US20140242324A1

US20140242324A1 - Laminate Fabrics

Info

Publication number: US20140242324A1
Application number: US14/188,482
Authority: US
Inventors: Walter Jones; Rebecca Klossner; James Flippin
Original assignee: Precision Fabrics Group Inc
Current assignee: Precision Fabrics Group Inc
Priority date: 2013-02-22
Filing date: 2014-02-24
Publication date: 2014-08-28

Abstract

The present invention provides laminate fabrics comprising two or more spunlaced fabric layers.

Description

RELATED APPLICATIONS

The present invention claims the benefit of priority under 35 U.S.C. §119(e) to U.S. Patent Application No. 61/767,984, filed Feb. 22, 2013, the disclosure of which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to laminate fabrics comprising two or more spunlaced fabric layers.

BACKGROUND

Spunlaced fabrics are produced by hydroentangling the fibers of a fibrous substrate such as a batt or web of fibers. See, e.g., U.S. Pat. No. 3,403,862.

SUMMARY OF THE CLAIMED INVENTION

A first aspect of the invention is a laminate fabric comprising a first nonwoven, spunlaced fabric layer and a second nonwoven, spunlaced fabric layer, wherein each nonwoven, spunlaced fabric layer comprises a three-dimensional pattern on its face. The first and second nonwoven, spunlaced fabric layers are laminated together such that the back of the first nonwoven, spunlaced fabric layer is coupled to the back of the second nonwoven, spunlaced fabric layer. Thus, the faces of the first and second nonwoven, spunlaced fabric layers face outward from the site of coupling. This combination of fabric characteristics and lamination, creates a laminate fabric that is textile-like in handle, flexibility, strength, and durability. In some embodiments, the first and second nonwoven, spunlaced fabric layers are coupled using an adhesive. In some embodiments, the laminate comprises a binder finish.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram depicting a cross-section of a laminate fabric according to some embodiments of the present invention.

FIG. 2 depicts four nonwoven, spunlaced fabric layers that may be incorporated into laminate fabrics of the present invention.

FIGS. 3A and 3B depict the face (A) and the back (B) of a nonwoven, spunlaced fabric layer that may be incorporated into laminate fabrics of the present invention.

FIG. 4 depicts a nonwoven, spunlaced fabric layer that may be incorporated into laminate fabrics of the present invention.

FIG. 5 depicts a nonwoven, spunlaced fabric layer that may be incorporated into laminate fabrics of the present invention.

FIG. 6 depicts a nonwoven, spunlaced fabric layer that may be incorporated into laminate fabrics of the present invention.

FIG. 7 depicts a nonwoven, spunlaced fabric layer that may be incorporated into laminate fabrics of the present invention.

