Composite nonwovens and methods for the preparation thereof

Abstract

A composite nonwoven for controlled acquisition and distribution of liquid, comprising at least a first support layer and a first bulky layer, the bulky layer functioning to acquire and distribute liquid and the support layer being suitable for use either as a coverstock or as a transfer layer between the bulky layer and a liquid retention layer, the support layer and the bulky layer being bonded together, by non-chemical bonding, by a network of individual bonding points to form a liquid control system that facilitates liquid distribution within the individual layers and liquid transfer between the layers, the composite nonwoven showing a combination of a low strike-through time and a low rewet; and a high-speed in-line process for producing the composite nonwoven, the process comprising forming a first support layer, e.g. by carding or spunbonding, consolidating the first support layer, forming at least a first bulky layer containing carded fibers on top of the first support layer, and bonding the combination of the support layer and the bulky layer by non-chemical bonding means, e.g. thermobonding, during which process draft is reduced at least during formation of the first bulky layer by means of at least one laydown suction box providing suction at least at the point at which the bulky layer is formed and by means of at least one holddown suction box providing suction after formation of the bulky layer and until the point at which bonding between the layers takes place, said laydown and holddown suction boxes being located beneath an air-permeable conveyor belt.