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United States Patent [19]

Barnes et al.

[54] HYDRAULICALLY NEEDLED NONWOVEN PULP FIBER WEB

[75] Inventors: Harold K. Barnes, Augusta; Ronald F. Cook, Marietta; Cherie H. Everhart, Alpharetta; Ann L. McCormack, Cumming; Fred R. Radwanski, Roswell, all of Ga.; Paulette M. Rosch, Appleton, Wis.; Adrian J. Trevisan, Marietta, Ga.

[73] Assignee: Kimberley-Clark Corporation,

Neenah, Wis.

[21] Appl. No.: 608,095
[22] Filed: Nov. 1,1990

[51] Int. a.5 D04H 1/46; D21H 25/04;

D21H 27/00

[52] U.S. a 162/115; 28/105;

428/120; 428/311.1; 428/311.5; 428/311.7

428/311.1, 311.5, 311.7, 120

[56] References Cited

U.S. PATENT DOCUMENTS

2,666.369' 1/1954 Niks 92/38

3,042.576 7/1962 Harmon et al. 162/114

3,081,500 3/1963 Griswold et al 19/161

3,081,515 3/1963 Griswold et al 28/78

3,220,914 11/1965 Boadway et al 161/128

3,284,857 11/1966 Hynek 19/161

3,471,907 10/1969 Beckers 26/18.6

3,477,906 11/1969 Rabstad 162/205

3,486,706 12/1969 Evans 161/72

3,498,874 3/1970 Evans et al 161/109

3,565,756 2/1971 Kashiwabara et al 162/297

3,750,237 8/1973 Kalwaites 19/161 P

3,821,068 6/1974 Shaw 162/111

4,109,353 8/1978 Mitchell et al 28/104

4,166,877 9/1979 Brandon et al 428/221

4,228,123 10/1980 Marshall 264/557

4,329,763 5/1982 Alexander et al 28/104

4,440,597 4/1984 Wells et al 162/111

4,542,060 9/1985 Yoshida et al 428/287

4,623,575 11/1986 Brooks et al 428/113

4,665,957 5/1987 Suzuki et al 28/104

4,693,922 9/1987 Buyofsky et al 428/134

4,695,500 9/1987 Dyer et al 428/134

4,735,842 4/1988 Buyfosky et al 428/134

4,755,421 7/1988 Manning et al 428/224

US005137600A

[ii] Patent Number: 5,137,600 [45] Date of Patent: Aug. 11, 1992

4,775,421 7/1988 Manning et al 428/224

4,810,568 3/1989 Buyofsky et al 428/284

4,883,709 11/1989 Nozaki et al 428/288

4,920,001 4/1990 Lee et al 428/289

4,931,355 6/1990 Radwanski et al 428/283

5,009,747 4/1991 Viazmensky et al 162/115

FOREIGN PATENT DOCUMENTS

841938 5/1970 Canada .

128667 12/1984 European Pat. Off. .

308320A 3/1989 European Pat. Off. .

333228A 9/1989 European Pat. Off. .

411752 6/1991 European Pat. Off. .

1212473 11/1970 United Kingdom .

OTHER PUBLICATIONS

J.P. Abstract, 2,080,699-A2, Mar. 20, 1990, Sanyo Kokusaku Pulp.

Aspects of Jetlace Technology As Applied To WetLaid Non-Wovens; Nonwovens Conference—Nov., 1987.

Wipes For Hydroentanglement Systems;—Nonwoven Fabrics Forum; Jun. 1988.

Hydroentanglement Technology Applied To Wet-
Formed And Other Precursor Webs; TAPPI Journal;
Jun. 1990.

Primary Examiner—James C. Cannon
Attorney, Agent, or Firm—Karl V. Sidor

[57] ABSTRACT

A hydraulically needled nonwoven pulp fiber web is disclosed. This nonwoven pulp fiber web has a mean flow pore size ranging from about 18 to about 100 microns, and a Frazier porosity of at least about 100 cfm/ft2. The web may also be characterized by a specific volume ranging from about 8 to about 15 cm3/g. The nonwoven pulp fiber web may contain a significant proportion of low-average fiber length pulp and still have a total absorptive capacity greater than about 500 percent and a wicking rate greater than about 2 centimeters per 15 seconds. The hydraulically needled nonwoven pulp fiber web may be used as a hand towel, wipe, or as a fluid distribution material in an absorbent personal care product. Also disclosed is a method of making the hydraulically needled nonwoven pulp fiber web.

33 Claims, 11 Drawing Sheets

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