US3834983A - Process of forming wet laid tufted non-woven fibrous web from a viscous fibrous dispersion and product - Google Patents

Process of forming wet laid tufted non-woven fibrous web from a viscous fibrous dispersion and product Download PDF

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Publication number
US3834983A
US3834983A US00341699A US34169973A US3834983A US 3834983 A US3834983 A US 3834983A US 00341699 A US00341699 A US 00341699A US 34169973 A US34169973 A US 34169973A US 3834983 A US3834983 A US 3834983A
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Prior art keywords
fibers
fiber
web
tufted
tufts
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US00341699A
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English (en)
Inventor
B Conway
J Moran
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Dexter C & Sons Inc
Dexter C & Sons Inc us
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Dexter C & Sons Inc
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Priority to US00341699A priority Critical patent/US3834983A/en
Priority to CA187,822A priority patent/CA997542A/en
Priority to AU63806/73A priority patent/AU479651B2/en
Priority to AR252252A priority patent/AR204914A1/es
Priority to IN122/CAL/74A priority patent/IN140855B/en
Priority to NL7401749.A priority patent/NL166737C/xx
Priority to FI593/74A priority patent/FI57994C/fi
Priority to DE2410346A priority patent/DE2410346C3/de
Priority to SE7403106A priority patent/SE412777B/sv
Priority to FR7409348A priority patent/FR2221561B1/fr
Priority to GB1139574A priority patent/GB1450831A/en
Priority to BE141996A priority patent/BE812294A/xx
Priority to DK141374AA priority patent/DK141636B/da
Priority to JP49029873A priority patent/JPS587745B2/ja
Priority to ES424323A priority patent/ES424323A1/es
Priority to ES1974201482U priority patent/ES201482Y/es
Priority to US05/489,411 priority patent/US3960652A/en
Application granted granted Critical
Publication of US3834983A publication Critical patent/US3834983A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/006—Making patterned paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/004—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines by modification of the viscosity of the suspension
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S162/00—Paper making and fiber liberation
    • Y10S162/02—Chip soaking
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23979—Particular backing structure or composition

