5 denier rayon staple fibers and 30% Weyerhauser Kraft in a solution of polyacrylamide ("Separan ÅP-30") with viscosity 25 cP. The resulting web material exhibited excellent tufting properties at a basis weight of 2,81.6 g / m 2.

EXAMPLE IV A 0.12% fiber dispersion was prepared from 1.12 cm 1.5 denier rayon staple fibers dispersed in a caraway rubber solution having a viscosity of 40 cP. The fiber dispersion was poured into a hand sheet mold provided with polyester wire measuring 1.19 x 1.19 mm according to Example II, after which a vacuum was applied to the underside of the wire to assist in removing the dispersing medium. An excellent nonwoven tufted fabric was produced having a basis weight of 224.4 g / m2.

EXAMPLE V A dispersion of 1.9 cm 1.5 denier rayon staple fibers was prepared in an aqueous solution of a solution of polyacrylamide ("Separan AP-30") having a viscosity of 50 cP and fed into the headbox of a paper machine having a fiber consistency of 0. 2%. The machine was equipped with a sloping bronze cable wire 0.71 x 1.00 mm with openings with an average hollow surface of approx. 44.37 x 10 'cm2. The dispersion was fed to the paper machine headbox without changing viscosity and drainage was assisted by vacuum. The resulting product was an excellent tufted fabric with a basis weight of 96.9 g / m 2.

The example was repeated using the regular 1.19 x 1.19 mm polyester woven fabric of Example II to again obtain excellent tufted nonwoven web material.

EXAMPLE VI As an example of the increased viscosity required to produce tufted products when using higher denier and less flexible fibers, the fibers listed below were dispersed in a solution of specified viscosity. In all cases, a tufted product was produced exhibiting excellent properties in terms of height, fall and feel comparable to textile products. fiber Denier Length (cm) Concentration Viscosity Glass 9 * 2.54 .os z 250 CP Rayon 15.0 dpf 1.9 .05% 150 cP Rayon 5.5 dpf 1.25 .1% 100 cP Rayon 3.0 dpf 1.25 .1% 50 cP Rayon 1.5 dpf 1.25 .25% 12 cP Rayon 1.5 dpf 1.9 .1% 3 cP x Diameter in microns. EXAMPLE VII The procedure of Example I was repeated using rayon staple fibers 1.5 denier and 0.48 cm long and nylon fibers 3 denier and 3.81 cm long. In all cases, the resulting web material exhibited excellent tufting properties, with the longer nylon fibers yielding tufts of substantially greater length than those made from the shorter rayon fibers.

EXAMPLE VIII The procedure of Example I was repeated using rayon fibers 1.5 denier and length 1.9 dm and a dispersion viscosity of 100 cP. The fiber consistency was 0.1% and sheets were produced exhibiting excellent tufting properties and with basis weights expressed in g / m2 of 20.3, 37.3, 57.8, 75, 88.5, 112.5, 129.5, 153, 235 and 306.

As previously stated, the tufted nonwoven fabric made in accordance with the present invention is particularly suitable for use in the manufacture of "disposable" products. These include not only washcloths, wipes, towels, cosmetic towels, nappy covers, sanitary napkins and the like, blankets, dishcloths, bandages, compresses and other medical articles, neck creams for hairdressers, headrests, dust-collecting felt materials, cloths and mops. all kinds but also clothing articles such as bathing suits and bathing jackets for single use, surgeons' mouth guards, disposable headgear and industrial and household clothing such as suits and clothing items including intermediate lining for clothing. The nonwoven web material can also be advantageously used for disposable bibs, washcloths, small rugs, face napkins, disposable drapes, mats and semi-hard mats, wall coverings, insulating materials including cryogenic insulation, obstetric cloths, sleeping bag liners, lining for bed cushions and bedspreads, protective covers or as a basis for a coating of fabric softening composition. The web material can also be used as a filter material for either air or liquid, such as coffee filters or infusion web materials such as for tea bags, and if treated appropriately it can be used as a coating substrate for various products such as synthetic leather substrates or as a replacement for internal inner linings. stiff canvas. By implication, laminated structures may also be formed from the nonwoven web material including laminates for reinforced layers of plastic film, laminated or shaped paper, light diffusers, lampshades or decorative paper for sliding doors or the material may be used in ropes, stretchable bags or sacks. used as upholstery for home furniture and automobiles. As can be seen, the stated list of areas of use must not be seen as exhaustive, but only form examples of the usefulness of the material produced according to the present invention.