DETAILED DESCRIPTION

The present invention is explained in greater detail below. This description is not intended to be a detailed catalog of all the different ways in which the invention may be implemented or of all the features that may be added to the instant invention. For example, features illustrated with respect to one embodiment may be incorporated into other embodiments, and features illustrated with respect to a particular embodiment may be deleted from that embodiment. In addition, numerous variations and additions to the various embodiments suggested herein, which do not depart from the instant invention, will be apparent to those skilled in the art in light of the instant disclosure. Hence, the following specification is intended to illustrate some particular embodiments of the invention, and not to exhaustively specify all permutations, combinations and variations thereof.
It will be understood that when an element or layer is referred to as being “on”, “attached to”, “connected to”, “coupled to”, “coupled with” or “contacting” another element or layer, it can be directly on, connected or coupled to the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to” or “directly coupled to” another element or layer, there are no intervening elements or layers present. It will be appreciated by those of skill in the art that a structure referred to as being “directly on,” “directly connected to, or “directly coupled to another structure may partially or completely cover one or more surfaces of the other structure. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another structure or feature may have portions that overlap or underlie the adjacent structure or feature.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and/or clarity.
As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
As used herein, the term “about,” when used in reference to a measurable value such as an amount of mass, dose, time, temperature, and the like, is meant to encompass variations of 20%, 10%, 5%, 1%, 0.5%, or even 0.1% of the specified amount.
As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
As used herein, the terms “comprise,” “comprises,” “comprising,” “include”, “includes” and “including” specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
As used herein, the term “consists essentially of” (and grammatical variants thereof), as applied to the compositions and methods of the present invention, means that the compositions/methods may contain additional components so long as the additional components do not materially alter the composition/method. The term “materially alter,” as applied to a composition/method, refers to an increase or decrease in the effectiveness of the composition/method of at least about 20% or more. For example, a component added to a composition of the present invention would “materially alter” the composition if it increases or decreases the composition's durability by at least 20%.
As used herein, the terms “increase” and “enhance” (and grammatical variants thereof) refer to an increase in the specified parameter of at least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more.
As used herein, the terms “inhibit” and “reduce” (and grammatical variants thereof) refer to a decrease in the specified parameter of at least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 99% or more.
As used herein, the term “three-dimensional pattern” refers to a discernible regularity in the three-dimensional structure of a fabric layer. In some embodiments, the three-dimensional structure of the fabric layer is discernibly regular over at least about 50%, 55%, 60%, 65%, 70%, 75% 80%, 85%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99% or 100% of the face of the fabric layer. A three-dimensional pattern may be formed in a nonwoven, spunlaced fabric by/during the hydroentangling process(es) used to produce the nonwoven, spunlaced fabric. That is, the parameters of the spunlacing process(es) used to produce a nonwoven, spunlaced fabric may be selectively adjusted such that the fibers in the fibrous substrate are reorganized to form a desired three-dimensional pattern. In some embodiments, the parameters of the spunlacing process(es) are adjusted to produce a nonwoven, spunlaced fabric whose three-dimensional pattern imparts textile-like absorbency, handle, flexibility, strength, and/or durability.
All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety.
The present invention provides laminate fabrics comprising, consisting essentially of or consisting of two or more nonwoven, spunlaced fabric layers.
As shown in FIG. 1, in some embodiments, the laminate fabric comprises a first nonwoven, spunlaced fabric layer 1 and a second nonwoven, spunlaced fabric layer 2, wherein each nonwoven, spunlaced fabric layer comprises a three-dimensional pattern 1 p, 2 p on its face 1 f, 2 f. The first and second nonwoven, spunlaced fabric layers are laminated together such that the back of the first nonwoven, spunlaced fabric layer 1 b is coupled to the back of the second nonwoven, spunlaced fabric layer 2 b (i.e., with the faces of the first and second nonwoven, spunlaced fabric layers 1 f, 2 f facing outward from the site of coupling 12). In some embodiments, the first and second nonwoven, spunlaced fabric layers 1, 2 are coupled using an adhesive 3. In some embodiments, the laminate fabric 0 comprises a finish that comprises one or more binders (not shown).
Nonwoven, spunlaced fabric layers may comprise any suitable three-dimensional pattern(s). In some embodiments, one or more of the nonwoven, spunlaced fabric layers comprises a three-dimensional pattern that mimics the three-dimensional texture of a woven textile (e.g., hopsack, terrycloth or twill). In some embodiments, one or more of the nonwoven, spunlaced fabric layers comprises a three-dimensional pattern such that one or more surfaces of the nonwoven, spunlaced fabric layer (e.g., the face of the nonwoven, spunlaced fabric layer) has an average surface roughness of at least about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 125, 150, 175, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, 1000 or more microns (as measured in accordance with the Kawabata Evaluation System (KES) using a KES-FB4 Surface Roughness Tester and/or as measured using a profilometer, for example). In some embodiments, one or more of the nonwoven, spunlaced fabric layers comprises a three-dimensional pattern such that one or more surfaces of the nonwoven, spunlaced fabric layer (e.g., the face of the nonwoven, spunlaced fabric layer) has an average surface roughness of about 5 to about 50 microns, about 25 to about 100 microns, about 100 to about 250 microns, about 250 to about 500 microns or about 500 to about 1000 microns (as measured in accordance with the KES using a KES-FB4 Surface Roughness Tester and/or as measured using a profilometer, for example). Surface roughness may be measured as the relief (in microns, for example) from the lowest point of the surface to the highest point of the surface. The differential of the coefficient of friction (COF) may also be measured. For an aggressive surface the change in COF is rougher generally for increased ΔCOF. In those embodiments wherein two or more of the nonwoven, spunlaced fabric layers comprise a three-dimensional pattern, their three-dimensional patterns may be the same or substantially the same. For example, the laminate fabric may comprise a first nonwoven, spunlaced fabric layer and a second nonwoven, spunlaced fabric layer, wherein the first and second nonwoven, spunlaced fabric layers comprise the same (or substantially the same) three-dimensional pattern.