Definitions

  • a tufted nonwoven waterlaid web material exhibiting high loft, bulk and absorbency is comprised of a substantially planar web body portion of randomly arranged water dispersible fibers and a multitude of separate, spaced fiber tufts of high concentration arrayed on at least one surface.
  • the tufts are composed of a plurality of closely associated, substantially aligned fibers anchored within but extending from the web body portion in the form of weft-like fiber bundles.
  • the nonwoven web material is produced by a wet papermaking process that includes the steps of providing an aqueous fiber dispersing medium having a controlled fluid viscosity of about 3 centipoises and more dispersing within the viscous medium select fibers having a denier of at least 1 d.p.f. at a fiber concentration of at least about .02 percent by weight and depositing the fibers within said dispersion on an apertured fiber collecting element wherein the average hole area of the apertures is about 3X10 sq. in. and more to form the tufted nonwoven fibrous web with the tufts formed by bundles of substantially aligned fibers extending through the apertures.
  • the present invention relates generally to the production of tufted nonwoven fibrous web materials. More particularly, it is concerned with a new and improved wet paper-making technique for the production of tufted nonwoven materials exhibiting the appearance and characteristics of high loft absorbent bath toweling and the like.
  • Another technique for imparting some of the characteristics of woven fabrics to non-woven fibrous materials is the use of a needle punch operation that forms pegs 3,834,983 Patented Sept 10, 1974 of fibers which increase the structural integrity of the web while improving the flexibility and hand thereof. Still other techniques involve light surface brushing to provide a raised nappy surface exhibiting improved softness, for example in US. Pat. No. 3,101,520, or the use of electrostatic fiber flocking to achieve a comparable nappy surface.
  • a further technique involves the utilization of a crepe or loop-forming operation either alone or in combination with a needle punch. The nonwoven fabrics containing the looped fibers tend to imitate the looped configuration characteristics of woven terry cloth and reportedly exhibit improved softness and high loft.
  • Another object of the present invention is to provide a new and improved wet paper-making technique and resultant product which uniquely combines the advantageous features of the wet paper-making technology in a new and controlled manner to provide a product characterized by having on at least one surface thereof a multiplicity of fiber tufts or bundles extending outwardly from the continuous planar body portion of the product in the form of multiple strand fiber bundles exhibiting an appearance similar to a weft of hair or pigtail.
  • a further object is to provide a technique of the type described utilizing a viscous fiber suspending medium and a coarse fiber collecting paper forming element. Included in this object is the provision for a technique capable of using a wide variety of fibers including most conventional papermaking and textile fibers.
  • the web is comprised of a substantially planar web body portion of randomly arranged water dispersible fibers and a multitude of separate, spaced fiber tufts of high concentration arrayed on at least one surface thereof.
  • the tufts are composed of a plurality of closely associated, relatively independent, substantially aligned fibers anchored within but extending from the web body portion in the form of weft-like fiber bundles.
  • the nonwoven web material is produced by a wet paper-making process that has been modified to include the steps of .providing an aqueous fiber-dispersing medium having a controlled fluid viscosity of about 3 centipoises and more, dispersing within the viscous medium select fibers having a size of at least 1 d.p.f. at a fiber concentration of at least about .02 percent by weight and depositing the fibers .within said dispersion on an apertured fiber collecting element wherein the average open area of the apertures .is about 3 10- in. and more to form the tufted nonwoven fibrous web with the tufts formed by bundles of closely associated, substantially aligned individual fibers extending through the apertures.
  • the new and improved tufted nonwoven web material of the present invention is produced in accordance with the present invention by a papermaking operation characterized by its utilization of a coarse web forming member coupled with a viscosity controlled fiber dispersing medium.
  • This technique results in a nonwoven material having a high concentration of separate fiber tufts or wefts extending from the surface of the web material at substantially a right angle thereto when formed.
  • This tufted nonwoven material can be better visualized by first appreciating the structural configuration of both woven toweling and nonwoven looped and nappy web materials.
  • Turkish or terry toweling is a loosely woven fabric characterized by a nap comprised of a larger number of individual loops of thread projecting outwardly from the body of the fabric. These individual loops provide a pliable or yieldable cushion effect and readily bend or distort during use not only to give the soft feel of high bulk or loft, but also to expose greater thread surface area to perform the desired absorbing and wiping function.
  • Nonwoven high loft looped fabrics are somewhat similar but have a flexible adhesive base with fibers individually looped outwardly from the base and adhesively embedded in the base.
  • the fabric can be formed by first producing a dry formed striated base web of substantially aligned fibers having fiber length of about 23 inches. The Web is then imprinted with a lattice-like pattern of adhesive and tensioned to retain the aligned fiber array. The adhesive is cured and the fibers in the web are looped by feeding the web to a gathering blade. 7
  • the tufted nonwoven high loft material of the present invention has a characteristic surface that differs substantially from either looped material or conventional Webs with a brushed on nappy surf-ace. Instead, as shown in FIGS. 3 and 4, it is characterized as having a large number and high concentration of separate fiber bundles or turfts that extend outwardly from the main fibrous body portion of the web.
  • the multiple fibers in each tuft terminate in free fiber ends spaced at randomly different distances from the main fibrous body.
  • the tufts exhibit a somewhat tapered appearance much like a weft of hair in that they are firmly attached to the main body portion of the web and taper to their longest length near the center of the bundle or tuft. As best seen in FIG.
  • the long tufts will tend to exhibit a waviness along their length and will loosely rest on the surface of the web material. Since each tuft is composed of a plurality of closely collected or bundled fibers yet each fiber is substantially aligned and relatively independent of other fibers Within the tuft, the tufts exhibit substantial flexibility, pliability and softness while also imparting high loft, bulk and absorbency to the web material. Unlike pegs produced from needle punch operations the fibers within the tufts are not substantially bent or ruptured and the tuft does not exhibit a pronounced central void or hole. As will be understood from the following description, the number of fibers in each tuft and the concentration of the tufts will vary substantially depending on the operating conditions employed in producing the web material.
