Three-Dimensional Nonwoven Materials and Methods of Manufacturing Thereof

Antonio J. Carrillo Ojeda, Appleton, WI; Davis Dang H. Nhan, Menasha, WI; Neil T. Scholl, Neenah, WI; Vasily A. Topolkaraev, Appleton, WI; David G. Biggs, New London, WI; Mark M. Mleziva, Appleton, WI; Steven J. Roffers, Neenah, WI; and Dustin J. Smith, Green Bay, WI.

Assigned to Kimberly-Clark Worldwide, Inc., Neenah, WI.

Filed: 11/27/19
Issued: 6/30/26

A method for manufacturing a three-dimensional nonwoven material, the method comprising: providing a precursor web, the precursor web comprising a plurality of fibers; transferring the precursor web to a forming surface, the forming surface having a plurality of forming holes; providing a fluid entangling device having a plurality of fluid jets capable of emitting a plurality of pressurized fluid streams of entangling fluid from the plurality of fluid jets in a direction towards the forming surface; directing the plurality of pressurized fluid streams of the entangling fluid from the plurality of fluid jets in a direction towards the precursor web on the forming surface to move at least some of the fibers into the plurality of forming holes to create a fluid entangled web comprising a first surface and a second surface opposite the first surface; removing the fluid entangled web from the forming surface such that the at least some of the fibers moved into the plurality of forming holes provide a plurality of nodes extending away from a base plane on the first surface of the fluid entangled web, the plurality of nodes having an anisotropy value greater than 1.0 as determined by the Node Analysis Test Method; and drying the fluid entangled web to provide a three-dimensional nonwoven material.