Non-woven structures and methods of making the same

Abstract

Provided are layered non-woven structures comprising a fibrous, water-permeable anchoring layer and a fibrous layer having fibers entangled about the anchoring layer, including patterned and non-patterned structures. Also provided are personal care products comprising the present structures and methods of making the structures.

Description

FIELD OF THE INVENTION

[0001] The present invention relates generally to layered, composite materials. More specifically, the present invention relates to layered, composite materials exhibiting advantageous lamination strength, and one or more additional beneficial properties such as drapeability, loftiness, abrasion resistance, liquid absorbency, softness, and / or visual appeal.BACKGROUND

[0002] Non-woven materials are used widely in a variety of commercially-available personal care products including, for example, wipes and feminine hygiene products, such as napkins, liners, and tampons, and the like. In many of these applications, it is desirable for the non-woven materials to be abrasion resistant, so that the material maintains its integrity in use. Applicants have further recognized that it is also desirable for such abrasion resistant materials to have other beneficial properties.

[0003] For example, Applicant's have recognized that it would be desirable to have an abrasion resista...

Examples

example 1

[0075]In each of the following examples, a target web was placed on a 80-mesh metal screen forming surface, on a rotating cylindrical drum. The target web consisted of a layer of fibrous material and a fluid-permeable anchoring layer. The fluid permeable anchoring layer used was a 12 gsm layer of spun-bonded polypropylene, commercially available from BBA Fiberweb. The fibrous material was a blend of 70% rayon fibers and 30% polyester fibers of varying basis weight. The drum was rotated to move the layer of fibers at a linear speed of 100 fpm. The jets were oriented to expel a stream of pressurized water to strike the target web perpendicularly to the target web. The jets were arranged in a row of jets spaced to a jet density of 30 jets / inch. All fibrous layers were subject to an initial stabilization treatment in which water was urged though each of a number of 0.005-inch diameter jets at 600 psi to loosely bond the fibers prior to entangling with the spun-bonded polypropylene. The ...

example 1a

[0089]The spunbond material layer as placed “under” the fibrous layer (i.e., the fibrous layer was positioned between the jets and the fluid-permeable anchoring layer). The jet pressure was 1500 psi. The web was moved across the jets 4 times. The resulting layered, composite material had a lamination strength (LSV) of 25 grams (g.), a thickness of 0.77 mm, a basis weight of 85 gsm, a density of 0.11 g / cc, and a drapeability of 7.9 gsm / g.

example 1b

[0090]The spunbond material layer as placed under the fibrous layer. The jet pressure was 1500 psi. The web was moved across the jets 8 times. The resulting layered, composite material had a lamination strength of 65 grams (g.), a thickness of 0.73 mm, a basis weight of 88 gsm, a density of 0.12 g / cc, and a drapeability of 8.6 gsm / g.

FIELD OF THE INVENTION

[0001] The present invention relates generally to layered, composite materials. More specifically, the present invention relates to layered, composite materials exhibiting advantageous lamination strength, and one or more additional beneficial properties such as drapeability, loftiness, abrasion resistance, liquid absorbency, softness, and / or visual appeal.BACKGROUND

[0002] Non-woven materials are used widely in a variety of commercially-available personal care products including, for example, wipes and feminine hygiene products, such as napkins, liners, and tampons, and the like. In many of these applications, it is desirable for the non-woven materials to be abrasion resistant, so that the material maintains its integrity in use. Applicants have further recognized that it is also desirable for such abrasion resistant materials to have other beneficial properties.

[0003] For example, Applicant's have recognized that it would be desirable to have an abrasion resista...

Examples

example 1

[0075]In each of the following examples, a target web was placed on a 80-mesh metal screen forming surface, on a rotating cylindrical drum. The target web consisted of a layer of fibrous material and a fluid-permeable anchoring layer. The fluid permeable anchoring layer used was a 12 gsm layer of spun-bonded polypropylene, commercially available from BBA Fiberweb. The fibrous material was a blend of 70% rayon fibers and 30% polyester fibers of varying basis weight. The drum was rotated to move the layer of fibers at a linear speed of 100 fpm. The jets were oriented to expel a stream of pressurized water to strike the target web perpendicularly to the target web. The jets were arranged in a row of jets spaced to a jet density of 30 jets / inch. All fibrous layers were subject to an initial stabilization treatment in which water was urged though each of a number of 0.005-inch diameter jets at 600 psi to loosely bond the fibers prior to entangling with the spun-bonded polypropylene. The ...

example 1a

[0089]The spunbond material layer as placed “under” the fibrous layer (i.e., the fibrous layer was positioned between the jets and the fluid-permeable anchoring layer). The jet pressure was 1500 psi. The web was moved across the jets 4 times. The resulting layered, composite material had a lamination strength (LSV) of 25 grams (g.), a thickness of 0.77 mm, a basis weight of 85 gsm, a density of 0.11 g / cc, and a drapeability of 7.9 gsm / g.

example 1b

[0090]The spunbond material layer as placed under the fibrous layer. The jet pressure was 1500 psi. The web was moved across the jets 8 times. The resulting layered, composite material had a lamination strength of 65 grams (g.), a thickness of 0.73 mm, a basis weight of 88 gsm, a density of 0.12 g / cc, and a drapeability of 8.6 gsm / g.

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