NONWOVEN FABRIC, METHOD FOR MAKING SAID NONWOVEN FABRIC, AND ARTICLE COMPRISING SAID NONWOVEN FABRIC

Abstract

Nonwoven fabrics are provided that include a melt-blown first layer, wherein the melt-blown first layer comprises a first polymeric material comprising (i) a first polymeric component and (ii) optionally, one or more first additives. The first polymeric component comprises a first recycled polypropylene (rPP).

Description

NON-WOVEN FABRICS INCLUDING RECYCLED POLYPROPYLENE TECHNICAL FIELD

[0001] Embodiments of the invention disclosed herein generally relate to nonwoven fabrics including at least one meltblown layer comprising recycled polypropylene (rPP). The nonwoven fabric may include an additional nonwoven layer, wherein the at least one meltblown layer provides an abrasive characteristic to the nonwoven fabric. In this regard, the nonwoven fabric may be provided in the form of a wipe (e.g., wet or dry), a filter medium, or a face mask. BACKGROUND

[0002] Nonwoven fabrics are generally used in the formation of cleaning wipes for a variety of cleaning applications, including personal, household, commercial, and industrial applications. In some types of cleaning wipes, the cleaning wipes may include a layer having an abrasive material to remove known “sticky” materials that are difficult to remove. SUMMARY OF THE INVENTION

[0003] One or more embodiments of the invention may address one or more of the aforementioned problems. Certain embodiments according to the invention provide a nonwoven fabric comprising a first nonwoven layer comprising a first meltblown layer. The first fiber layer may comprise a first polymeric material including (i) a first polymeric component and (ii), optionally, one or more first additives. The first polymeric component may comprise a first recycled polypropylene (rPP).

[0004] In another aspect, the present invention provides a method for making a nonwoven fabric. The method may comprise the following: (a) forming a first polymeric melt comprising (i) a first polymeric component and (ii), optionally, one or more first additives, wherein the first polymeric component comprises a first recycled polypropylene (rPP); (b) producing a first nonwoven layer comprising a first meltblown layer, wherein the first meltblown layer comprises a plurality of first meltblown fibers; and (c) consolidating the plurality of 239092 2050467 of 24 first melt-blown fibers to form the nonwoven fabric, as described and disclosed herein.

[0005] In yet another aspect, the present invention provides an article comprising a wipe material. The wipe material may comprise a plurality of interconnected individual wipes. The plurality of interconnected individual wipes may comprise a nonwoven fabric as described and disclosed herein. The plurality of interconnected individual wipes, in accordance with certain embodiments of the invention, may be defined by a plurality of perforations. The wipe material, in accordance with certain embodiments of the invention, may comprise a plurality of individual wipes (e.g., interconnected or spaced apart) comprising a nonwoven fabric, as described and disclosed herein, wherein the plurality of wipes are housed within a container.

[0006] In yet another aspect, the present invention provides an article comprising a filter medium. The filter medium may comprise a nonwoven fabric as described and disclosed herein, wherein the nonwoven fabric is optionally housed within a frame. The filter medium, according to certain embodiments of the invention, may comprise a face mask including a nonwoven fabric as described and disclosed herein. The face mask may include one or more straps directly or indirectly attached to the nonwoven fabric. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limiting the embodiments set forth herein; rather, these embodiments are provided so that the present disclosure complies with applicable legal requirements. Like numerals refer to like elements throughout, and wherein:

[0008] Figure 1 illustrates a nonwoven fabric comprising a first nonwoven fiber layer comprising rPP according to certain embodiments of the present invention; 239092 2050467 of 24

[0009] Figure 2 illustrates a nonwoven fabric including a first nonwoven layer comprising a first meltblown nonwoven layer comprising rPP supported on a second nonwoven layer according to certain embodiments of the invention;

[00010] Figure 3 illustrates a nonwoven fabric including a second nonwoven layer located between a first nonwoven layer and a third nonwoven layer, wherein the first nonwoven layer and the third nonwoven layer each comprise a meltblown layer comprising rPP;

[00011] Figure 4 illustrates the nonwoven fabric of Figure 2, wherein the nonwoven fabric further comprises a first nonwoven outer layer over the first meltblown layer; and

[00012] Figure 5 illustrates the nonwoven fabric of Figure 3, wherein the nonwoven fabric further comprises a first nonwoven outer layer over the first meltblown layer and a second nonwoven outer layer located over a second meltblown layer. DETAILED DESCRIPTION

[0013] The invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limiting the embodiments set forth herein; rather, these embodiments are provided so that the present disclosure will comply with applicable legal requirements. As used in the specification and appended claims, the singular forms “a,” “an,” “the,” include plural referents unless the context clearly dictates otherwise.

[00014] The terms “substantial” or “substantially” may encompass all of the specified amount, according to certain embodiments of the invention, or most, but not all, of the specified amount (e.g., 95%, 96%, 97%, 98%, or 99% of all of the specified amount) according to other embodiments of the invention.

[00015] The terms “polymer” or “polymeric”, as used interchangeably herein, may include homopolymers, copolymers, such as block, graft, random and alternating copolymers or terpolymers, etc., and mixtures and modifications thereof. 239092 2050467 of 24 thereof. Furthermore, except for specific limitations, the term "polymer" or "polymeric" shall include all possible structural isomers, stereoisomers, including, but not limited to, geometric isomers, optical isomers or enantiomers; and / or any chiral molecular configuration of said polymer or polymeric material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic configurations of said polymer or polymeric material. The term "polymer" or "polymeric" shall also include polymers made from various catalyst systems, including, but not limited to, the Ziegler-Natta catalyst system and the metallocene / single-site catalyst system. The term "polymer" or "polymeric" shall further include, in accordance with certain embodiments of the invention, polymers produced by fermentation processes or of biological origin.

