Abstract A method and apparatus utilizing fluid rearranging forces to produce, from a layer of fibrous material such as a fibrous web, nonwoven fabrics that contain apertures or holes, or other areas of low fiber density, and have a plurality of patterns of groups of fiber segments that alternate and extend throughout the fabric. One form of the method includes the steps of positioning the starting web between an apertured forming means and a backing means that has continuous imperforate portions that lie between and interconnect discontinuous permeable portions, then directing fluid rearranging forces through the apertures of the forming means against the fibers of the starting web, causing some of the fluid streams to strike the continuous imperforate portions of the backing means and all of the fluid streams ultimately to pass through the permeable portions of the backing means. Each of the discontinuous permeable portions of the backing means has an area less than about one-half, preferably less than one-quarter the area of one of the apertures of the forming means. The resulting fabric consists of fibers that have been rearranged to provide a first pattern of nubs of tightly packed, randomly oriented fiber segments corresponding to the discontinuous permeable portions of the backing means, a second pattern of yarn-like bundles of fiber segments arranged in a pattern complementary to the apertures of the apertured forming means, and a third pattern of flat, ribbonlike groups of substantially aligned fiber segments interconnecting the portions of the fabric in the first pattern with each other, as well as interconnecting some of them with the yarn-like bundles in the second pattern.
Apparatus for producing a patterned nonwoven fabric having a plurality of patterns that alternate and extend throughout said fabric, from a layer of fibrous starting material whose individual fibers are in mechanical engagement with one another but are capable of movement under applied fluid forces, which comprises: backing means having portions that are permeable and portions that are imperforate, said permeable portions being arranged in a discontinuous pattern, and the remainder of said backing means being imperforate and lying between and interconnecting said discontinuous permeable portions, each of said permeable portions having a width at its narrowest part of at least 0.04 inch and being spaced from adjacent permeable portions by a distance of from 0.04 inch to 0.5 inch; apertured forming means spaced from said backing means to provide a zone in which fiber movement in directions parallel to said backing means is permitted in response to applied fluid forces, the apertures in said forming means being longitudinally and transversely spaced with land areas therebetween, the distance between immediately adjacent apertures being at least .015 inch, each of said permeable portions of the backing means having an area less than about one-half the area of one of said apertures of the apertured forming means; means for moving said backing means and apertured forming means, with a layer of fibrous starting material positioned therebetween, through a rearranging zone without any translatory movement between said two means and the fibrous layer; and means for projecting streams of fluid through said apertures in the apertured forming means, and then against the fibrous layer to pass therethrough, and thereafter through and beyond said permeable portions of the backing means.
Claim 2
Dependent Claim
276 words
Apparatus for producing a patterned nonwoven fabric having a plurality of patterns that alternate and extend throughout said fabric, from a layer of fibrous starting material whose individual fibers are in mechanical engagement with one another but are capable of movement under applied fluid forces, which comprises: backing means having portions that are permeable and portions that are imperforate, said permeable portions being arranged in a discontinuous pattern, and the remainder of said backing means being imperforate and lying between and interconnecting said discontinuous permeable portions, each of said permeable portions having a width at its narrowest part of at least 0.04 inch and being spaced from adjacent permeable portions by a distance of from 0.04 inch to 0.5 inch; apertured forming means spaced from said backing means to provide a zone in which fiber movement in directions parallel to said backing means is permitted in response to applied fluid forces, the apertures in said forming means being longitudinally and transversely spaced with land areas therebetween, the distance between immediately adjacent apertures being at least .015 inch, each of said permeable portions of the backing means having an area less than about one-half the area of one of said apertures of the apertured forming means; means for moving said backing means and apertured forming means, with a layer of fibrous starting material positioned therebetween, through a rearranging zone without any translatory movement between said two means and the fibrous layer; and means for projecting streams of fluid through said apertures in the apertured forming means, and then against the fibrous layer to pass therethrough, and thereafter through and beyond said permeable portions of the backing means.
Claim 3
Dependent Claim
38 words
The apparatus of claim 1 in which the area of each of said discontinuous permeable portions of the backing means is less than about one-quarter of the area of one of said apertures in the apertured forming means.