Nonwoven, spunlaced fabric layers may comprise any suitable type(s) of fibers, including, but not limited to, natural fibers and synthetic fibers. In some embodiments, one or more of the nonwoven, spunlaced fabric layers comprises, consists essentially of or consists of natural fibers. For example, one or more of the nonwoven, spunlaced fabric layers may comprise, consist essentially of or consist of one or more of the following fiber types: bamboo, camel hair, graphite, cotton, flax, hemp, jute, polylactic acid, silk, sisal, wood pulp and wool (e.g., alpaca, angora, cashmere, chiengora, guanaco, llama, mohair, pashmina, sheep and/or vicuña). In some such embodiments, one or more of the nonwoven, spunlaced fabric layers comprises, consists essentially of or consists of one or more natural fibers selected from the group consisting of cotton, wood pulp and wool. In some embodiments, one or more of the nonwoven, spunlaced fabric layers comprises, consists essentially of or consists of synthetic fibers. For example, one or more of the nonwoven, spunlaced fabric layers may comprise, consist essentially of or consist of one or more of the following fiber types: acrylic, carbon, fluorocarbon, glass, lyocell, rayon, melamine, modacrylic, polyacrylonitrile (e.g., oxidized polyacrylonitrile), polyamide (e.g., nylon and/or aramid) polybenzimidazole, polyester, polyimides, polylactic acid, polyolefin (e.g., polyethylene and/or polypropylene), polyphenylene benzobisoxazole, polyphenylene sulfides, polyvinyl acetate, polyvinyl alcohol, polyvinyl chloride, polyvinyl fluoride, polyvinylidene chloride, viscose (e.g., silica-modified viscose) and zylon. In some such embodiments, one or more of the nonwoven, spunlaced fabric layers comprises, consists essentially of or consists of one or more synthetic fibers selected from the group consisting of acrylic, aramid (e.g., meta-aramid and/or para-aramid), modacrylic, nylon, polyester, polyethylene or polypropylene. In some embodiments, one or more of the nonwoven, spunlaced fabric layers comprises, consists essentially of or consists of cellulosic fibers. For example, one or more of the nonwoven, spunlaced fabric layers may comprise, consist essentially of or consist of one or more of the following fiber types: bamboo, cellulose acetate, cellulose triacetate, cotton, flax, hemp, jute, lyocell, ramie, sisal, viscose (e.g., silica-modified viscose), and wood pulp. In some such embodiments, one or more of the nonwoven, spunlaced fabric layers comprises, consists essentially of or consists of one or more cellulosic fibers selected from the group consisting of cotton, lyocell, viscose (e.g., silica-modified viscose), and wood pulp. In some embodiments, one or more of the nonwoven, spunlaced fabric layers comprises, consists essentially of or consists of bicomponent fibers. For example, one or more of the nonwoven, spunlaced fabric layers may comprise, consist essentially of or consist of one or more fibers comprising at least two distinct constituent monomers (e.g., polyester and polypropylene). In some embodiments, one or more of the nonwoven, spunlaced fabric layers comprises, consists essentially of or consists of continuous fibers. For example, one or more of the nonwoven, spunlaced fabric layers may comprise, consist essentially of or consist of one or more spunbonded fibers (e.g., flash spunbonded fibers), one or more meltblown fibers and/or one or more spunbonded-meltblown-spunbonded composite fibers.
Nonwoven, spunlaced fabric layers may be laminated together using any suitable means known in the art, including, but not limited to, adhesive bonding, needling, powder bonding, RF welding, thermal bonding and ultrasonic bonding. In some embodiments, two nonwoven, spunlaced fabric layers are laminated together by bonding the two layers at multiple, spaced apart locations, which may enhance the flexibility, softness and/or handle of the laminate fabric. For example, the two nonwoven, spunlaced fabric layers may be laminated together using a web or net of adhesive material (e.g., polyester, copolyester, polyamide, pressure sensitive SIS or SBS, APAO, polyolefin, EVA, urethane, moisture cure urethane, polypropylene, acrylic, and/or natural rubber) between the two layers. In some embodiments, the nonwoven, spunlaced fabric layers in the laminate fabric are not ultrasonicly bonded.
Nonwoven, spunlaced fabric layers may be laminated together in any suitable orientation. In some embodiments, the nonwoven, spunlaced fabric layers are laminated together such that the laminate fabric comprises a first three-dimensional pattern on its face and a second three-dimensional fabric on its back. For example, the laminate fabric may comprise two nonwoven, spunlaced fabric layers, each with a three-dimensional pattern on the face thereof, and the backs of the nonwoven, spunlaced fabric layers may be laminated together such that the face of one nonwoven, spunlaced fabric layer becomes the face of the laminate and the face of the other nonwoven, spunlaced fabric layer becomes the back of the laminate. In some embodiments, the nonwoven, spunlaced fabric layers are laminated together such that the three-dimensional patterns they comprise are aligned in the resultant laminate fabric. For example, the laminate fabric may comprise two nonwoven, spunlaced fabric layers, each with the same three-dimensional pattern on its face, and the nonwoven, spunlaced fabric layers may be laminated together such that three-dimensional pattern on the face of one nonwoven, spunlaced fabric layer is perfectly aligned with the three-dimensional pattern of the face of the other nonwoven, spunlaced fabric layer.
Nonwoven, spunlaced fabric layers and laminate fabrics may be treated with any suitable finish, including, but not limited to finishes that render the nonwoven, spunlaced fabric layer or laminate fabric more abrasion resistant, alcohol repellant, durable (e.g., wash durable and/or dry clean durable), elastic, electrically conductive, flame retardant, flexible, oil repellant, soil and/or stain repellant, UV resistant, anti-microbial, anti-fungal, low-linting, antistatic, wettable, absorbant and/or water repellant than it was prior to application of the finish. For example, the finish may comprise one or more substances that impart antimicrobial and/or antifungal properties to the nonwoven, spunlaced fabric layer or laminate fabric. Similarly, the finish may comprise one or more substances that impart color to the nonwoven, spunlaced fabric layer or laminate fabric. In some embodiments, the finish is predominantly or exclusively present on one or more surfaces of the nonwoven, spunlaced fabric layers or laminate fabric. For example, in a laminate fabric comprising two nonwoven, spunlaced laminate fabric layers, the finish may be predominantly or exclusively present on the face of one or both of the nonwoven, spunlaced fabric layers. In some embodiments, at least a portion of the finish is present in the interior of the nonwoven, spunlaced fabric layers or laminate fabric. For example, in a laminate fabric comprising two nonwoven, spunlaced laminate fabric layers, the finish may be present in the interior of one or both of the nonwoven, spunlaced laminate fabrics and/or in the boundary between the two nonwoven, spunlaced fabric layers. In some embodiments, the finish comprises, consists essentially of or consists of one or more substances that increase the durability of the nonwoven, spunlaced fabric layers or laminate fabric. For example, the finish may comprise one or more isocyanates (e.g., blocked ioscyanates). In some embodiments, the finish comprises, consists essentially of or consists of one or more flame retardant