Abstract: The present invention is directed to a method of forming a nonwoven fabric, which exhibits a pronounced three-dimensional image that is durable to both converting and end-use application. In particular, the present invention contemplates that a fabric is formed from a precursor web comprising at least one support layer or scrim, which when subjected to hydroentanglement on a moveable imaging surface of a three-dimensional image transfer device, an enhanced product is achieved. By formation in this fashion, hydroentanglement of the precursor web results in a more pronounced three-dimensional image; an image that is durable to abrasion and distortion due to elongation.

Abstract: The present invention relates generally to a method of making nonwoven fabrics, wherein the fabrics are formed from splittable filaments or staple length fibers having a plurality of sub-components which are at least partially separable. The filaments or fibers are at least partially separated into their sub-components attendant to hydroentanglement, which can be effected on a three-dimensional image transfer device. Improved physical properties, including improved tensile strength, elongation, and Taber Abrasion resistance are achieved.

Abstract: The present invention is directed to a method of forming a two-sided nonwoven fabric, which exhibits a pronounced three-dimensional image that is durable to both converting and end-use application. In particular, the present invention contemplates that a fabric is formed from a first precursor web comprising a first fibrous matrix and a second precursor web comprising a second fibrous matrix. Between the first and second precursor web, a fluid-pervious support layer or scrim, is interposed and subjected to hydroentanglement on a moveable imaging surface having a three-dimensional image transfer device. By formation of a nonwoven fabric in this fashion, a three-dimensional image that is durable to abrasion and distortion due to elongation is imparted and a product formed which exhibits on its opposite surfaces the unique properties of the respective fibrous matrix used.

Abstract: The present invention is directed to a method of forming a nonwoven fabric, which exhibits a first three-dimensional image and a second three-dimensional image whereby the first and second three-dimensional images are dissimilar from one another. In particular, the present invention contemplates a fabric comprised of sequentially formed three-dimensional images that are formed from a pre-entangled precursor web entangled on a first three-dimensional transfer device so as to impart a first image therein, then subjected to hydroentanglement on a second three-dimensional image transfer device wherein a second three-dimensional image is imparted to the web that is different from the first three-dimensional image, the resulting nonwoven fabric presenting aesthetic and tactile qualities representative of both imparted images.

Abstract: The present invention is directed a nonwoven fabric which is imparted with a three-dimensional image or pattern, and apertures essentially devoid of fiber, during the fabrication stage. The nonwoven fabric exhibits a fibrous extension out of the plane of the material, while apertures are present that have a pronounced uniformity and a significant reduction in fibrous occlusion.

Abstract: A three-dimensionally imaged nonwoven fabric, as formed in accordance with the principles of the present invention, contemplates a material formed by hydroentanglement of at least one lightly bonded continuous filament layer upon a device having a three-dimensional foraminous forming surface. The preferred continuous filament substrate is in the form of a precursor web comprising spunbond continuous polymeric filaments. A nonwoven fabric formed in accordance with the present invention may be formed to include substantially continuous filaments (from a relatively lightly bonded spunbond precursor web), with the resulting fabric having a machine direction tensile strength of at least about 1,472 grams per centimeter at 47% machine-direction elongation.

Abstract: The present invention is directed to a method of forming a nonwoven fabric, which exhibits a pronounced three-dimensional image that is durable to both converting and end-use application. In particular, the present invention contemplates that a fabric is formed from a precursor web comprising at least one support layer or scrim, which when subjected to hydroentanglement on a moveable imaging surface of a three-dimensional image transfer device, an enhanced product is achieved. By formation in this fashion, hydroentanglement of the precursor web results in a more pronounced three-dimensional image; an image that is durable to abrasion and distortion due to elongation.

Abstract: A composite nonwoven fabric is formed by providing a synthetic fiber web comprising staple length polymeric fibers, and a cellulosic fiber web, preferably comprising wood pulp fibers. Prior to integration of the webs, the synthetic fiber web is subjected to hydroentangling to form a partially entangled web, with the cellulosic fiber web thereafter juxtaposed with the partially entangled web for hydroentanglement and integration of the webs. Pre-entanglement of the synthetic fiber web desirably acts to minimize the energy input required for integration of the cellulosic fiber and synthetic fiber webs, and also desirably acts to abate loss of the cellulosic fibers during hydroentanglement and integration of the webs.

Abstract: A composite nonwoven fabric is formed by providing a synthetic fiber web comprising staple length polymeric fibers, and a cellulosic fiber web, preferably comprising wood pulp fibers. Prior to integration of the webs, the synthetic fiber web is subjected to hydroentangling to form a partially entangled web, with the cellulosic fiber web thereafter juxtaposed with the partially entangled web for hydroentanglement and integration of the webs. Pre-entanglement of the synthetic fiber web desirably acts to minimize the energy input required for integration of the cellulosic fiber and synthetic fiber webs, and also desirably acts to abate loss of the cellulosic fibers during hydroentanglement and integration of the webs.

Abstract: Shipping container for transporting a fragile cylindrical sleeve is constructed to facilitate mounting and demounting of the sleeve without any damage thereto. The container is designed to align the sleeve with a mandrel in a surfacing machine or a drum of a nonwoven fabric producing machine, which is useful when a cylindrical sleeve is being transferred from the shipping container onto the mandrel or drum, or vice versa. The container is useful in transporting a blank cylindrical sleeve from its production facility to a surfacing facility, aligning and mounting the blank sleeve on a mandrel in a surfacing machine, removing the machined sleeve from the surfacing machine, transporting the machined sleeve to a nonwoven fabric production facility, and mounting and aligning the machined sleeve on a nonwoven fabric producing machine. The container includes an elongated outer housing having front and rear ends.