[00016] The terms “elastomer” or “elastomeric,” as used interchangeably herein, may encompass any material that upon application of a biasing force can be stretched to an elongated length of at least 110% or even 125% of its original relaxed length (i.e., can be stretched to at least 10% or even 25% more of its original length), without breaking. Upon release of the applied force, for example, the material may recover at least 40%, at least 60%, or even at least 80% of its elongation. In certain embodiments of the invention, the material may recover between 20% and 100% of its elongation, between 25% and 95% of its elongation, between 30% and 90% of its elongation, between 40% and 80% of its elongation, or between 50% and 70% of its elongation.For example, a material having an initial length of 100 mm can be extended to at least 110 mm and, upon removal of the force, would retract to a length of about 106 mm (e.g., exhibiting a recovery of 40%). Examples of elastomers may include Vistamaxx™ propylene-based elastomers (commercially available from ExxonMobile), which comprise copolymers of propylene and ethylene. Vistamaxx™ propylene-based elastomers, for example, comprise microcrystalline regions of isotactic polypropylene and random amorphous regions.

[00017] The terms “nonwoven” and “nonwoven web” as used herein may comprise a web having a structure of individual fibers, filaments, and / or yarns which are interwoven but not in an identifiable repeating manner as in a knitted or woven fabric. Nonwoven fabrics or webs, according to certain embodiments of the invention, ... structure of individual fibers, filaments, and / or yarns which are interwoven but not in an identifiable repeating manner as in a knitted or woven fabric. 239092 2050467 of the invention, can be formed by any process conventionally known in the art, such as, for example, meltblown processes, spinning processes, needle punching, hydroentanglement, air, and carded weaving processes. A “nonwoven web,” as used herein, can comprise a plurality of individual fibers that have not undergone a consolidation process.

[00018] The terms “fabric” and “nonwoven fabric,” as used herein, may comprise a web of fibers in which a plurality of the fibers are mechanically entangled or interconnected, fused, and / or chemically bonded. For example, a nonwoven web of individually placed fibers may be subjected to a bonding or consolidation process to bond at least a portion of the individual fibers together to form a coherent (e.g., bonded) web of interconnected fibers.

[00019] The terms “consolidated” and “consolidation,” as used herein, may comprise bringing at least a portion of the fibers of a nonwoven web into closer proximity or bonding to one another (e.g., thermally fused, chemically bonded, and / or mechanically entangled) to form a bond site, or bond sites, that function to increase resistance to external forces (e.g., abrasion and tensile forces), as compared to the unconsolidated web. The bond site or bond sites, for example, may comprise a discrete or localized region of the web material that has been softened or meltblown and, optionally, subsequently or simultaneously compressed to form a discrete or localized deformation in the web material.Furthermore, the term "consolidated" may encompass an entire nonwoven web that has been processed such that at least a portion of the fibers are brought together or bonded (e.g., thermally fused, chemically bonded, and / or mechanically entangled), such as by thermal bonding or mechanical entanglement (e.g., hydroentanglement). Such a web may be considered a consolidated nonwoven, a nonwoven fabric, or simply a fabric according to certain embodiments of the invention.

[0020] The term staple fiber, as used herein, may comprise a fiber cut from a filament. According to certain embodiments, any type of filament material may be used to form staple fibers. For example, staple fibers may be formed from polymeric fibers and / or elastomeric fibers. Non-limiting examples of materials may comprise polyolefins (e.g., a 239092 2050467 of 24 polypropylene copolymer or containing polypropylene), polyethylene terephthalate, and polyamides. The average staple fiber length may range, by way of example only, from about 2 centimeters to about 15 centimeters.

[0021] The term “spunbond” as used herein may comprise fibers that are formed by extruding molten thermoplastic material in the form of filaments from a plurality of fine, typically circular capillaries of a spinneret, with the extruded filaments then rapidly reducing in diameter. In one embodiment of the invention, the spunbond fibers are generally tacky when laid down on a collecting surface and may be generally continuous as disclosed and described herein. It is noted that the spunbond used in certain composites of the invention may include a nonwoven described in the literature as SPINLACE®. The spunbond fibers, for example, may comprise continuous fibers.

[00022] As used herein, the term “continuous fibers” refers to fibers that are not cut from their original length before a nonwoven web or nonwoven fabric is formed. Continuous fibers may have average lengths ranging from more than 15 centimeters to more than one meter and up to the length of the web or fabric being formed. For example, a continuous fiber, as used herein, may comprise a fiber in which the fiber length is at least 1,000 times greater than the average fiber diameter, such as the fiber length being at least about 5,000, 10,000, 50,000, or 100,000 times greater than the average fiber diameter.

[0023] The term “meltblown,” as used herein, may encompass fibers that are formed by extruding a molten thermoplastic material through a plurality of fine capillaries in the die as molten yarns or filaments in high velocity, converging gas (e.g., air) streams that attenuate the molten thermoplastic filaments to reduce their diameter, which may be to microfiber diameters, according to certain embodiments of the invention. According to one embodiment of the invention, the capillaries in the die may be circular. The meltblown fibers are then entrained by the high velocity gas stream and deposited on a collecting surface to form a randomly dispersed network of meltblown fibers.Meltblown fibers may comprise microfibers that may be continuous or discontinuous and are generally sticky when laid down. 239092 2050467 of 24 collection surface. However, meltblown fibers are shorter than spunbond fibers.