chemistries. For example, the finish may comprise one or more flame retardant antimony compounds (e.g., antimony oxides), one or more flame retardant boron compounds (e.g., ammonium borate, borax, boric acid, ethylammonium borate and/or zinc borate), one or more flame retardant halogen compounds (e.g., ammonium bromide, ammonium chloride, brominated/chlorinated binders and/or brominated/chlorinated paraffin), one or more flame retardant nitrogen compounds (e.g., ammonium polyphosphate), one or more flame retardant phosphorous compounds (e.g., ammonium borate, ammonium bromide, ammonium chloride, ammonium polyphosphate, ammonium sulfamate and/or ethanolylammonium borate) and/or one or more flame retardant sulfur compounds (e.g., ammonium sulfamate). In some such embodiments, the finish comprises, consists essentially of or consists of one or more flame retardant chemistries selected from the group consisting of phosphorous compounds and nitrogen compounds. In some such embodiments, the finish comprises, consists essentially of or consists of one or more flame retardant chemistries selected from the group consisting of ammonium polyphosphate and ammonium phosphate. In some embodiments, the finish comprises, consists essentially of or consists of one or more antistats. For example, the finish may comprise one or more salts, sodium chloride, sodium nitrate, sodium sulfate, phosphate esters and/or one or more quaternary ammonium compounds.
Nonwoven, spunlaced fabric layers and laminate fabrics may be finished using any suitable means known in the art, including, but not limited to, coating, corona discharge, dipping, hot melt application, pad finishing, plasma finishing, printing, rotogravure, slot-die application, spraying and vacuum metallization. In some embodiments, one or more of the nonwoven, spunlaced fabric layers is treated with a finish prior to its incorporation into the laminate fabric. In some embodiments, one or more of the nonwoven, spunlaced fabric layers is treated with a finish after it is incorporated into the laminate fabric. In some embodiments, the laminate fabric is treated with a finish following incorporation of all its nonwoven, spunlaced fabric layers. In some embodiments, each of the nonwoven, spunlaced fabric layers in the laminate fabric is treated with a finish that comprises one or more binders. In some embodiments, fewer than all of the nonwoven, spunlaced fabric layers in the laminate fabric is treated with a finish that comprises one or more binders.
Nonwoven, spunlaced fabric layers and laminate fabrics may undergo any suitable mechanical treatment known in the art, including, but not limited to, calendaring, creping, embossing, ring rolling and stretching. In some embodiments, one or more of the nonwoven, spunlaced fabric layers is mechanically treated prior to its incorporation into the laminate fabric. In some embodiments, the laminate fabric is mechanically treated following incorporation of all its nonwoven, spunlaced fabric layers.
Laminate fabrics of the present invention may demonstrate enhanced strength. In some embodiments, the strength of the laminate fabric is increased by at least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more as compared to a control fabric (i.e., a fabric that lacks the three-dimensional patterning of the laminate fabric but is otherwise identical to the laminate fabric). In some embodiments, the strength of the laminate fabric is increased by at least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more as compared to a single layer fabric having the same amounts/types of fibers, weight, thickness and finish as the laminate fabric. In some embodiments, strength is measured in accordance with INDA Standard Test Method WSP 110.1 (04) and/or INDA Standard Test Method WSP 110.5 (05).
Laminate fabrics of the present invention may demonstrate enhanced absorption capabilities. In some embodiments, the absorbency of the laminate fabric is increased by at least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more as compared to a control fabric (i.e., a fabric that lacks the three-dimensional patterning of the laminate fabric but is otherwise identical to the laminate fabric). In some embodiments, the absorbency of the laminate fabric is increased by at least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more as compared to a single layer fabric having the same amounts/types of fibers, weight, thickness and finish as the laminate fabric. In some embodiments, absorption is measured in accordance with INDA Standard Test Method WSP 10.1 (04).
Laminate fabrics of the present invention may demonstrate enhanced durability (e.g., wash durability, as measured by weight loss and/or shrinkage amounts after laundering). In some embodiments, the durability of the laminate fabric is increased by at least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more as compared to a control fabric (i.e., a fabric that lacks the three-dimensional patterning of the laminate fabric but is otherwise identical to the laminate fabric). In some embodiments, the durability of the laminate fabric is increased by at least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more as compared to a single layer fabric having the same amounts/types of fibers, weight, thickness and finish as the laminate fabric. In some embodiments, durability is measured in accordance with INDA Standard Test Method WSP 150.2 (05).
Laminate fabrics of the present invention may demonstrate enhanced abrasion resistance. In some embodiments, the abrasion resistance of the laminate fabric is increased by at least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more as compared to a control fabric (i.e., a fabric that lacks the three-dimensional patterning of the laminate fabric but is otherwise identical to the laminate fabric). In some embodiments, the abrasion resistance of the laminate fabric is increased by at least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more as compared to a single layer fabric having the same amounts/types of fibers, weight, thickness and finish as the laminate fabric. In some embodiments, absorption is measured in accordance with INDA Standard Test Method WSP 20.2 (05) and/or INDA Standard Test Method WSP 20.4 (03).
Laminate fabrics of the present invention may demonstrate enhanced skid resistance. In some embodiments, the skid resistance of the laminate fabric is increased by at least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more as compared to a control fabric (i.e., a fabric that lacks the three-dimensional patterning of the laminate fabric but is otherwise identical to the laminate fabric). In some embodiments, the skid resistance of the laminate fabric is increased by at least about 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 125%, 150%, 175%, 200%, 250%, 300% or more as compared to a single layer fabric having the same amounts/types of fibers, weight, thickness and finish as the laminate fabric. In some embodiments, skid resistance is measured in accordance with INDA Standard Test Method WSP 90.3 (05).
Accordingly, laminate fabrics of the present invention may be suitable for use in numerous applications, including, but not limited to, towels (e.g., dish towels, bar towels, wash towels, industrial shop tools, food service towels, scrubbing towels, bath towels, clean room towels and/or surgical towels), wipes (e.g., scrubbing wipes and/or cosmetic wipes), medical drapes, window treatments, mattresses, abrasive cloths, tack cloths, dust cloths, mops and car wash mitts.
As shown in Table 1 below, laminate fabrics of the present invention may exhibit properties comparable to those of woven towels.