  • the fibers forming the tufts receive their projecting orientation during sheet formation by controlling a number of factors associated with the wet paper-making process.
  • the principal factor involved in this technique in the production of suitable fluid dynamics within the system at the time the fibers are initially deposited on the fiber collecting structure and formed into the non- Woven Web.
  • Two of the factors considered essential in achieving the optimum fluid conditions required for the tufted nonwoven product of the present invention are (1) the use of a relatively coarse paper forming element; such as a wire screen or apertured plate having thicker solid areas and larger open areas relative to a standard Fourdrinier paper forming Wire and (2) a controlled fluid viscosity in the fiber dispersion used in forming the nonwoven material.
  • a relatively coarse paper forming element such as a wire screen or apertured plate having thicker solid areas and larger open areas relative to a standard Fourdrinier paper forming Wire
  • a controlled fluid viscosity in the fiber dispersion used in forming the nonwoven material are also alfect the formation of the desired tufted nonwoven material. These include inter alia, the consistency or fiber concentration of the dispersion, the vacuum used to effect removal of the dispersing medium, the type and composition of fibers employed as well as their denier and length and the basis weight of the resultant product.
  • one of the primary and necessary factors associated with the new and improved technique of the present invention is the utilization of fiber collecting or paper forming elements which are substantially coarser than those normally used in manfacturing papers having the basis weights exhibited by the products of the present invention.
  • the standard Fourdrinier screens are typically fine wire members and have about 60-100 strands per inch in each direction with the strands having a thickness or diameter of about 0.006 inch.
  • the screening elements used in accordance with the present invention are well below the typical 75 mesh of Fourdrinier screens and in fact, are about 45 mesh or less and preferably about 14 to 24 mesh. Additionally, the thickness of the solid areas is at least twice that of the Fourdrim'er screen and may be four or five times thicker or wider. Thus, suitably apertured plates or screens can be used with good results.
  • the coarse paper forming screens or wires such as the so-called cabled or twisted cable type or the more recent plastic screens are generally preferred. These have strand thicknesses of at least 0.012 inch and preferably in the range of .0l8.035 inch resulting in drainage openings generally having an average hole area about 2 to 60 times greater than the approximately 0.95 sq. in. area of the Fourdrinier screen openings. It will be appreciated that the exact screen type and size utilized will vary depending on the desired product, the type, denier and length of fiber used in the furnish, the consistency of the furnish as well as the viscosity of the suspending fluid and the amount of vacuum applied during web formation. Quite naturally, and in fact preferably, the open or coarse screens tend to result in an undulating web configuration and tuft waviness which also adds to size employed can vary substantially depending on the numerous other considerations relating to the process.
  • a second essential feature of the paper-making technique of the present invention involves the use of a viscous dispersing fluid for the fibers. That is, a dispersing fluid exhibiting a viscosity greater than that exhibited by water.
  • the high viscosity advantageously permits the utilization of numerous fibers and mixtures thereof not heretofore used in a wet paper-making process, including mixtures of textile staple fibers with fibers having a substantially shorter length.
  • the viscous solution used to disperse the fibers prevents the formation of fiber clumps within the dispersion and reduces the tendency of the dispersed fibers to entangle.
  • the dispersing medium maintains the fibers in their dispersed condition during drainage and assures a more uniform fiber distirbution within the resultant web material thereby contributing to the improved softness, flexibility and drape characteris TABLE I.-WEB FORMING SCREEN Average hole size Distance between Material Diameter (in.) wires (in (XAIZea;
  • the open, coarse configuration of the screen or plate permits greater laminar flow of the dispersing fluid through the apertures of the foraminous fiber collecting element during web formation so as to drive the fibers into the orientation required for producing the desired tufted configuration.
  • the size of the openings in the screen or plate should not be so great that the fibers within the fiber dispersion are not retained or hung-up on the screen during the web forming processes and the size of the solid areas should not be so great as to interfere with the drainage of the fiber dispersion.
  • the precise size required is one which is large enough to provide the required fluid flow during drainage but small enough to permit the requisite fiber collection as the fiber dispersing medium passes rapidly through the screen.
  • a nonwoven or woven scrim or gauze may be used as the primary fiber collecting element.
  • the screen and the openings in the scrim would facilitate tuft formation while simultantously embedding the scrim in the nonwoven fibrous web deposited thereon.
  • Such an arrangement would substantially strengthen the web without undue sacrifice in the softness of the tufted material.
  • the web forming element is preferably a screen of about mesh or less constructed of plastic strands or twisted cable wires.
  • screens having as few as 8 strands per inch and containing openings having an average hole area as much as sixty times larger than conventional web forming elements have been effectively employed.
  • wires from different sources of supply will vary, a few typical exemplary wire sizes are set forth in Table I together with some of their physical characteristics.
  • the size of the hole area will relate to the fiber diameter since the thicker fibers form tufts more effectively on the coarser, lower mesh screens. For most applications, an average hole area between 3 X 10- and 20 10 sq. in.
  • the viscous medium of the present invention substantially expands the number and type of fibers that can be used. At present, only dispersions wherein all of the fibers are very short hard wood fibers are ineffective to provide a well tufted web. However, this is due primarily to the openness of the screen employed for the short fibers and is not full attributable to the viscosity of the dispersing medium. On the other hand, the dispersing medium will permit the utilization of percent natural, or synthetic paper-making or textile staple fibers or appropriate mixtures thereof.