[00024] The term “meltblown shots,” as used herein, may comprise a thick, non-uniform or non-continuous layer applied in a meltblown process deliberately operated to generate random globules of a polymer interconnected with strands. Furthermore, the term “meltblown rope,” as used herein, may further comprise a thick, non-uniform or non-continuous layer applied in a meltblown process deliberately operated to generate random “ropes” or bundles of a polymer interconnected with strands. Meltblown ropes differ from meltblown shots in that the meltblown rope may be more elongated and / or narrower than the meltblown rope. Both ropes and / or meltblown shots may comprise irregularly shaped fibers, bales, or particles.In this regard, for example, meltblown ropes and / or meltblown shots may comprise fibers, bundles, particles, or globules with non-circular cross-sections. The ropes and / or meltblown shots may be randomly and irregularly distributed within the body of a meltblown layer and / or on a surface of a meltblown layer. For example, the ropes and / or meltblown shots may extend in random paths and may intersect and / or cross at random locations. However, the ropes and / or meltblown shots may not intersect at all.

[00025] The term “layer,” as used herein, may comprise a generally recognizable combination of similar material types and / or functions existing in the XY plane.

[0026] All integer endpoints disclosed herein that may create a smaller range within a given range disclosed herein are within the scope of certain embodiments of the invention. By way of example, a disclosure of about 10 to about 15 includes disclosure of intermediate ranges, e.g., from: about 10 to about 11; from about 10 to about 12; from about 13 to about 15; from about 14 to about 15; etc. In addition, all simple decimal endpoints (e.g., numbers reported to the nearest tenth) that may create 239092 2050467 of 24 a smaller range within a given range disclosed herein are within the scope of certain embodiments of the invention. By way of example, a disclosure of about 1.5 to about 2.0 includes disclosure of intermediate ranges, for example, from about 1.5 to about 1.6; from about 1.5 to about 1.7; from about 1.7 to about 1.8; etc.

[00027] In one aspect, the present invention provides a nonwoven fabric comprising a nonwoven fabric comprising a first nonwoven layer comprising a first meltblown layer. The first meltblown layer may comprise a first polymeric material including (i) a first polymeric component and (ii), optionally, one or more first additives. The first polymeric component comprises a first recycled polypropylene (rPP). The rPP used in any of the nonwoven layers of the nonwoven fabric (e.g., the first meltblown layer or any other layers that may be present in the nonwoven fabric) may be derived from waste material or scrap, such as residue from spinning production. For example, a polypropylene spinning line may produce waste material (e.g., cut material, low quality web formation, etc.) which can be used as the source of polypropylene to form, for example, the meltblown layers of the nonwoven fabric. In this regard, polypropylene production scrap can be recycled from upstream operations of, for example, melt spinning (e.g., the production scrap is melted to produce meltblown rPP and form meltblown fibers therefrom). According to certain embodiments of the invention, for example, the polypropylene production scrap comprises spinning-grade polypropylene having a relatively low melt flow rate that may not be viable for meltblown fiber production.In this regard, molten rPP formed from production scrap (e.g., spinning-grade polypropylene) may further include one or more additives, such as viscosity-reducing agents, such that the resulting molten rPP is higher than that of the spinning-grade polypropylene used as the polypropylene source. By increasing the melt flow rate, e.g., by viscosity reduction, the rPP may be melt-blown to form a melt-blown layer comprising rPP. 239092 2050467 of 24

[0028] According to certain embodiments of the invention, the first polymer component may comprise from 75% to 100% by weight of the first rPP, such as at least about one of the following: 75, 78, 80, 82, 85, 88, and 90% by weight of the first rPP, and / or at most about one of the following: 100, 99, 98, 96, 95, 94, 92, 90% by weight of the first rPP. According to certain embodiments, the rPP may be blended with virgin polypropylene, virgin elastomeric polymers, etc. (e.g., the balance of the first polymer component may be virgin polypropylene and / or virgin elastomeric polymers). Examples of virgin elastomeric polymers, for example, may include VistamaxxTM polymers (e.g., VistamaxxTM6202), which are propylene-based elastomers comprising a copolymer of propylene and ethylene.These propylene-based elastomers comprise, for example, isotactic microcrystalline regions of polypropylene and random amorphous regions (e.g., ethylene). Such olefinic copolymers may comprise hard blocks and soft blocks, where the hard blocks are primarily propylene and the soft blocks are primarily ethylene. In this regard, the hard blocks (e.g., propylene) may comprise from 10 to 90% by weight of the copolymer, while the soft blocks may comprise from 90 to 10% by weight of the copolymer. In this regard, these copolymers include a random distribution of ethylene throughout the copolymer. Vistamaxx™ copolymers (e.g., Vistamaxx™ 6202) are commercially available from ExxonMobil. VistamaxxTM6202 has a density of 0.862 g / cc, an MI (190°C / 2.16 kg) of 9.1, an MFR (230°C / 2.16 kg load) of 20, and an ethylene content of 15% by weight.A further example includes an olefin diblock copolymer comprising an EP-iPP diblock polymer, such as Intune™, which is a polypropylene-based block copolymer that includes ethylene monomers. By way of further examples, the polypropylene-based elastomer may comprise an EP-iPP diblock polymer having an ethylene content of 43 to 48% by weight, or 43.5 to 47% by weight, or 44 to 47% by weight, based on the weight of the diblock copolymer. In an exemplary embodiment, the EP-iPP diblock polymer may have a polypropylene content of 57 to 52% by weight, or 56.5 to 53% by weight, or 56 to 53% by weight, based on the weight of the EP-iPP diblock polymer.

[00029] According to certain embodiments of the invention, the molten rPP and the resulting meltblown layer comprising rPP are devoid of a 239092 2050467 of 24 elastomeric polymer. In this regard, for example, the rPP and the resulting meltblown layer comprising rPP can be formed entirely from polypropylene (e.g., rPP, virgin polypropylene, or blends thereof).

[0030] According to certain embodiments of the invention, the first meltblown layer may comprise a plurality of first meltblown fibers with an average diameter greater than about 3 microns. For example, the average diameter of the plurality of first meltblown fibers may be from about 3 microns to about 12 microns, such as at least about any of the following: 3, 4, 5, 6, 7, and 8 microns and / or a maximum of about any of the following: 12, 11, 10, 9, and 8 microns. According to certain embodiments of the invention, the plurality of first meltblown fibers impart an abrasive characteristic and / or surface to the nonwoven fabric.