TABLE 1

	Finished laminate
Finished laminate	comprising
comprising	adhesively bonded
adhesively bonded	wood pulp-polyester	Stan-
wood pulp-polyester	spunlaced fabric	dard
spunlaced fabric	layers (finished as	woven
layers (unfinished)	in Example 5 below)	towel
Avg.	Avg.	Avg.

Basis	3.10	2.78	6.03
Weight,
osy
Caliper, in	0.034	0.022	0.034
MD Grabs	50.0	45.1	28
XD Grabs	26.7	25.1	47.4
Wet	3.5	4.5	4
Crocking
Dry	4.5	5	5
Crocking
MD Bonds,	435.1	187	N/A
g/in
XD Bonds,	361.0	229.5	N/A
g/in
HOM, MD	32.2	25.4	9.725
HOM, XD	7.3	8.7	9.725
Water	1	1	1
Drop, s
Abs Rate,	4.0	2.8	3.3
s
Abs Cap, %	826.5	768.8	499
Dry	3839	759	326975
Particle
Count,
#/ft³/min

EXAMPLES

The following examples are not intended to be a detailed catalog of all the different ways in which the present invention may be implemented or of all the features that may be added to the present invention. Persons skilled in the art will appreciate that numerous variations and additions to the various embodiments may be made without departing from the present invention. Hence, the following descriptions are intended to illustrate some particular embodiments of the invention, and not to exhaustively specify all permutations, combinations and variations thereof.

Example 1

Laminate fabrics comprising two nonwoven, spunlaced fabric layers were formed. Each of the nonwoven, spunlaced fabric layers had a basis weight of approximately 2.2 osy and comprised approximately 55% wood pulp and approximately 45% polyester. Each of the nonwoven, spunlaced fabric layers had a face comprised predominantly of wood pulp fibers and an opposing face comprised predominantly of polyester fibers. Each of the nonwoven, spunlaced fabric layers was treated with a finish comprising 0.1% FoamPress NS-99, 0.3% Tergitol™ GR-5M (Dow®), 1.5% Trixene Aqua B.I. 201 (Baxenden Chemicals Ltd., United Kingdom) and 3.0% Binder VC-1 (Momentive Specialty Chemicals, Roebuck S.C.) (by weight, based upon the weight of the finish bath (% owb)). The finish was applied to each of the nonwoven, spunlaced fabric layers using a dip-and-nip application method with an approximate wet pick-up of 130%. Following application of the finish, each of the nonwoven, spunlaced fabric layers was dried and cured in a conventional tenter frame overn for approximately 20 seconds at 190° C. Griltex 1332 (EMS-CHEMIE AG (North America), Inc., Sumter, S.C.) was applied in discrete dots (187 dots per square inch) to the predominantly polyester face of one of the nonwoven, spunlaced fabric layers using a gravure application method with an approximate add-on weight of 20 grams per square meter. The predominantly polyester face of the other nonwoven, spunlaced fabric layer was placed against the adhesive-laden, predominantly polyester face of the first nonwoven, spunlaced fabric layer, and the two nonwoven, spunlaced fabric layers are nipped together by two rolls.
The laminate fabrics had a basis weight in the range of approximately 4.4 to 4.6 osy, a grab tensile of approximately 70 to 80 pounds in the machine direction and approximately 35 to 50 pounds in the cross direction, a bond strength of approximately 800 to 1000 grams/inch in both the machine and cross directions, a handle of approximately 80 to 115 grams in the machine direction and approximately 30 to 55 in the cross direction, and an absorption capacity of approximately 500 to 650 percent. The laminate fabric was durable to 180° F. industrial washing, with bleach, and 180° F. drying for at least 5 cycles.
The laminate fabrics were then compacted at 3-4% compaction to increase their drape. The laminate fabrics were compacted using a smooth roller on a micrex unit.
Each laminate fabric was approximately 17 inches long and approximately 19 inches wide.