  • the dispersing medium should exhibit a viscosity greater than about three centipoises. Although some tufting can be achieved even at this low viscosity level when other operating characteristics are appropriately controlled and where select fibers are employed, a viscosity greater than 10 centipoises is required for good results. Preferably, a viscosity level of 30 centipoises and more is used for best results. The viscosity actually utilized will vary and for practical applications can be as high as 250-300 centipoise. As will be appreciated, certain practical considerations will control the upper limit since extremely high viscosities may tend to interfere with the drainage characteristics of the system. Other practical limits relating to the runability of the paper-making machine include the vacuum available for removing the dispersing medium without disrupting the web, the extractability of the medium and the effect of its residual presence in the web as well as the economics associated with the system.
  • the viscosity controlling material may be a natural or synthetic material or blends thereof.
  • the preferred viscosity controlling materials are the high molecular weight resins, such as the water soluble polymers formed from the polymerization of acrylamide. These polymers are preferably used since their dilute aqueous solutions can be easily controlled to provide the desired viscosity at the drainage area of the system,
  • the preferred acrylamide polymer employed is a material sold by Dow Chemical Company under the trade name Separan AP-30.
  • Other materials such as polyethylene oxide sold by Union Carbide Corporation under the name Polyox WSR 301 as well as selected viscosity producing carboxymethyl cellulose solutions can also be utilized.
  • viscosity controlling material should be one that is stable to shearing forces
  • . can be added to the headbox and will maintain its viscosity up to and through the drainage area of the system.
  • tufted webs can be produced from a wide variety of natural and synthetic paper-making and textile fibers.
  • synthetic or manmade paper-making or textile staple fibers such as rayon, nylon, polyesters or vinyl polymers or copolymers can be used either alone or in combination with natural fibers such as bleached or unbleached Kraft, manila hemp, jute and similar papermaking fibers.
  • inorganic fibers such as glass, quartz, ceramic, mineral wool, asbestos and similar materials may also be employed in accordance with the teachings of the present invention.
  • the synthetic fibers may vary in both denier and length although the lower denier fibers are generally preferred. Fibers from about 1 or 1.5 denier per filament (d.p.f.) to about 15 d.p.f. and more have been successfully used and have produced excellent results. However, with the higher denier material it is generally necessary to use a lower fiber concentration and a more viscous dispersing medium. As will be appreciated the minimum and maximum denier employed will depend on many other related factors including the product requirements, machine operating conditions, consistency, screen size, etc.
  • the length of the synthetic fibers employed depends to a large degree upon the particular wire or screen used and will range from about A; of an inch or more up to several inches and can be of the straight cut-tow type used in papermaking operations or the crimped or straight textile staple fiber type. As mentioned, it is preferred to utilize the finer denier material having a length of about /2 to inch or more in order to impart to the material improved softness while retaining the desired loft and absorbency characteristics. However, mixtures using natural and synthetic papermaking fibers having lengths down to & inch or less may also be employed depending upon the particular properties and characteristics required in the final product.
  • the fiber consistency or concentration in the dispcrsion prior to web formation requires appropriate control to facilitate formation of the tufted configuration.
  • the lowest fiber concentration or consistency compatible with good release of the resulting product from the web forming wire is most desirable for best tuft formation. Accordingly, a fiber concentration ranging from about .02 percent to about 1.0 percent can be used, with the preferred range being about .05 percent to .5 percent fiber concentration. In standard laboratory operations a fiber concentration of about .1 percent has been found to produce consistently good results. The consistency on large papermaking machines will of course vary with machine conditions.
  • the fiber concentration and the viscosity of the dispersant will also affect the degree of vacuum or suction that must be applied to the underside of the paper forming element during web formation in order to provide the desired tufted effect. Although good tufting can be obtained under appropriate conditions even in the absence of vacuum, it is generally preferred that a vacuum be applied to the underside of the web forming wire as the fibers are deposited thereon in order to insure the appropriate fluid dynamics of the system.
  • these variations will depend not only on fiber concentration and the viscosity of the dispering medium but also on on other factors associated with these systems such as the coarseness of the wire and the type and length of fiber utilized.
  • An additional factor for consideration when using the technique of the present invention is the weight of the material being produced.
  • the technique described herein is capable of producing a tufted product at weights as low as about /2 ounce per square yard and even as low as /4 ounce per square yard.
  • such light weight materials are only produced by very fine control over the other factors associated with the technique and the basis weight of most materials is at least one ounce per square yard or higher.
  • the tuft is the first portion of the web to be formed as the fibers are draped over the solid portion of the web forming element and are drawn through the intermediate opening due to the fluid dynamics of the system. This is depicted illustratively in FIG. 2. As the web gains thickness more fibers are deposited both in the tufts or bundles and within the body of the web until it reaches its described basis weight and strength. If the deposition of the fibers were terminated after only the original tuft formation, it would be noted that although a network of tufts was provided, the fibrous material exhibited very little strength, was substantially without sheet character and could not be removed from the web forming wire. Additionally, it has been noted that when the basis weight exceeds about 6 ounces per square yard few if any additionally deposited fibers take part in the tuft formation but merely form a mat on top of the tufted base with little or no fiber integration with the tufts.
  • the higher denier fibers generally require a coarser wire and also require a higher viscosity and lower consistency than corresponding fibers of a finer denier.
  • a 1.5 d.p.f. fiber will provide an acceptable tufted product at a viscosity of 50 cps and a fiber concentration of about .2 percent, whereas comparable results can only be obtained with a 15 d.p.f. fiber at a viscosity of cps and a consistency of .1 percent.