[00031] The plurality of first meltblown fibers, for example, may comprise meltblown shots, or meltblown cords, or both. The shot or meltblown cord, or both, may be randomly or irregularly distributed throughout the meltblown layer, on a first outer surface of the meltblown layer, or both. If present, the shot or meltblown cord, or both, impart an increased abrasive characteristic and / or surface to the nonwoven fabric. For example, the first meltblown layer may comprise a shot height or average chord height, or both, of about 0.1 mm to about 1.0 mm, such as at least about one of the following: 0.1, 0.2, 0.3, 0.4, and 0.5 mm, and / or a maximum of about any of the following: 1, 0.9, 0.8, 0.7, 0.6, and 0.5 mm.

[0032] According to certain embodiments of the invention, the meltblown shot (if present) may comprise irregular fibers, bales, or particles. The meltblown rope (if present) may comprise bundles of bonded meltblown fibers having a varying cross-section over the length of the meltblown rope.

[00033] The first polymer component absent a viscosity reducing agent may have a first melt flow rate (MFR) of about 10 to about 300 g / 10 min as determined by ASTM D1238 (230 C° / 2.16 kg), such as at least any of the following: 239092 2050467 of 24 10, 20, 40, 60, 80, 100, 120, 140, and 150 g / 10 min, per ASTM D1238 (230C° / 2.16 kg), and / or at most approximately any of the following: 300, 280, 260, 240, 220, 200, 180, 160, and 150 g / 10 min, per ASTM D1238 (230C° / 2.16 kg).

[00034] As noted above, the first polymeric material may include one or more first additives, wherein the one or more first additives may comprise a first viscosity reducing agent. The first viscosity reducing agent, for example, may comprise a first sterically hindered hydroxylamine ester, which may be a free peroxide additive. Such an additive is available as Irgatec® (i.e., a sterically hindered hydroxylamine ester in a matrix from BASF). This additive, for example, reduces the melt viscosity, thereby controlling the molecular weight degradation of polypropylene during spinning. Additionally, it narrows the molecular weight distribution which provides the advantage of improved spinnability and viable formation of meltblown layers from rPP.In this regard, the first polymeric material in the presence of one or more first additives may have a second MFR of about 100 to about 2500 g / 10 min as determined by ASTM D1238 (230 C° / 2.16 kg), such as at least any of the following: 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 800, 900, 1000, 1100, and 1200 g / 10 min as determined by ASTM D1238 (230 C° / 2.16 kg), and / or at most any of the following: 2500, 2200, 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300 and 1200 g / 10 min according to ASTM D1238 (230C° / 2.16 kg).

[00035] According to certain embodiments of the invention, the first polymeric material may comprise from about 0.1 to about 10% by weight of the first viscosity reducing agent, such as at least about any of the following: 0.1, 0.5, 1, 2, 3, 4 and 5% by weight of the first viscosity reducing agent and / or at most about any of the following: 10, 9, 8, 7, 6 and 5% by weight of the first viscosity reducing agent.

[00036] According to certain embodiments of the invention, the first meltblown layer may have a first basis weight of about 1 to about 150 gsm, such as at least about any of the following: 1, 3, 5, 10, 15, 25, 50, and 75 gsm and / or at most about any of the following: 150, 125, 100, and 75 gsm. 239092 2050467 of 24

[00037] The nonwoven fabric, according to certain embodiments of the invention, may further comprise a hydrophilic finish disposed on an outer surface of the first meltblown layer. Additionally or alternatively, the first polymeric material may comprise a first hydrophilic melt additive (e.g., present within the body of the meltblown fibers and may bloom to the surface of the meltblown fibers over time).Additionally or alternatively, the hydrophilic finish may be imparted by topical coating of a hydrophilic additive (e.g. an anionic or cationic surfactant) such as the products available under the name Stantex® from Pulcra Chemicals such as Stantex grades S 6118, S6087-4, 7290 and S 6327 or “Silastol” from SChill+Seilacher (various grades) such as Silastol PHP 26 or PHP 16 each of which are cationic surfactants providing a long lasting cationic coating.

[00038] Figure 1 illustrates a nonwoven fabric 1 comprising a first meltblown nonwoven layer 10 comprising rPP according to certain embodiments of the invention. In this regard, the nonwoven fabric may be entirely formed of meltblown fibers (e.g., from either a single meltblown bundle or multiple meltblown bundles). In accordance with certain embodiments of the invention, the first meltblown nonwoven layer may be consolidated by any suitable means, such as those described and disclosed herein.

[0039] According to certain embodiments of the invention, the nonwoven fabric may further comprise a second nonwoven layer (e.g., a backing layer for the first meltblown layer) bonded to the first nonwoven layer (i.e., the first meltblown layer). The second nonwoven layer may comprise a spunbond layer, a meltblown layer, a carded web of staple fibers, a mechanically bonded layer, or any combination thereof. The second nonwoven layer may comprise a synthetic polymer, such as a polyolefin, a polyester, a polyamide, or any combination thereof. For example, the synthetic polymer may comprise a virgin polypropylene, a recycled polypropylene, a virgin polyethylene, a recycled polyethylene, a virgin polyester, a recycled polyester, or any combination thereof. Additionally or alternatively, the second nonwoven layer may comprise fibers 239092 2050467 of 24 cellulosic, such as natural cellulosic fibers, synthetic cellulosic fibers or any combination thereof.