Example 2

Several (17″×20″) swatches of greige 1.65 osy DuPont style 9995 woodpulp/polyester spunlaced fabric (light blue color) were finished in the lab. The fiber content of the fabric was 55% woodpulp fiber/45% polyester fiber. The swatches were finished using a dip and nip (saturation) type finish with the following finish components. The wet pick-up of the finish measured 106%. The lab oven temperature was set at 177° C. (350° F.) and the speed (dwell time) at 30 seconds.
Lab #320-146 Mix #1
Finish component Purpose % o.w.b.

FoamPress NS-99 Defoamer 0.1

Tergitol TMN-6 Surfactant 0.2

Propylene Glycol Processing aid 0.6

BY 16-876 Silicone rewetter 0.9

Ultraphil TG Surfactant 0.9

Water 97.3

Lab-finished swatches were stretched approximately 8.0% in the lab before being ultrasonically bonded using pattern #320-130A (small dot pattern). The ultrasonic bonding unit was set for a pressure of 35 psi, and amplitude of 85%. Two swatches were ultrasonically bonded together with the woodpulp sides facing out. The resulting laminate fabric had the physical properties described in Table 2 below.

TABLE 2

Basis weight (oz/yd2)		2.8
(ASTM D3776)
Grab Tensile (lbs.)	MD	35
(ASTM D5034)	XD	21
Elongation (%)	MD	52
(ASTM D5034)	XD	105
Bond strength (grams/inch)	MD	56
AATCC 136	XD	51
Caliper (inches)		0.025
(ASTM D1777)
Handle-o-meter	MD	30
(grams/force)
(4″ × 7″, 20 mm gap)	XD	13
(INDA 90.3)
Dry crock (rating)		4.5
(AATCC 8)
Wet crock (rating)		4.5
(AATCC 8)
Absorbency Rate (seconds)		1.5
(INDA 10.1)
Absorbent Capacity (%)		769
(INDA 10.1)
Total liquid capacity/sq.yd.		24.6
Ounces/sq. yard

Example 3

Laminate fabrics comprising two nonwoven, spunlaced fabric layers (Style 22016 from Spuntech Industries, Roxboro, Inc.) were formed. Each of the nonwoven, spunlaced fabric layers had a basis weight of approximately 2.5 to 3.0 osy and comprised of approximately 50% viscose and approximately 50% polyester. The out surface of each nonwoven, spunlaced fabric layer comprised about 60 to 95% viscose. Each of the nonwoven, spunlaced fabric layers was spunlaced from a layered web with a pattern that allowed for apertures and a texture surface. A rubber-based adhesive (577, 3M, Minneapolis, Minn.) was sprayed on the face of one of the nonwoven, spunlaced fabric layers with an approximate add-on weight of 10 grams per square meter. The other nonwoven, spunlaced fabric layer was placed against the adhesive-laden, polyester face of the first nonwoven, spunlaced fabric layer to form a laminate fabric having viscose-rich outer surfaces and the properties described in Table 3 below.

TABLE 3

Basis weight (oz/yd2)		5.65
(ASTM D3776)
Grab Tensile (lbs.)	MD	86
(ASTM D5034)	XD	50
Elongation (%)	MD	44
(ASTM D5034)	XD	108
Bond strength (grams/inch)	MD	na
AATCC 136	XD	na
Caliper (inches)		0.050
(ASTM D1777)
Handle-o-meter	MD	70
(grams/force)
(4″ × 7″, 20 mm gap)	XD	21
(INDA 90.3)
Dry crock (rating)		5
(AATCC 8)
Wet crock (rating)		5
(AATCC 8)
Absorbency Rate (seconds)		2.6
(INDA 10.1)
Absorbent Capacity (%)		784
(INDA 10.1)
Total liquid capacity/sq. yd.		43.9
Ounces/sq. yard

Example 4

A woodpulp/lyocell spunlaced fabric, style 8705, was obtained from the DuPont Company. This fabric was composed of 100% cellulose, with 55% of the web being woodpulp, and 45% of the web lyocell fiber. The fabrics exhibited strong orientation of the wood fibers to one side of the fabric with the viscose fibers residing on the other side. The fabrics were laminated using 3M 577 adhesive with the lyocell-rich surfaces facing towards the center (FIG. 4). The resulting laminate fabric had the physical properties described in Table 4 below.

TABLE 4

Basis weight (oz/yd2)		4.65
(ASTM D3776)
Grab Tensile (lbs.)	MD	40.3
(ASTM D5034)	XD	28.9
Elongation (%)	MD	23
(ASTM D5034)	XD	62
Bond strength (grams/inch)	MD	Na
AATCC 136	XD	Na
Caliper (inches)		.024
(ASTM D1777)
Handle-o-meter	MD	184
(grams/force)
(4″ × 7″, 20 mm gap)	XD	34
(INDA 90.3)
Dry crock (rating)		5
(AATCC 8)
Wet crock (rating)		4
(AATCC 8)
Absorbency Rate (seconds)		1.3
(INDA 10.1)
Absorbent Capacity (%)		569
(INDA 10.1)
Total liquid capacity/sq. yd.		26.5
Ounces/sq. yard

Example 5

A woodpulp/polyester spunlaced fabric; style 8868, was obtained from the DuPont Company. This fabric was 55% woodpulp and 45% polyester, and was entangled with a screen design that created a patterned and aperture structure, Two rolls of this fabric were laminated with the polyester rich side of the fabrics facing inwards, using a rotary ultrasonic bonder from Branson Inc. Bond pattern was a dot shape at about 11% bond area. Speed was 50 ypm (yards per minute). The resulting laminate fabric had the physical properties described in Table 5 below.