  • the lower limit on the basis weight of the tufted product will vary with the coarseness of the wire employed, such that a lower basis weight material can be obtained with a finer forming Wire than with a coarser wire.
  • the tufts are produced on one side of the material only and products exhibiting tufts on both sides can be readily formed by arranging tufted Web materials in back-to-back relationship. Interlocking of plies and the incorporation of strengthening or binding agents can be employed in a Conventional fashion either during or after web formation. Subsequent softening or other treatments may also be used.
  • a fiber dispersing medium having a viscosity of 150 cps was prepared as a .15 aqueous solution of a water soluble polyacrylamide (Separan AP-30). Sufficient /1 inch, 15 d.p.f. rayon staple fibers were added to the viscous medium to prepare a 0.1% fiber dispersion. The fiber dispersion was poured into a hand sheet mold fitted with a 24 x 16 mesh bronze cabled wire screen having an average hole area of 8.16 sq. in. and was drained with the assistance of a vacuum. The resultant fibrous product was an excellent tufted fabric web having a basis weight of 2.55 ounces per square yard.
  • EXAMPLE II Following the general procedure of Example I, a .1% fiber dispersion was prepared from /1 inch 1.5 denier rayon staple fibers dispersed in a polyacrylamide (Separan AP-30) solution having a viscosity of 50 cps. The fiber dispersion was poured into a hand sheet mold fitted with a 16 x 16 mesh polyester regular weave wire having openings with an average hole area of about 12.2 104 sq. in. Vacuum was applied to the underside of the wire and a nonwoven web material was produced having excellent tuft characteristics and a basis weight of about 2.55 ounces per square yard.
  • a polyacrylamide Separan AP-30
  • Example III The procedure of Example II was repeated using a .05 fiber dispersion of 70% inch 1.5 denier rayon staple fibers and 30% Weyerhauser Kraft in a polyacrylamide (Separan AP-30) solution having a viscosity of 25 cps.
  • the resultant web material exhibited excellent tuft characteristics at a basis weight of 2.4 ounces per square yard.
  • EXAMPLE IV A .12% fiber dispersion was prepared from /2 inch 1.5 denier rayon staple fiber dispersed in a karaya gum solution having a viscosity of 40 cps. The fiber dispersion was poured into a hand sheet mold fitted with the 16 x 16 mesh polyester wire of Example II and a vacuum was applied to the underside of the wire to aid in the removal of the dispersing medium. An excellent nonwoven tufted fabric was produced having a basis weight of 6.6 ounces per square yard.
  • EXAMPLE V A dispersion of inch 1.5 denier rayon staple fibers was prepared in an aqueous solution of a polyacrylamide (Separan AP-30) solution having a viscosity of 50 cps. and was fed into the head box of the papermaking machine at a fiber consistency of 0.2%. The machine was provided with an inclined 24 x 18 mesh bronze cabled wire having openings with an average hole area of about 6.78 10 sq. in. The dispersion was fed to the head box of the papermaking machine without change in viscosity and the drainage was assisted by vacuum. The resultant product was an excellent tufted fabric having a basis weight of 2.85 ounces per square yard.
  • a polyacrylamide Separan AP-30
  • Example 2 was repeated using the 16 x 16 mesh polyester regular weave wire of Example II and also produced excellent tufted nonwoven web material.
  • EXAMPLE VI As an example of the increased viscosity required to produce tufted products when higher denier and less flexible fibers are employed, the fibers set forth below were dispersed in a solution having the viscosity indicated.
  • Example VII The procedure of Example I was repeated using rayon staple fibers of 1.5 denier and inch length and nylon fibers of 3 denier and 1.5 inch length. In each case the resultant web material exhibited excellent tufted characteristics, with the longer nylon fibers producing tufts of substantially greater length than those produced by the shorter rayon fibers.
  • Example VIII The procedure of Example I was repeated using rayon fibers 1.5 denier, inch length and a dispersion viscosity of 100 cps. The fiber consistency was .1% and sheets were prepared exhibiting excellent tufted characteristics and having basis weights in ounces per square yard of 0.6, 1.1, 1.7, 2.2, 2.6, 3.3, 3.8, 4.5, 6.9 and 9.0.
  • the tufted nonwoven web material of the present invention is particularly well suited for use in the manufacture of disposable items.
  • These uses include not only wash cloths, wiping cloths, towels, cosmetic wipes, coverstock for diapers, santiary napkins and the like, blankets, dish cloths, bandages, dressings and other medical supplies, barbers neck bands, head rests, dust collector felts, dust cloths and mops and wiping cloths of all kinds but also wearing apparel such as disposable bathing suits and jackets, surgical masks, disposable cap and industrial and domestic clothing such as costumes and novelty clothing including interlining for clothing.
  • nonwoven web material of the present invention may also be advantageously employed for disposable bibs, tray covers, placemats, facial tissue, disposable draperies, carpet backing and semidurable rugs, wall covering, insulating materials including cryogenic insulation, obstetrical sheets, sleeping bag liners, bed pad liners and covers, protective wrapping or as substrates for a coating of a fabric softening composi tion.
  • the web material might also be employed as a filter material for either air or fluid, such as coffee filters or infusion web materials such as tea bags, and if suitably treated could be used as a coating substrate for various items such as a substrate for synthetic leather or as a substitute for buckram interliners.
  • laminated structures could also be formed from the nonwoven web material of the present invention including laminates for reinforced layers of plastic film, laminated or molded papers, light diffusers, lampshades or decorative sliding door paper or the material could be used in cordage, stretchable bags or sacks or for use in the upholstery for home furnishings and automobiles.
  • the foregoing list of uses is not intended to be exhaustive but is merely exemplary of the versatility of the material produced in accordance with the present lnvention.
  • a process for producing a tufted nonwoven waterlaid fibrous web material comprising the steps of providing an aqueous fiber dispersing medium having a controlled fluid viscosity of about 3 cps. and more and an T1 1 apertured fiber collecting element wherein the average hole areaof the apertures .isv at least about twicethe 0.95 sq. in. area of the apertures in a Fourdrinier wire; dispersing within the viscousmedium suflicient water 'dispersible fibers to provide a fiber concentration of at.
  • the viscous fiber dispersing medium has a viscosity of at least 10 cps. up to about 300 cps.
  • the fiber dispersing medium is an aqueous resin solution and the water dispersible fibers include synthetic fibers of about at least 1.0 d.p.f. and a length in the range of about A; inch up to 1 inch and more.

