Claims
- 1. A method of making a lofty nonwoven fabric layer, comprising:creating a layer of crimped fibers; and traversing the layer of crimped fibers through a diffuse flow of heated air at a temperature, flow rate, and traversal rate sufficient to set the crimps of the fibers without substantial melt bonding or relaxation of the fibers.
- 2. The method of making a lofty nonwoven fabric layer according to claim 1, wherein the crimped fibers comprise homofilament crimped fibers.
- 3. The method of making a lofty nonwoven fabric layer according to claim 1, wherein the crimped fibers comprise helically crimped fibers.
- 4. The method of making a lofty nonwoven fabric layer according to claim 1, wherein the crimped fibers comprise homofilament helically crimped fibers.
- 5. The method of making a lofty nonwoven fabric layer according to claim 1, where the fibers are comprised of polypropylene polymer.
- 6. The method of making a lofty nonwoven fabric layer according to claim 1, where the fibers are substantially continuous.
- 7. The method of making a lofty nonwoven fabric layer in a single, in-line process according to claim 1, wherein the flow of heated air is provided by a diffuse hot air knife.
- 8. The method of making a lofty nonwoven fabric layer according to claim 1, wherein the temperature is between about 200° F. and about 360° F.
- 9. The method of making a lofty nonwoven fabric layer according to claim 1, wherein the flow rate is between about 550 fpm to about 1000 fpm.
- 10. The method of making a lofty nonwoven fabric layer according to claim 1, wherein the traversal rate is between about 200 fpm to about 1200 fpm.
- 11. A method of making a lofty nonwoven fabric layer, comprising:creating a layer of substantially continuous filament crimped fibers; and traversing the layer of crimped fibers through a diffuse flow of heated air at a temperature, flow rate, and traversal rate sufficient to set the crimps of the fibers without substantial melt bonding or relaxation of the fibers.
- 12. The method of making a lofty nonwoven fabric layer according to claim 11, wherein the crimped fibers comprise homofilament crimped fibers.
- 13. The method of making a lofty nonwoven fabric layer according to claim 11, wherein the crimped fibers comprise helically crimped fibers.
- 14. The method of making a lofty nonwoven fabric layer according to claim 11, wherein the crimped fibers comprise homofilament helically crimped fibers.
- 15. The method of making a lofty nonwoven fabric layer according to claim 11, where the fibers are comprised of polypropylene polymer.
- 16. The method of making a lofty nonwoven fabric layer in a single, in-line process according to claim 11, wherein the flow of heated air is provided by a diffuse hot air knife.
- 17. The method of making a lofty nonwoven fabric layer according to claim 11, wherein the temperature is between about 270° F. and about 290° F.
- 18. The method of making a lofty nonwoven fabric layer according to claim 11, wherein the flow rate is between about 700 fpm to about 850 fpm.
- 19. The method of making a lofty nonwoven fabric layer according to claim 11, wherein the traversal rate is between about 300 fpm to about 800 fpm.
- 20. A method of making a lofty nonwoven fabric layer, comprising:creating a layer of meltspun crimped fibers; and traversing the layer of crimped fibers through a diffuse flow of heated air at a temperature, flow rate, and traversal rate sufficient to set the crimps of the fibers without substantial melt bonding or relaxation of the fibers.
- 21. The method of making a lofty nonwoven fabric layer according to claim 20, wherein the crimped fibers comprise homofilament crimped fibers.
- 22. The method of making a lofty nonwoven fabric layer according to claim 21, wherein the crimped fibers comprise helically crimped fibers.
- 23. The method of making a lofty nonwoven fabric layer according to claim 20, wherein the crimped fibers comprise homofilament helically crimped fibers.
- 24. The method of making a lofty nonwoven fabric layer according to claim 23, where the fibers are comprised of polypropylene polymer.
- 25. The method of making a lofty nonwoven fabric layer according to claim 24, where the fibers are substantially continuous.
- 26. The method of making a lofty nonwoven fabric layer in a single, in-line process according to claim 25, wherein the flow of heated air is provided by a diffuse hot air knife.
- 27. The method of making a lofty nonwoven fabric layer according to claim 26, wherein the temperature is between about 270° F. and about 290° F.
- 28. The method of making a lofty nonwoven fabric layer according to claim 27, wherein the flow rate is between about 700 fpm to about 850 fpm.
- 29. The method of making a lofty nonwoven fabric layer according to claim 28, wherein the traversal rate is between about 300 fin to about 800 fpm.
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/257,982, filed Dec. 22, 2000.
US Referenced Citations (17)
Foreign Referenced Citations (5)
Number |
Date |
Country |
1219165 |
Jun 1966 |
DE |
2 044 098 |
Feb 1971 |
FR |
1126552 |
Sep 1968 |
GB |
9514799 |
Jun 1995 |
WO |
WO 0111119 |
Feb 2001 |
WO |
Provisional Applications (1)
|
Number |
Date |
Country |
|
60/257982 |
Dec 2000 |
US |