TABLE 5

Basis weight (oz/yd2)		3.49
(ASTM D3776)
Grab Tensile (lbs.)	MD	46
(ASTM D5034)	XD	30
Elongation (%)	MD	22
(ASTM D5034)	XD	87
Bond strength (grams/inch)	MD	56
AATCC 136	XD	93
Caliper (inches)		.022
(ASTM D1777)
Handle-o-meter(grams/force)	MD	81
(4″ × 7″, 20 mm gap)	XD	14
(INDA 90.3)
Dry crock (rating)		5
(AATCC 8)
Wet crock (rating)		4
(AATCC 8)
Absorbency Rate (seconds)		2.4
(INDA 10.1)
Absorbent Capacity (%)		667
(INDA 10.1)
Total liquid capacity/sq. yd.		16.0
Ounces/sq. yard

Example 6

A particular example consisted of a bi-laminate towel created from two layers of DuPont® Sontara® wood pulp/polyester spunlace, style number 90508. The greige material was light blue in color, with a basis weight of 1.65 osy, and was comprised of 55% polyester and 45% wood pulp, with one side having a greater concentration of wood pulp and the remaining side being rich in polyester. The greige material had also undergone a secondary process during manufacturing, which created a more textured surface.
Single layers of the greige material were pad finished in a bath via the “dip and nip” method with a binder finish comprised of the chemicals in concentrations listed in Table 6, below. The wet pick up achieved was roughly 100%. FoamPress NS-99 (The Marlin Company, Inc.) was present in the mix in order to reduce the amount of foaming encountered in the finishing pan. Tergitol TMN-6 (Univar) was used to enhance the absorbent properties of the towel. Nacrylic X-4484 (Celanese Ltd.), an acrylic binder, was used to soften the hand, and aid in the control of lint. Ammonium hydroxide was present in the finish in order to keep the binder from curing in the pan, and is known to flash off in the oven as the material is dried. The fabric was pad finished, and run through a tenter frame and oven where it was stretched approximately 10% from the original greige width. The fabric temperature, upon exiting the oven, was 285° F.-300° F. in order to cure the acrylic binder properly.

	TABLE 6

	Component	#/100 gal

	Water	816.15
	FoamPress NS-99	1
	Tergitol TMN-6	1.25
	Ammonium Hydroxide	0.6
	Nacrylic X-4484	15

Two single layers of finished material were then laminated together via ultrasonic bonding in a face to face relationship, whereas the polyester rich sides of the fabric are in contact with one another, leaving the two wood pulp rich sides exposed. A bond pattern with approximately 4-12% bond area, comprised of rectangular bond points with rounded edges, was used to ultrasonically laminate the materials. The bonding occurred at 38 yards/min, and resulted in bonds that averaged 188 Win in the MD direction and 213 g/in in the XD direction.
The ultrasonically laminated material was then subjected to microcreping in order to soften the hand and create a more “drapeable” product. In this instance, a compression rate of 4-5% was employed at a speed of 133 yards/min. Additionally, a smooth roll was used in the microcreper, as opposed to a comb and groove, or an additional type of configuration. However, both comb and groove and smooth rolls have been used on this material in past trials.
The finished, ultrasonically bonded and microcreped laminate was then folded using a FMC Corporation Hudson Sharp towel folding machine, where it underwent a modified W fold with Grab Tab®. This folding style employs a folding scheme of one half fold, followed by a full fold, then partial, partial, full, and one half fold in the MD direction. In the XD direction, the towel underwent one full fold, resulting in a towel that has a folded dimension of 5.5″ by 8.5″. The towel folding machine ran approximately 60-80 yards/min. The resulting laminate fabric had the physical properties described in Table 7 below.

	TABLE 7

	Basis Weight, osy	2.98
	Water Drop, s	1
	MD Grab Tensile, lbf	39.6
	XD Grab Tensile, lbf	22.1
	Caliper, in	0.027
	MD Handle-o-meter	11.8
	XD Handle-o-meter	5.5
	Wet Crocking	4.5
	Dry Crocking	4.5
	Absorbency Rate, s	2.97
	Absorbent Capacity, %	930.2
	Dry Particle Count,	1,846
	#/ft³/min

Example 7

A woodpulp/polyester spunlaced fabric from DuPont, style 9995, with a basis weight of 1.65 ounces per square yard, is composed of approximately 55% woodpulp and 45% polyester. The woodpulp is predominately on one side of the fabric and the polyester predominately on the other side. Two rolls of this greige (unfinished) fabric are laminated together with the polyester rich side of each fabric facing inward. The method of lamination is a rotary ultrasonic bonder using a dot shaped pattern with approximately 11% bond area. The machine speed for the ultrasonic bonding step is 55 feet per minute. The properties shown in Table 8 below were obtained when two layers of style 9995 unfinished spunlaced fabric were ultrasonically bonded.

