Hybrid mixed media nonwovens composed of macrofibers and microfibers. Part I: three-layer segmented pie configuration

Nonwoven fabrics, composed of microdenier fibers, can be easily created by using splittable bicomponents such as segmented pie. Hydroentangling has been shown as a very effective method for mechanically splitting these fibers. Such structures are known to form a densely packed nonwoven fabric with concomitant consequences in low porosity and tear strength. It is not, therefore, uncommon to insert a reinforcing scrim as a “rip-stop” mechanism in the middle of such structures to improve their properties, especially tear resistance. Instead, we propose a hybrid structure where the middle portion consists of solid homocomponent fibers, made from the same polymer as one of the components used in the bicomponent fibers, produced simultaneously during web formation, without causing noticeable changes in the fabrics’ overall texture. We report on the production and properties of fabrics composed entirely of bicomponent segmented pie fibers as well as our hybrid fabrics arranged in a three-layer configuration.