[00040] The second nonwoven layer may comprise from 50% to 100% by weight of a virgin synthetic polymer, such as virgin polypropylene, such as at least about any of the following: 50, 55, 60, 65, 70, 75, 78, 80, 82, 85, 88 and 90% by weight of the virgin synthetic polymer and / or at most about any of the following: 100, 99, 98, 96, 95, 94, 92 and 90% by weight of the virgin synthetic polymer. Additionally or alternatively, the second nonwoven layer may comprise from 50% to 100% by weight of a recycled synthetic polymer, such as at least about any of the following: 50, 55, 60, 65, 70, 75, 78, 80, 82, 85, 88, and 90% by weight of the recycled synthetic polymer and / or at most about any of the following: 100, 99, 98, 96, 95, 94, 92, 90% by weight of the recycled synthetic polymer.

[0041] According to certain embodiments of the invention, the second nonwoven layer may comprise one or more spunbond nonwoven layers, such as at least about any of the following: 1, 2, 3, 4, and 5 spunbond nonwoven layers and / or at most about any of the following: 10, 9, 8, 7, 6, and 5 spunbond nonwoven layers. Additionally or alternatively, the second nonwoven layer may comprise an SMS structure or a spunbond-cellulosic-spunbond structure, wherein the spunbond-cellulosic-spunbond structure comprises a mechanically bonded material, such as a hydroentangled nonwoven, a needle-punched nonwoven, or an air-entangled nonwoven.

[00042] According to certain embodiments of the invention, the second nonwoven layer may have a first basis weight of about 1 to about 150 gsm, such as at most about any of the following: 1, 3, 5, 10, 15, 25, 25, 50, and 75 gsm and / or at most about any of the following: 150, 125, 100, and 75 gsm. In this context, for example, the nonwoven fabric may have a basis weight (combination of the first nonwoven layer and the second nonwoven layer) of about 2 to about gsm, such as at least about any of the following: 2, 6, 10, 20, 30, 50, 100, 125, and 150 gsm and / or at most about any of the following: 300, 275, 250, 225, 200, 175, and 150 gsm. 239092 2050467 of 24

[00043] Figure 2, for example, illustrates a nonwoven fabric 1 including a first nonwoven layer 10 comprising a first meltblown nonwoven layer comprising rPP supported on a second nonwoven layer 20 according to certain embodiments of the invention.

[0044] According to certain embodiments of the invention, the nonwoven fabric may comprise a third nonwoven layer. The third nonwoven layer may comprise a second meltblown layer, wherein the second nonwoven layer is located directly or indirectly between the first and third nonwoven layers. In this regard, the second nonwoven layer may function as a backing layer that provides structural integrity to both the first and third meltblown layers. The second meltblown layer comprises a second polymeric material that includes (i) a second polymeric component and (ii), optionally, one or more second additives, wherein the first and second polymeric components may be the same or different and the one or more first additives and the one or more second additives may be the same or different.

[0045] According to certain embodiments of the invention, the second polymer component may comprise from 75% to 100% by weight of the second rPP, such as at least about any of the following: 75, 78, 80, 82, 85, 88, and 90% by weight of the second rPP and / or at most about any of the following: 100, 99, 98, 96, 95, 94, 92, and 90% by weight of the second rPP. According to certain embodiments of the invention, the rPP may be blended with virgin polypropylene, virgin elastomeric polymers such as those described and disclosed herein, etc. (e.g., the remainder of the first polymer component may be virgin polypropylene and / or virgin elastomeric polymers). According to certain embodiments of the invention, the molten rPP for the second polymeric material and the resulting second meltblown layer comprising rPP are devoid of an elastomeric polymer.In this regard, for example, the rPP and the resulting meltblown layer comprising the rPP may be formed entirely of polypropylene (e.g., rPP, virgin polypropylene, or mixtures thereof).

[0046] According to certain embodiments of the invention, the second meltblown layer may comprise a plurality of second meltblown fibers with a second average diameter greater than about 3 microns. For example, the 239092 2050467 of 24 average diameter of the plurality of first meltblown fibers may be from about 3 microns to about 12 microns, such as at least about any of the following: 3, 4, 5, 6, 7, and 8 microns and / or at most about any of the following: 12, 11, 10, 9, and 8 microns. According to certain embodiments of the invention, the plurality of second meltblown fibers impart an abrasive characteristic and / or surface to the nonwoven fabric.

[00047] The plurality of second meltblown fibers, for example, may comprise meltblown shots, meltblown cords, or both. The meltblown shot, meltblown cord, or both may be randomly or irregularly distributed throughout the meltblown layer, on a first exterior surface of the second meltblown layer, or both. If present, the meltblown shot, meltblown cords, or both, impart a greater abrasive characteristic and / or surface to the nonwoven fabric. For example, the second meltblown layer may comprise an average shot height, chord height, or both of about 0.1 mm to about 1.0 mm, such as at least about any of the following: 0.1, 0.2, 0.3, 0.4, and 0.5 mm, and / or at most about any of the following: 1, 0.9, 0.8, 0.7, 0.6, and 0.5 mm.

[0048] According to certain embodiments of the invention, the meltblown shot (if present) may comprise irregularly shaped fibers, bales, or particles. The meltblown rope (if present) may comprise bundles of bonded meltblown fibers having a varying cross-section over the length of the meltblown rope.

[00049] The second polymer component absent a viscosity reducing agent may have a third melt flow rate (MFR) of about 10 to about 300 g / 10 min as determined by ASTM D1238 (230 C° / 2.16 kg), such as at least any of the following: 10, 20, 40, 60, 80, 100, 120, 140, and 150 g / 10 min, according to ASTM D1238 (230 C° / 2.16 kg), and / or at most any of the following: 300, 280, 260, 240, 220, 200, 180, 160, and 150 g / 10 min, according to ASTM D1238 (230 C° / 2.16 kg).

