US 12,234,583 B2
Apertured hydro-patterned nonwoven and method of making the same
Karthik Ramaratnam, Anderson, SC (US); Peter Zajaczkowski, Greenville, SC (US); John C. Parsons, Annville, PA (US); Michael Heinz Kauschke, PRIEN am Chiemsee (DE); and Antonius Lambertus Johannes De Beer, Loveland, OH (US)
Assigned to PFNONWOVENS LLC, Hazleton, PA (US); and PFNONWOVENS HOLDING S.R.O, Prague (CZ)
Filed by PFNONWOVENS LLC, Hazleton, PA (US); and PFNONWOVENS HOLDING S.R.O, Prague (CZ)
Filed on May 3, 2022, as Appl. No. 17/735,687.
Claims priority of provisional application 63/183,190, filed on May 3, 2021.
Prior Publication US 2022/0356617 A1, Nov. 10, 2022
Int. Cl. D04H 1/46 (2012.01); D04H 1/724 (2012.01)
CPC D04H 1/465 (2013.01) [D04H 1/724 (2013.01); D10B 2321/022 (2013.01)] 81 Claims
OG exemplary drawing
 
1. A method of forming an apertured hydro-patterned nonwoven web, comprising:
forming a nonwoven batt comprising continuous spunmelt fibers;
calender bonding the nonwoven batt to form a fully bonded precursor nonwoven web with a regular bond pattern that defines individual bond impressions and unbonded areas between the individual bond impressions, the regular bond pattern having a percentage bond area of 10% to 25%; and
hydraulically imparting the fully bonded precursor nonwoven web with a plurality of apertures, the step of hydraulically imparting comprising hydraulically treating the fully bonded precursor nonwoven web by a plurality of steps of water injection as the fully bonded nonwoven web passes over a plurality of pins.