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  • Paper (AREA)
  • Laminated Bodies (AREA)
US00341699A 1973-03-15 1973-03-15 Process of forming wet laid tufted non-woven fibrous web from a viscous fibrous dispersion and product Expired - Lifetime US3834983A (en)

Priority Applications (17)

Application Number Priority Date Filing Date Title
US00341699A US3834983A (en) 1973-03-15 1973-03-15 Process of forming wet laid tufted non-woven fibrous web from a viscous fibrous dispersion and product
CA187,822A CA997542A (en) 1973-03-15 1973-12-10 Tufted nonwoven fibrous web material
AU63806/73A AU479651B2 (en) 1973-03-15 1973-12-19 Process of forming wet laid tufted nonwoven fibrous web froma viscous fibrous dispersion and product
AR252252A AR204914A1 (es) 1973-03-15 1974-01-01 Procedimiento para obtener material laminar fibroso no tejido y esponjoso y el material asi obtenido
IN122/CAL/74A IN140855B (xx) 1973-03-15 1974-01-17
NL7401749.A NL166737C (nl) 1973-03-15 1974-02-08 Niet-geweven tuftvezelvlies.
FI593/74A FI57994C (fi) 1973-03-15 1974-02-28 Fibroest icke vaevt filtat banformigt material samt foerfarande foer dess framstaellning
DE2410346A DE2410346C3 (de) 1973-03-15 1974-03-05 Faservliesstoff großer Fälligkeit und Verfahren zu seiner Herstellung
SE7403106A SE412777B (sv) 1973-03-15 1974-03-08 Forfarande for framstellning av ett tuftat icke-vevt vattenlagt fibrost banmaterial med hjelp av ett vattenhaltigt fiberdispergerande medium och ett med oppningar forsett fibersamlande element
FR7409348A FR2221561B1 (xx) 1973-03-15 1974-03-12
GB1139574A GB1450831A (en) 1973-03-15 1974-03-14 Tufted nonwoven fibrous web material
BE141996A BE812294A (fr) 1973-03-15 1974-03-14 Materiau en feuille continue fibreux
DK141374AA DK141636B (da) 1973-03-15 1974-03-14 Fremgangsmåde til fremstilling af et fibrøst, uvævet banemateriale med udragende fibertotter.
JP49029873A JPS587745B2 (ja) 1973-03-15 1974-03-15 房付き不織布の製造方法
ES424323A ES424323A1 (es) 1973-03-15 1974-03-15 Procedimiento para producir un material de banda no tejido,fibroso, mechoso y tendido con agua.
ES1974201482U ES201482Y (es) 1973-03-15 1974-03-15 Material en forma de banda, fibroso, no tejido y tendido con agua.
US05/489,411 US3960652A (en) 1973-03-15 1974-07-17 Process of forming wet laid tufted nonwoven fibrous web and tufted product

