Milliken + Co

Sara A Arvidson

Walter A Scrivens

Ryan W Johnson

Randolph S Kohlman

Patrick A Petri

Brandon T Roberts

Xin Li

Andrew M Honohan

Paul A Rundquist

Iii Franklin S Love

The application relates to a process for forming a nonwoven composite. The process includes forming a lofty nonwoven layer, obtaining a thermoplastic polymer, and applying the thermoplastic polymer to the second surface of the nonwoven layer, where the thermoplastic polymer is in the form of a molten polymer, semi-molten polymer, or solid film. Next, pressure and optionally heat is applied to the nonwoven layer and thermoplastic polymer, where the thermoplastic polymer and the second surface of the nonwoven layer are subjected to a textured surface forming a plurality of peak regions and a plurality of valley regions in the second surface of the nonwoven layer and embedding a portion of the primary fibers from the nonwoven layer into the thermoplastic polymer within the valley regions. The thermoplastic polymer is cooled forming a thermoplastic film and the nonwoven layer which together form the nonwoven composite.

Process for forming a nonwoven composite

The application relates to a nonwoven composite containing a lofty nonwoven layer and a film. The lofty nonwoven layer contains a plurality of primary fibers and defines a plurality of peak regions and a plurality of valley regions. The film contains a thermoplastic polymer and has a peak film thickness in the peak regions of the layer. The film is present on at least a majority of the second surface of the nonwoven layer. Within the valley regions, the film encapsulates a plurality of fibers from the nonwoven layer. The cross-sectional area fraction of total fibers in the film within the valley regions is at least about 8% and the cross-sectional area fraction of total fibers in the film within the peak regions is less than about 5%.

Nonwoven composite

Growing community of inventors

Simpsonville, SC, United States of America

Sara A Arvidson