Soft, thick, non-linting nonwoven

Abstract

The nonwoven web 10 of the present invention is a layered structure that takes advantage of the beneficial properties of different types of fibers advantageously distributed in each layer. In particular, the present invention is a multi-layer nonwoven web suitable for use as a wet wipe, the web having a first fibrous outer layer comprising from about 10% to about 60% conjugate fiber, from about 10% to about 90% cellulosic fibers, a fibrous inner layer bonded at discrete bond sites to the first outer layer in a face to face relationship comprising from about 10% to about 60% conjugate fiber, and from about 10% to about 65% cellulosic fibers. A second fibrous outer layer, which can be the same composition as the first outer layer, is bonded at discrete bond sites to the inner layer in a face to face relationship. A method for forming the web of the present invention is also disclosed.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001]This patent application is a continuation of Nonprovisional Utility patent application Ser. No. 09 / 824,454, filed Apr. 2, 2001, which claims priority to Provisional Patent Application Ser. No. 60 / 196,972, filed Apr. 13, 2000, the substances of which are incorporated herein by reference.FIELD OF THE INVENTION[0002]The present invention is related to nonwoven materials. In particular, the present invention is related to soft, thick, and non-linting nonwoven materials suitable for use as a substrate for pre-moistened wipes.BACKGROUND OF THE INVENTION[0003]Nonwoven fabrics are desirable for use in a variety of products such as bandaging materials, garments, disposable diapers, and other personal hygiene products, including pre-moistened wipes. Pre-moistened wipes are often packaged as discrete wipes in a stack in a moisture proof container, and are often referred to as wet wipes. Wet wipes are commonly used as baby wipes for the cleaning of a ...

AI Technical Summary

Problems solved by technology

However, optimizing all the desirable properties is often not possible.

For example, often a balance of properties results in less than desirable softness or strength levels.

However, these processes, while increasing the strength of the nonwoven, generally detract from other desirable properties.

For example, thermal bonding is effective at maintaining the thickness (bulk) of the nonwoven, but maintaining a relatively soft product suitable for wet wipes requires the use of relatively expensive conjugate fibers throughout the nonwoven web.

The use of conjugate fibers throughout the nonwoven can also negatively affect the drape of the resulting material.

Such a reduction in thickness is undesirable in a wet wipe application.

To increase the basis weight of the starting material such that after hydroentangling the material retains sufficient thickness to be used as a baby wipe would be prohibitively expensive.

However, adhesive adds to the expense of the resulting web, often costing more than the fibers of the base web to which it is applied.

Additionally, the presence of adhesive can negatively impact the fragrance and preservative ingredients in a wet wipe.

Adhesive application systems also add cost and complexity to a nonwoven manufacturing process, as well as creating hygiene problems in the application equipment and other equipment in the vicinity.

Linting results in fibers remaining on the skin of the user, a highly undesirable condition for wet wipe users.

However, as mentioned above, the increased level of adhesive contributes to greater stiffness and decreased levels of softness.

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