Multi-layer nonwoven having a printed layer and products made therefrom

Abstract

A multi-layered nonwoven having a printed layer comprises a pair of outer layers, with each of the outer layers comprising a carded web. An inner layer is disposed between the outer layers and includes printed indicia, which may be in the form of text, graphics, colors, or other suitable indicia. The inner layer is bonded to each of the outer layers by hydroentanglement. A method of making such a nonwoven may include the steps of providing a pair of outer layers comprising carded webs, providing a pulp inner layer having printed indicia, positioning the inner layer between the outer layers, passing the outer layers and the inner layer together through a hydroentangling system to secure the inner layer to each of the outer layers to form a web, and drying the web.

Description

FIELD OF THE INVENTION[0001]The present invention relates generally to substrates including nonwoven substrates and, more specifically, to a nonwoven substrate comprising a multi-layer structure in which one of the layers includes printed indicia or colors, or both.BACKGROUND OF THE INVENTION[0002]Consumers use a wide variety of substrate products including wet and dry disposable wipes, diapers, feminine protection products, and other substrate products, in a variety of applications. Such substrates products are constructed from substrate materials which may be cut and formed into a variety of configurations, depending on the desired end use of the product being manufactured. During manufacture, the web is cut to the desired size and shape and, if desired, joined to other materials or moistened with a lotion or other suitable substance.[0003]In the case of wipe products, the wipes may be wet or dry wipes. During manufacture, a nonwoven or other suitable web is cut to the desired siz...

AI Technical Summary

Benefits of technology

[0008]Nonwovens are used in many product applications including diapers, wipes, feminine protection products and the like. In order to make these products most useful to consumers, such products will frequently include a number of features that increase their utility, ease of use, appropriateness of use, ancillary benefits, etc. to best meet the needs of the consumers.

[0010]For example, some nonwoven-based products, such as wipes, are often used for cleaning and / or scrubbing. Thus, placing the printed or colored elements inside the nonwoven may provide increased abrasion-resistance of the printed elements. Specifically, placing the printed or colored elements away from the surface of the nonwoven helps to retain the integrity of the image or the color, even in circumstances where the surface of the nonwoven is disrupted due to scrubbing or other surface abrasion.

[0011]Separately, for skin-contact products such as absorbent articles and wipes intended for use on the body (for example, baby wipes, cosmetic wipes, topical-applicator wipes, and other such products), placing the printed or colored elements internally or within the nonwoven reduces the potential transfer to the skin of the inks, dyes, pigments and the like used in the printing or coloring process. This aspect may offer particular advantages in the context of baby wipes, where safety concerns can be particularly important to consumers.

[0012]Additionally, in accordance with the disclosed example, joining the printed or colored layer to a nonwoven layer by hydroentanglement may offer certain advantages. Although it may be contemplated to bond a printed layer to a nonwoven layer as a means of removing the printed image from the outermost surface of the resulting nonwoven using conventional bonding methods such as adhesive-bonding or thermal-bonding, these alternative bonding techniques typically impart the finished nonwoven with undesirable properties, such as increased stiffness, reduced drapability, and reduced flexibility. Nonwoven products based on stiff and / or inflexible nonwovens can be undesirable to consumers, particularly for skin-contact products such as wipes, and absorbent articles. Furthermore, these conventional bonding techniques may have the disadvantage of requiring the use of adhesives and / or specific thermoplastic polymeric additives to achieve the required lamination. These additional components may add unnecessary cost and complexity to the manufacturing of the nonwovens, and these components have the potential to interact negatively with applied lotions or other treatments.

Problems solved by technology

Unfortunately, cost considerations and the above-described desired physical properties often present a hindrance to incorporating additional features into the finished nonwoven and / or the resulting end product.

Moreover, because the web or other substrate used in nonwovens is often incorporated into products which are used to scrub surfaces (i.e. wipes) or used in skin-contact environments (i.e. wipes, diapers, feminine protection products), it may be difficult to add some attractive features, such as text, graphics, colors or other indicia, and still maintain the desired degree of image integrity and / or prevent or minimize the potential for transfer of the inks and / or pigments used in creating the graphics or other indicia to the skin.

Further, it may be difficult to add these desired features without unduly hampering the drape, flexibility, and other desirable physical properties of the nonwoven.

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