	TABLE 8

	Basis weight (oz/yd2)	3.20
	(ASTM D3776)

	Grab Tensiles (lbs.)	MD	38
	(ASTM D5034)	XD	23

	Caliper (inches)	0.038
	(ASTM D1777)

	Bond Strength (grams/inch)	MD	134
	(AATCC 136)	XD	150

	Absorbency Rate (seconds)	1.5
	(INDA 10.1)
	Absorbent Capacity (%)	1,014
	(INDA 10.1)

Handle-o-meter (grams)	MD	34
(INDA 90.3)	XD	23

After bonding the fabric was run through a micrex machine which utilizes a smooth roll pattern and a 5.2% compression setting. The line speed for the micrex machine was 400 feet per minute. The properties for the micrexed material are set forth in Table 9 below.

	TABLE 9

	Basis weight (oz/yd2)	3.31
	(ASTM D3776)

	Handle-o-meter (grams)	MD	12.3
	INDA 90.3	XD	4.3

	Caliper (inches)	0.030
	ASTM D1777

Grab Tensiles (lbs.)	MD	45
(ASTM D5034)	XD	21

The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.

Claims

1. A laminate fabric, comprising:

a first nonwoven, spunlaced fabric layer comprising a front surface and a back surface opposite the front surface, said front surface comprising a first three-dimensional pattern; and

a second nonwoven, spunlaced fabric layer comprising a front surface and a back surface opposite the front surface, said front surface comprising a second three-dimensional pattern,

wherein the first and second nonwoven, spunlaced fabric layers are laminated together such that the back surface of the first nonwoven, spunlaced fabric layer is coupled to the back surface of the second nonwoven, spunlaced fabric layer.

2. The laminate fabric of claim 1, wherein the first three-dimensional pattern and the second three-dimensional pattern are substantially the same.

3. The laminate fabric of claim 1, wherein the first three-dimensional pattern and the second three-dimensional pattern are aligned such that the laminate fabric appears to comprise one consistent pattern throughout the depth of the fabric.

4. The laminate fabric of claim 1, wherein the first nonwoven, spunlaced fabric layer comprises one or more fibers selected from the group consisting of cellulose, viscose and lyocell.

5. The laminate fabric of claim 1, wherein the first nonwoven, spunlaced fabric layer comprises one or more fibers selected from the group consisting of polyester, polyethylene and polypropylene.

6. The laminate fabric of claim 1, wherein the second nonwoven, spunlaced fabric layer comprises one or more fibers selected from the group consisting of cellulose, viscose and lyocell.

7. The laminate fabric of claim 1, wherein the second nonwoven, spunlaced fabric layer comprises one or more fibers selected from the group consisting of polyester, polyethylene and polypropylene.

8. The laminate fabric of claim 1, wherein the first and second nonwoven, spunlaced fabric layers are laminated together using an adhesive.

9. The laminate fabric of claim 1, wherein the first three-dimensional pattern is generated by the spunlacing process used to form the first nonwoven, spunlaced fabric.

10. The laminate fabric of claim 1, wherein the second three-dimensional pattern is generated by the spunlacing process used to form the second nonwoven, spunlaced fabric.

11. The laminate fabric of claim 1, wherein the laminated fabric is a towel.

12. The laminate fabric of claim 1, wherein at least one of the first and second nonwoven, spunlaced fabric layers has been treated with a finish comprising an antimicrobial agent, an antistat, a flame retardant, a surfactant, a wetting agent, a binder, a cross-linker, and/or a blocked isocyanate.

13. The laminate fabric of claim 1, wherein the average surface roughness of the front surface of the first nonwoven, spunlaced fabric layer is at least about 50 microns.

14. The laminate fabric of claim 1, wherein the average surface roughness of the front surface of the first nonwoven, spunlaced fabric layer is about 100 to about 250 microns.

15. The laminate fabric of claim 1, wherein the average surface roughness of the front surface of the second nonwoven, spunlaced fabric layer is at least about 50 microns.

16. The laminate fabric of claim 1, wherein the average surface roughness of the front surface of the second nonwoven, spunlaced fabric layer is about 100 to about 250 microns.

17. A laminate fabric, comprising:

wherein the first and second nonwoven, spunlaced fabric layers are laminated together such that the back surface of the first nonwoven, spunlaced fabric layer is coupled to the back surface of the second nonwoven, spunlaced fabric layer,

wherein the first and second three-dimensional patterns resulted from the spunlacing process(es) used to form the first and second nonwoven, spunlaced fabric layers.

18. The laminate fabric of claim 17, wherein the first nonwoven, spunlaced fabric layer comprises cellulose, viscose and/or lyocell fibers, as well as polyester, polyethylene and/or polypropylene fibers.

19. The laminate fabric of claim 17, wherein the second nonwoven, spunlaced fabric layer comprises cellulose, viscose and/or lyocell fibers, as well as polyester, polyethylene and/or polypropylene fibers.

20. The laminate fabric of claim 17, wherein the first and second nonwoven, spunlaced fabric layers are laminated together using an adhesive.