Method of fabricating fibrous laminate structures with variable color

• US 6,671,936 B1
• Filed: 08/08/2000
• Issued: 01/06/2004
• Est. Priority Date: 06/23/2000
• Status: Expired due to Fees

• Current Assignee: Polymer Group Incorporated (Berry Global Group Inc.)
• Original Assignee: Polymer Group Incorporated (Berry Global Group Inc.)
• Inventors: Chier, Andrew Leonard, Lenox, James Patrick, Carter, Nick Mark, Carlson, Cheryl Lynn
• Primary Examiner(s): Vanatta, Amy B.
• Application Number:
  US09/634,482
• Time in Patent Office: 1,246 Days
• Field of Search: 281/03, 281/04, 281/05, 281/06, 281/63, 281/67, 281/07, 281/09, 281/12, 281/58, 442/382, 442/384, 442/387, 442/389, 442/408, 428/133, 428/137, 428/138, 428/139
• US Class Current: 28/104
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D04H 1/4374 using different kinds of webs, e.g. by layering webs
• CPC Class Codes: D04H 1/492 by fluid jet D04H1/49 takes precedence
• CPC Class Codes: D04H 1/495 for formation of patterns, e.g. drilling or rearrangement
• CPC Class Codes: D04H 1/498 entanglement of layered webs
• CPC Class Codes: D06C 23/00 Making patterns or designs on fabrics
• CPC Class Codes: D06N 2209/083 Multi-coloured
• CPC Class Codes: D06N 7/0092 Non-continuous polymer coating on the fibrous substrate, e.g. plastic dots on fabrics
• CPC Class Codes: D06Q 1/00 Decorating textiles
• CPC Class Codes: D06Q 1/14 by transferring fibres, or adhesives for fibres, to the textile
• CPC Class Codes: Y10T 156/1007 Running or continuous length work
• CPC Class Codes: Y10T 442/20 Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
• CPC Class Codes: Y10T 442/659 Including an additional nonwoven fabric

Abstract

A method of providing a color enhanced, patterned nonwoven based composite fabric wherein a hydroentangled, imaged nonwoven facing fabric exhibits variable fiber density in selected regions and where a colored backing material is laminated to the facing layer such that the color of the backing layer is observed as variable hues which coincide with regions of lower fiber density in the facing layer.

Claims

1. A method of making a colored non-woven composite material, comprising the steps of:

providing a first non-woven layer having a heterogeneous fiber density described in a predetermined pattern or image and a first color,

providing a second non-woven layer having a different aesthetic quality than the first non-woven layer and having a heterogeneous fiber density described in a predetermined pattern or image,

positioning said first and second non-woven layers in surface to surface juxtaposition, applying high pressure fluid streams upon the second non-woven layer to induce relocation of the fibrous component of the second non-woven layer into the fibrous structure of the first non-woven layer,

whereby the fibrous component of the second non-woven layer is apparent on the face of the first non-woven layer in the regions of the first non-woven layer where the fiber density is lower than the surround areas of the first non-woven layer.

2. A method of making a non-woven composite material in accordance with claim 1, wherein:

the first non-woven layer is a hydroentangled fabric.

3. A method of making a non-woven composite material in accordance with claim 1, wherein:

the first non-woven layer is comprised of material selected from the group consisting of staple length natural fiber, staple length polymeric fiber, continuous polymeric filament, and mixtures thereof.

4. A method of making a non-woven composite material in accordance with claim 1, wherein:

the different aesthetic quality of the second non-woven layer is selected from variations in color, tint, hue, brightness, opacity, or combinations thereof.

5. A method of making a non-woven composite material in accordance with claim 1, wherein:

the second non-woven layer is selected from the group consisting of a carded fibrous batt, an air-laid fiber web, a spun-laid filament web, a melt-blown filament web, a consolidated non-woven fabric, and combinations thereof.

6. A method of making a non-woven composite material in accordance with claim 5, wherein:

the second non-woven layer is comprised of material selected from the group consisting of staple length natural fiber, staple length polymeric fiber, continuous polymeric filament, and mixtures thereof.

7. A method of making a non-woven composite material in accordance with claim 1, wherein:

first non-woven layer is in the basis weight range of about 1.0 to 6.0 ounces per square yard.

8. A method of making a non-woven composite material in accordance with claim 1, wherein:

the second non-woven fabric layer is in the basis weight range of about 0.5 to 4.5 ounces per square yard.

9. A method of making a non-woven composite material in accordance with claim 1, wherein:

the high pressure fluid streams may be at equivalent or differing pressures.