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US00341699A US3834983A (en) 1973-03-15 1973-03-15 Process of forming wet laid tufted non-woven fibrous web from a viscous fibrous dispersion and product

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US (1) US3834983A (xx)
JP (1) JPS587745B2 (xx)
AR (1) AR204914A1 (xx)
BE (1) BE812294A (xx)
CA (1) CA997542A (xx)
DE (1) DE2410346C3 (xx)
DK (1) DK141636B (xx)
ES (2) ES424323A1 (xx)
FI (1) FI57994C (xx)
FR (1) FR2221561B1 (xx)
GB (1) GB1450831A (xx)
IN (1) IN140855B (xx)
NL (1) NL166737C (xx)
SE (1) SE412777B (xx)

Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3950293A (en) * 1973-10-18 1976-04-13 Basf Aktiengesellschaft Production of non-foaming aqueous suspensions of polyethylene or polypropylene fibrids
US3960652A (en) * 1973-03-15 1976-06-01 The Dexter Corporation Process of forming wet laid tufted nonwoven fibrous web and tufted product
US3992344A (en) * 1973-10-18 1976-11-16 Basf Aktiengesellschaft Production of non-foaming aqueous suspensions of polyethylene or polypropylene fibrids
US4001157A (en) * 1973-10-18 1977-01-04 Basf Aktiengesellschaft Production of non-foaming aqueous suspensions of polyethylene or polypropylene fibrids
US4179543A (en) * 1976-08-19 1979-12-18 Hoechst Fibers Industries, Division Of American Hoechst Corporation Staple fiber, finish therefor and process for use of same
US4294883A (en) * 1976-08-19 1981-10-13 Hoechst Fibers Industries, Div. Of American Hoechst Corporation Staple fiber, finish therefor and process for use of same
US4368272A (en) * 1980-03-12 1983-01-11 Forsyth Dental Infirmary For Children Device for identifying and locating dental microorganisms
US4759391A (en) * 1986-01-10 1988-07-26 Wangner Gmbh & Co. Kg Two layer papermachine embossing fabric with depressions in the upper fabric layer for the production of tissue paper
US6420100B1 (en) 2000-10-24 2002-07-16 The Procter & Gamble Company Process for making deflection member using three-dimensional mask
US6576091B1 (en) 2000-10-24 2003-06-10 The Procter & Gamble Company Multi-layer deflection member and process for making same
US6576090B1 (en) 2000-10-24 2003-06-10 The Procter & Gamble Company Deflection member having suspended portions and process for making same
US6660129B1 (en) * 2000-10-24 2003-12-09 The Procter & Gamble Company Fibrous structure having increased surface area
US6743571B1 (en) 2000-10-24 2004-06-01 The Procter & Gamble Company Mask for differential curing and process for making same
WO2005100689A1 (en) * 2004-04-14 2005-10-27 M-Real Oyj Paper manufacturing process
US20080102250A1 (en) * 2006-10-31 2008-05-01 The Procter & Gamble Company Absorbent paper product having non-embossed surface features
US20080245498A1 (en) * 2006-10-31 2008-10-09 Ward William Ostendorf Papermaking belt for making multi-elevation paper structures
USD636608S1 (en) 2009-11-09 2011-04-26 The Procter & Gamble Company Paper product
WO2012052333A1 (de) * 2010-10-21 2012-04-26 Karl Otto Braun Gmbh & Co. Kg Bandage zum anlegen an einen menschlichen oder tierischen körper
CN116182718A (zh) * 2023-04-25 2023-05-30 菏泽市纺织纤维检验所 一种纺织纤维长度测量设备

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB8916242D0 (en) * 1989-07-14 1989-08-31 Crompton J R Plc Improvements in or relating to non-wovens
US5098519A (en) * 1989-10-30 1992-03-24 James River Corporation Method for producing a high bulk paper web and product obtained thereby
DE102011012881A1 (de) 2010-09-22 2012-03-22 Krüger Gmbh & Co. Kg Portionskapsel und Verfahren zur Herstellung eines Getränks mit einer Portionskapsel