[00050] As noted above, the second polymeric material may include one or more second additives, wherein the one or more first additives may comprise 239092 2050467 of 24 a second viscosity reducing agent. The second viscosity reducing agent, for example, may comprise a second sterically hindered hydroxylamine ester, which may be a free peroxide additive. Such an additive is available as Irgatec® CR76 (i.e., a sterically hindered hydroxylamine ester in a matrix from BASF). This additive, for example, reduces the melt viscosity, thereby controlling the molecular weight degradation of polypropylene during spinning. Additionally, it narrows the molecular weight distribution, which provides the advantage of improved spinnability and viable formation of meltblown layers from rPP.In this regard, the second polymeric material in the presence of one or more first additives may have a fourth MFR of from about 100 to about 2500 g / 10 min as determined by ASTM D1238 (230 C° / 2.16 kg), such as at least any of the following: 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 800, 900, 1000, 1100, and 1200 g / 10 min as determined by ASTM D1238 (230 C° / 2.16 kg), and / or at most any of the following: 2500, 2200, 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300 and 1200 g / 10 min according to ASTM D1238 (230C° / 2.16 kg).

[00051] According to certain embodiments of the invention, the second polymeric material may comprise from about 0.1 to about 10% by weight of the second viscosity reducing agent, such as at least about any of the following: 0.1, 0.5, 1, 2, 3, 4 and 5% by weight of the first viscosity reducing agent and / or at most about any of the following, 10, 9, 8, 7, 6 and 5% by weight of the second viscosity reducing agent.

[00052] According to certain embodiments of the invention, the second meltblown layer may have a third basis weight of about 1 to about 150 gsm, such as at least about any of the following: 1, 3, 5, 10, 15, 25, 50, and 75 gsm and / or at most about any of the following: 150, 125, 100, and 75 gsm.

[0053] The nonwoven fabric, according to certain embodiments of the invention, may further comprise a hydrophilic finish disposed on an outer surface of the second meltblown layer. Additionally or alternatively, the second polymeric material may comprise a second hydrophilic melt additive (e.g., present within the body of the meltblown fibers and may bloom to the surface of the meltblown fibers over time). Additionally or alternatively, the hydrophilic finish 239092 2050467 of 24 may be provided by topical coating of a hydrophilic additive (e.g. an anionic or cationic surfactant) such as products available under the name Stantex® from Pulcra Chemicals e.g. Stantex grades S 6118, S6087-4, 7290 and S 6327 or “Silastol” from SChill+Seilacher (various grades) e.g. Silastol PHP 26 or PHP 16 each of which are cationic surfactants providing a long lasting cationic coating.

[00054] Figure 3 illustrates a nonwoven fabric 1 including a second nonwoven layer 20 positioned between a first nonwoven layer 10 (i.e., the first meltblown layer) and a third nonwoven layer 30 (i.e., the second meltblown layer), wherein the first nonwoven layer and the third nonwoven layer each comprise rPP as described and disclosed herein.

[0055] According to certain embodiments of the invention, the nonwoven fabric may comprise a first outermost nonwoven layer positioned over the first nonwoven layer. Figure 4, for example, illustrates the nonwoven fabric 1 of Figure 2, wherein the nonwoven fabric 1 further comprises a first outermost nonwoven layer 40 positioned over the first meltblown layer. The first outermost nonwoven layer 40 may be the same as or different from that of the second nonwoven layer 20. Additionally or alternatively, the nonwoven fabric may comprise a second outermost nonwoven layer positioned over the third nonwoven layer. Figure 5, for example, illustrates the nonwoven fabric 1 of Figure 3, wherein the nonwoven fabric 1 further comprises a first outermost nonwoven layer 40 positioned over the first meltblown layer 10 and a second outermost nonwoven layer 50 positioned over a second meltblown layer 30.The second outermost nonwoven layer 50 may be the same as or different from the second nonwoven layer 20 and / or the same as the first outermost nonwoven layer 40.

[0056] According to certain embodiments of the invention, the first outermost nonwoven layer, the second outermost nonwoven layer, or both may, independently, comprise a spunbond layer, a meltblown layer, a carded web of staple fibers, a mechanically bonded layer, or any combination thereof. The first outermost nonwoven layer, the second outermost nonwoven layer, or both may comprise a synthetic polymer, such as a polyolefin, a polyester, a polyamide, or any combination thereof. For example, the synthetic polymer may comprise a virgin polypropylene, a recycled polypropylene, a virgin polyethylene, a 239092 2050467 of 24 recycled polyethylene, a virgin polyester, a recycled polyester or any combination thereof.

[00057] Additionally or alternatively, the first outermost nonwoven layer, the second outermost nonwoven layer, or both may comprise cellulosic fibers, such as natural cellulosic fibers, synthetic cellulosic fibers, or any combination thereof.

[0058] According to certain embodiments of the invention, the first outermost nonwoven layer, the second outermost nonwoven layer, or both may, independently, comprise from 50% to 100% by weight of the virgin synthetic polymer, such as virgin polypropylene, such as at least about any of the following: 50, 55, 60, 65, 70, 75, 78, 80, 82, 85, 88, and 90% by weight of the virgin synthetic polymer and / or at most about any of the following: 100, 99, 98, 96, 95, 94, 92, and 90% by weight of the virgin synthetic polymer.According to certain embodiments of the invention, the first outermost nonwoven layer, the second outermost nonwoven layer, or both may, independently, comprise from 50% to 100% by weight of a recycled synthetic polymer, such as recycled polypropylene, such as at least about any of the following: 50, 55, 60, 65, 70, 75, 78, 80, 82, 85, 88, and 90% by weight of the recycled synthetic polymer and / or at most about any of the following: 100, 99, 98, 96, 95, 94, 92, and 90% by weight of the recycled synthetic polymer.