As will be apparent to those skilled in the art, various modifications, adaptations and variations may be made in the foregoing description without departing from the scope of the invention. 14 7403106-3 00.000 000..0 800.0 000.0 000.0 _. ._ 00.0 1 00.0 0.00. 00010 008.0 000.0 000.0 ._ _. 00.0 1 0 ... 0.00. 000..0 008.0 000.0 000.0 000 280 280 0.0 .. 1 0 ... 0.00 0000.0 008.0 08.0 000.0 0030 0.030 0 ... 1 0 ... 0.00 000..0 008.0 08.0 000.0 000.3 230 00 .. 1 K.0 0.00 00.10 0000.0 000.0 000.0 330 0.030 .0 .. 1 .0.0 0..0 00 ... 0 00.000 000.0 .8.0 0080 0080 0 ... 1 .0.0 U m 0.00 0000.0 0000.0 000.0 .00.0 3000M09 ._ 00 .. 1 .0.0 0.00 008.0 008.0 000.0 000.0 330 02.00 .0.0 1 .0.0 0.0. 008.0 008.0 000.0 000.0 _. ._ 00.0 1 00.0 0.0. 00006 080.0 000.0 000.0 0080 280 .0.0 1 00.0 EE Amso + | 0- xv muHw: H mHo> muHwcH QHu> mo fi mca mHu> xm fi uovwmmc fl ymmï mN% Aeuv ocnuvmnv cu flfl ms ¶cmv0 <m fl fl A A A A

Claims (7)

1s- 7403106-3 Patent Claim Il II II Il ll Il II II Il Il A process for producing a tufted nonwoven aqueous fibrous web material by means of an aqueous fiber dispersing medium and an apertured fiber collecting element, characterized in that the aqueous fiber dispersing medium is given a controlled fluid viscosity of 3 cP or more, that the average hollow surface of the openings in the fiber collecting element is given a size of at least twice the area of 5.9 x 10 0.02% by weight and that the fibers from the dispersion were deposited on the fiber-joining element to form a tufted nonwoven fibrous web with the tufts formed by bundles of loosely bonded individual fibers extending through the openings in the element. A method according to claim 1, characterized in that the fiber collecting element is formed with openings of a size comparable to a wire with an opening size in the range of about 2.32 to 0.35 mm and that the viscous fiber dispersing medium is given a viscosity greater than 3 cP. A method according to claim 1, characterized in that the fiber collecting element is designed as a wire with dimensions of about 1.41 to 0.71 mm and with the average hollow surface of the openings in the wire lying in the range 18.75 x 10-4 : m2 to 125 x 10-4 cm2. A method according to claim 1, characterized in that the viscous fiber dispersing medium is formed with a viscosity of at least 10 cP and up to about 300 cP. The method of claim 1, wherein the fiber dispersing medium is an aqueous solution of a high molecular weight plastic and the water dispersible fibers comprise synthetic fibers having at least about 1.0 denier per wire and a length in the range of 0.32 up to 2.54 cm or more. A method according to claim 7, characterized in that the fiber concentration is formed in the range 0.05 to 0.5%. 7. A method according to claim 7, characterized in that the fiber dispersing medium is given a viscosity of at least 50 cP and that the removal of the dispersing medium from the collecting element when the fibers are deposited thereon is assisted by means of vacuum. PRESENTATIONS: US 3,322,617 (162-296), 3,511,740 (161-67)