Enhanced co-formed/meltspun fibrous web structure

Abstract

An enhanced, co-formed fibrous web structure is disclosed. The web structure may have a co-formed core layer sandwiched between two scrim layers. The core layer may be formed of a blend of cellulose pulp fibers and melt spun filaments. The scrim layers may be formed of melt spun filaments, and the filaments forming one or both scrim layers may have a number average diameter of 4.5 μm or less. Filaments of one or both of the scrim layers, and optionally the core layer, may also be meltblown filaments. Alternatively, the filaments forming the scrim layers may constitute from 1 to 13 percent of the weight of the structure. Alternatively, the scrim layers may have a combined basis weight of from 0.1 gsm to less than 3.0 gsm. A method for forming the structure, including direct formation of layers, is also disclosed.

Description

BACKGROUND OF THE INVENTION[0001]Wet wipes cut from fibrous web structures formed in a co-forming process have been marketed for several years. The co-forming process involves melt spinning continuous filaments from polymer resin, and simultaneously, directing an air stream with entrained distributed cellulose fibers together with the filaments, typically into a co-forming box or similar blending apparatus, blending the filaments and fibers, and directing the blend along to a collecting / forming structure such as a moving forming belt. The filaments may be spun and introduced into the airstream carrying the cellulose fibers, or an airstream carrying the cellulose fibers may be introduced into the pathway of the filaments following spinning, the effect being the deposit of an entangled blend of filaments and fibers onto the moving forming structure and accumulation and formation of a batt thereof. Upon subsequent consolidation and bonding of the batt, a cohesive fibrous web structure ...

AI Technical Summary

Benefits of technology

The patent text describes a fibrous web structure that can be used as a wet wipe substrate. The structure is made through a co-forming process where polymer resin is melt spun and directed onto a moving forming belt with cellulose fibers. The resulting structure is strong enough to maintain its shape when wetted with a lotion, but also soft enough to give a comfortable sensory experience to the user. The structure has suitable absorbency, porosity, and surface texture to effectively absorb and carry the lotion, as well as clean soiled skin. The patent also discusses the addition of scrim layers to reduce lint release during use. The technical effects of the patent include improving the performance of wipes by making them better cleaning with less material, and identifying the best proportions of components in the scrim layers to make the structure more desirable for use as a wet wipe substrate.

Problems solved by technology

However, the ways in which inclusion of scrim layers, and the relative proportions of components of the scrim layers and intermediate or core layers, affect properties such as tensile strength, drape, surface friction, opacity, texture and feel of the web material, have not been apparent or predictable.

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