[00059] According to certain embodiments of the invention, the first outermost nonwoven layer, the second outermost nonwoven layer, or both may, independently, comprise one or more spunbond nonwoven layers, such as at least about any of the following: 1, 2, 3, 4, and 5 spunbond nonwoven layers and / or at most about any of the following: 10, 9, 8, 7, 6, and 5 spunbond nonwoven layers. Additionally or alternatively, the first outermost nonwoven layer, the second outermost nonwoven layer, or both may, independently, comprise a spunbond-cellulosic-spunbond structure. The spunbond-cellulosic-spunbond structure may, for example, comprise a mechanically bonded material, such as a hydroentangled nonwoven, a needle-punched nonwoven, or an air-entangled nonwoven.

[00060] The first outermost nonwoven layer, the second outermost nonwoven layer, or both may, independently, have a first basis weight lower than that of the second nonwoven layer. For example, the first outermost nonwoven layer, the second outermost nonwoven layer, 239092 2050467 of 24 outer, or both, may comprise a relatively light or thin layer that overlies and helps secure the meltblown fibers of the respective meltblown layers comprising rPP to the second nonwoven layer. In this regard, the first outermost nonwoven layer, the second outermost nonwoven layer, or both may facilitate reduction of linting of the respective meltblown layers comprising rPP, while having a basis weight and / or thickness low enough so as not to negate the abrasive characteristics imparted by the respective meltblown layers comprising rPP. For example, the first outermost nonwoven layer, the second outermost nonwoven layer, or both may constitute a thin veil or network through which the abrasive characteristics of the respective meltblown layers comprising rPP can be realized.In accordance with certain embodiments of the invention, the first outermost nonwoven layer, the second outermost nonwoven layer, or both may, independently, have a basis weight of about 1 to about 150 gsm, such as at most about any of the following: 1, 3, 5, 10, 15, 25, 25, 50, and 75 gsm and / or at most about any of the following: 150, 125, 100, and 75 gsm.

[00061] According to certain embodiments of the invention, the first outermost nonwoven layer, the second outermost nonwoven layer, or both, may comprise a hydrophilic finish applied to an outermost surface thereof. Additionally or alternatively, the first outermost nonwoven layer, the second outermost nonwoven layer, or both, may comprise a plurality of fibers that include the hydrophilic melt additive.

[0062] In another aspect, the present invention provides a method for making a nonwoven fabric. The method comprises the following: (a) forming a first polymeric melt comprising (i) a first polymeric component and (ii), optionally, one or more first additives, wherein the first polymeric component comprises a first recycled polypropylene (rPP); (b) producing a first nonwoven layer comprising a first meltblown layer, wherein the first meltblown layer comprises a plurality of first meltblown fibers; and (c) consolidating the plurality of first meltblown fibers to form the nonwoven fabric, as described and disclosed herein.

[00063] According to certain embodiments, the first polymer component (absent a viscosity reducing agent) may have a first melt flow index 239092 2050467 of 24 (MFR) of about [SIC] 10 to about 300 g / 10 min as determined by ASTM D1238 (230C° / 2.16 kg), such as at least any of the following: 10, 20, 40, 60, 80, 100, 120, 140, and 150 g / 10 min, as determined by ASTM D1238 (230C° / 2.16 kg), and / or at most any of the following: 300, 280, 260, 240, 220, 200, 180, 160, and 150 g / 10 min, as determined by ASTM D1238 (230C° / 2.16 kg).In this regard, the method may comprise forming the first polymeric melt by mixing the first polymeric component with the one or more first additives, such as a first viscosity reducing agent as described and disclosed herein, such that the first polymeric material has a second MFR of about 100 to about 2500 g / 10 min as determined by ASTM D1238 (230 C° / 2.16 kg), such as at least any of the following: 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 800, 900, 1000, 1100, and 1200 g / 10 min, as determined by ASTM D1238 (230 C° / 2.16 kg). kg), and / or at most approximately any of the following: 2500, 2200, 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300 and 1200 g / 10 min, according to ASTM D1238 (230C° / 2.16 kg).As indicated above, the first polymeric material may comprise from about 0.1 to about 10% by weight of the first viscosity reducing agent, such as at least any of the following: 0.1, 0.5, 1, 2, 3, 4, and 5% by weight of the first viscosity reducing agent and / or at most about any of the following: 10, 9, 8, 7, 6, and 5% by weight of the first viscosity reducing agent.

[0064] According to certain embodiments of the invention, the method may further comprise a step of forming or providing a second nonwoven layer, wherein the second nonwoven layer comprises a spunbond layer, a meltblown layer, a carded web of staple fibers, a mechanically bonded layer, or any combination thereof, and adhering the first nonwoven layer and the second nonwoven layer to form a multi-layer nonwoven fabric. In this regard, the adhering step may comprise any consolidation means as described and disclosed herein. According to certain embodiments of the invention, the method may comprise meltblowing the plurality of first meltblown fibers directly onto the second nonwoven layer, followed by adhering the first nonwoven layer and the second nonwoven layer. 239092 2050467 of 24

[00065] According to certain embodiments of the invention, the method may comprise forming or providing a third nonwoven layer comprising a second meltblown layer, wherein the second nonwoven layer is located directly or indirectly between the first nonwoven layer and the third nonwoven layer. The second meltblown layer may comprise a second polymeric material including (i) a second polymeric component and (ii), optionally, one or more second additives, wherein the second polymeric component comprises a second recycled polypropylene (rPP). According to certain embodiments of the invention, the first polymeric component and the second polymeric component may be the same or different and the one or more first additives and the one or more second additives may be the same or different.