Cited By (28)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3960652A (en) * 1973-03-15 1976-06-01 The Dexter Corporation Process of forming wet laid tufted nonwoven fibrous web and tufted product
US3950293A (en) * 1973-10-18 1976-04-13 Basf Aktiengesellschaft Production of non-foaming aqueous suspensions of polyethylene or polypropylene fibrids
US3992344A (en) * 1973-10-18 1976-11-16 Basf Aktiengesellschaft Production of non-foaming aqueous suspensions of polyethylene or polypropylene fibrids
US4001157A (en) * 1973-10-18 1977-01-04 Basf Aktiengesellschaft Production of non-foaming aqueous suspensions of polyethylene or polypropylene fibrids
US4179543A (en) * 1976-08-19 1979-12-18 Hoechst Fibers Industries, Division Of American Hoechst Corporation Staple fiber, finish therefor and process for use of same
US4294883A (en) * 1976-08-19 1981-10-13 Hoechst Fibers Industries, Div. Of American Hoechst Corporation Staple fiber, finish therefor and process for use of same
US4368272A (en) * 1980-03-12 1983-01-11 Forsyth Dental Infirmary For Children Device for identifying and locating dental microorganisms
US4759391A (en) * 1986-01-10 1988-07-26 Wangner Gmbh & Co. Kg Two layer papermachine embossing fabric with depressions in the upper fabric layer for the production of tissue paper
US6913859B2 (en) 2000-10-24 2005-07-05 The Proctor & Gamble Company Mask for differential curing and process for making same
US6576091B1 (en) 2000-10-24 2003-06-10 The Procter & Gamble Company Multi-layer deflection member and process for making same
US6576090B1 (en) 2000-10-24 2003-06-10 The Procter & Gamble Company Deflection member having suspended portions and process for making same
US6660129B1 (en) * 2000-10-24 2003-12-09 The Procter & Gamble Company Fibrous structure having increased surface area
US6743571B1 (en) 2000-10-24 2004-06-01 The Procter & Gamble Company Mask for differential curing and process for making same
US20040126710A1 (en) * 2000-10-24 2004-07-01 The Procter & Gamble Company Mask for differential curing and process for making same
US6420100B1 (en) 2000-10-24 2002-07-16 The Procter & Gamble Company Process for making deflection member using three-dimensional mask
WO2005100689A1 (en) * 2004-04-14 2005-10-27 M-Real Oyj Paper manufacturing process
US20070284070A1 (en) * 2004-04-14 2007-12-13 M-Real Oyj Paper Manufacturing Process
US20080102250A1 (en) * 2006-10-31 2008-05-01 The Procter & Gamble Company Absorbent paper product having non-embossed surface features
US20080245498A1 (en) * 2006-10-31 2008-10-09 Ward William Ostendorf Papermaking belt for making multi-elevation paper structures
US7799411B2 (en) 2006-10-31 2010-09-21 The Procter & Gamble Company Absorbent paper product having non-embossed surface features
US20110008583A1 (en) * 2006-10-31 2011-01-13 Ward William Ostendorf Absorbent paper product having non-embossed surface features
US7914649B2 (en) 2006-10-31 2011-03-29 The Procter & Gamble Company Papermaking belt for making multi-elevation paper structures
US8202605B2 (en) 2006-10-31 2012-06-19 The Procter & Gamble Company Absorbent paper product having non-embossed surface features
USD636608S1 (en) 2009-11-09 2011-04-26 The Procter & Gamble Company Paper product
WO2012052333A1 (de) * 2010-10-21 2012-04-26 Karl Otto Braun Gmbh & Co. Kg Bandage zum anlegen an einen menschlichen oder tierischen körper
AU2011319557B2 (en) * 2010-10-21 2014-06-19 KOB GmbH Bandage for applying to a human or animal body
RU2604396C2 (ru) * 2010-10-21 2016-12-10 Карл Отто Браун Гмбх Унд Ко. Кг Бандаж для тела человека или животного
CN116182718A (zh) * 2023-04-25 2023-05-30 菏泽市纺织纤维检验所 一种纺织纤维长度测量设备

Also Published As

Publication number Publication date
ES201482Y (es) 1976-02-01
FI57994C (fi) 1980-11-10
IN140855B (xx) 1977-01-01
FR2221561A1 (xx) 1974-10-11
NL166737C (nl) 1981-09-15
ES424323A1 (es) 1976-10-16
AR204914A1 (es) 1976-03-19
ES201482U (es) 1975-10-01
DE2410346B2 (de) 1980-05-14
JPS587745B2 (ja) 1983-02-12
SE412777B (sv) 1980-03-17
DK141636C (xx) 1980-10-13
BE812294A (fr) 1974-07-01
DE2410346A1 (de) 1974-09-19
GB1450831A (en) 1976-09-29
NL7401749A (xx) 1974-09-17
DE2410346C3 (de) 1981-01-15
AU6380673A (en) 1975-06-19
CA997542A (en) 1976-09-28
FR2221561B1 (xx) 1977-06-17
NL166737B (nl) 1981-04-15
DK141636B (da) 1980-05-12
FI57994B (fi) 1980-07-31
JPS49118961A (xx) 1974-11-13

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