[00066] According to certain embodiments of the invention, the first polymer component, the second polymer component, or both may, independently, comprise from 75% to 100% by weight of the rPP, such as at least about any of the following: 75, 78, 80, 82, 85, 88, and 90% by weight of the rPP and / or at most about any of the following: 100, 99, 98, 96, 95, 94, 92, and 90% by weight of the rPP. According to certain embodiments of the invention, the rPP may be blended with virgin polypropylene, virgin elastomeric polymers such as those described and disclosed herein, etc. (e.g., the remainder of the first polymer component may be virgin polypropylene and / or virgin elastomeric polymers). According to certain embodiments of the invention, the molten rPP and the resulting meltblown layers comprising rPP are devoid of an elastomeric polymer.In this regard, for example, the rPP and the resulting meltblown layers comprising the rPP may be formed entirely of polypropylene (e.g., rPP, virgin polypropylene, or mixtures thereof).

[0067] According to certain embodiments of the invention, the method may further comprise a step of providing or forming a first outermost nonwoven layer (e.g., as described and disclosed herein) located over the first nonwoven layer. The method may further include a step of providing or forming a second outermost nonwoven layer (e.g., as described and disclosed herein) located over the third nonwoven layer. The first outermost nonwoven layer, the second outermost nonwoven layer, or both may, independently, comprise a layer 239092 2050467 of 24 spunbond, a meltblown ply, a carded web of staple fibers, a mechanically consolidated ply, or any combination thereof.

[00068] In accordance with certain embodiments of the invention, one or more of the nonwoven layers may be individually or together consolidated to form the nonwoven fabric by a variety of consolidation means, such as those described and disclosed herein. For example, one or more of the nonwoven layers that may be individually or together consolidated to form the nonwoven fabric may comprise a thermal bonding operation, an ultrasonic bonding operation, a mechanical bonding operation, an adhesive bonding operation, or any combination thereof. The consolidation step, for example, may comprise forming a plurality of individual bond sites by a thermal bonding operation or an ultrasonic operation. In this regard, the plurality of individual bond sites define a bond area.The bonding area, for example, may comprise from about 3% to about 30% of the nonwoven fabric, such as at least about any of the following: 3, 4, 5, 6, 8, 10, 12, 14, and 15%, and / or at most about any of the following: 30, 28, 26, 25, 24, 22, 20, 18, 16, and 15%.

[00069] In yet another aspect, the present invention provides an article comprising a cleaning material. The cleaning material may comprise a plurality of interconnected individual wipes. The plurality of interconnected individual wipes may comprise a nonwoven fabric, such as those described and disclosed herein. The plurality of interconnected individual wipes, in accordance with certain embodiments of the invention, may be defined by a plurality of perforations. The cleaning material, in accordance with certain embodiments of the invention, may comprise a plurality of individual wipes (e.g., interconnected or spaced apart) comprising a nonwoven fabric such as those described and disclosed herein, wherein the plurality of wipes are housed within a container.

[00070] According to certain embodiments of the invention, the cleaning material may comprise a wet wipe or a dry wipe. For example, a wet wipe may be pre-loaded with a cleaning composition, an antimicrobial composition, or a lotion. Such wet wipes may be removed from a package and immediately used to clean and / or disinfect a surface of interest. According to certain embodiments, the cleaning material may comprise a wet wipe or a dry wipe. For example, a wet wipe may be pre-loaded with a cleaning composition, an antimicrobial composition, or a lotion. Such wet wipes may be removed from a package and immediately used to clean and / or disinfect a surface of interest. 239092 2050467 of 24 embodiments of the invention, a dry wipe may be devoid of a liquid composition (e.g., cleaning composition, antimicrobial composition, lotion, etc.). In such dry wipes, the dry wipe may be removed from a package and used directly on a surface to be cleaned or first treated with a liquid composition (e.g., cleaning composition, antimicrobial composition, lotion, etc.) at the point of use. In this regard, the wipe material may be suitable for a wide variety of cleaning applications. For example, the cleaning material may be a scouring wipe utilizing the abrasive characteristic associated with the meltblown layer(s) comprising rPP, a disinfectant wipe (e.g., a dry or wet wipe), or an industrial wipe.

[00071] In yet another aspect, the present invention provides an article comprising a filter medium. The filter medium may comprise a nonwoven fabric as described and disclosed herein, wherein, optionally, the nonwoven fabric is housed within a frame. For example, the filter medium may be incorporated as a residential or commercial air filter for associated HVAC systems, vehicle air filters, or air filters for industrial applications (e.g., clean rooms). The filter medium, according to certain embodiments of the invention, may comprise a face mask including a nonwoven fabric as described and disclosed herein. The face mask may include one or more straps directly or indirectly attached to the nonwoven fabric.

[00072] These and other modifications and variations can be made by those skilled in the art without departing from the spirit and scope of the invention, which is more particularly set forth in the appended claims. Furthermore, it is to be understood that aspects of the various embodiments may be interchanged in whole or in part. Furthermore, those skilled in the art will appreciate that the foregoing description is exemplary only and is not intended to limit the invention as described in the appended claims. Therefore, the spirit and scope of the appended claims should not be limited to the exemplary description of the versions contained herein. 239092 2050467 of 24 20225952036 CRISTIAN DANIEL BITTEL - 20225952036 Digitally signed by PORTALTRAMITES - INPI Date: 2022.11.29 17:03:20 -03:00 Reason: Digitally signed by the INPI Location: Buenos Aires, Argentina 2050467

Claims

1. A nonwoven fabric comprising: a first nonwoven layer comprising a first melt-blown layer, characterized in that the first melt-blown layer comprises a first plurality of melt-blown fibers comprising non-fibrillated melt-blown particles, melt-blown strings, or both, wherein the non-fibrillated melt-blown particles, melt-blown strings, or both define an abrasive feature for a first outer surface of the nonwoven fabric, the first melt-blown layer comprising a first polymeric material including (i) a first polymeric component and (ii), optionally, one or more first additives, wherein the first polymeric component comprises a first recycled polypropylene (rPP). 14 Claims follow