Nonwoven fabric with improved hand

Abstract

Nonwoven fabrics having desirable wiping properties while also providing comfortable tactile properties are provided. The nonwoven fabrics can include a first nonwoven outer layer, a second nonwoven outer layer, and a core layer positioned between the first nonwoven layer and the second nonwoven outer layer. At least one of the first nonwoven outer layer and the second nonwoven outer layer can include a plurality of hybrid filaments including a mixture of a polymer and an elastomeric polyolefin.

Description

[0001] Priority Statement

[0002] This application claims priority to U.S. Provisional Application Serial No. 62 / 276,391, filed January 8, 2016, pursuant to 35 USC §119(e), the entire contents of which are expressly incorporated herein by reference. Technical Field

[0003] The invention disclosed herein generally relates to nonwoven fabrics that provide desired wiping properties and comfortable tactile properties, wherein the outermost surface is generally free of cellulose fibers and includes filaments comprising elastomeric polyolefins. Background Technology

[0004] Traditionally, wet wipes used for personal care have been primarily made from blends of hydro-entangling cellulose fibers and thermoplastic fibers, or through a coform process in which wood pulp fibers and meltblown fibers are blended into a stabilized web. In both cases, cellulose fibers appear in substantial concentration on the surface of the wipe and impart the comfort generally associated with traditional cellulose-based textiles like cotton facecloths. The problem with these approaches is that the former is relatively expensive, while the latter lacks sufficient abrasion resistance.

[0005] To achieve a good balance of absorbency, abrasion resistance, and low cost, attempts have been made to combine polypropylene-based spunbond webs with low-cost cellulose fibers such as wood pulp fibers. However, these structures sometimes primarily consist of polypropylene filaments exposed on one or two of their outer surfaces. Consequently, these structures do not provide a comfortable sensory experience for the user because the washes or fluids used with personal care products formed from these structures lubricate the smooth surfaces of the polypropylene fibers to a point where they feel slippery or slippery, typically lacking the textured surface experience of cellulose fibers. This slippery or slippery feeling is sometimes available... Fabric experience The fabric comprises layers of wood pulp fibers trapped between two spunbond layers and subsequently hydroentangled. The smooth or slippery feel of these hydroentangled composites is associated with one side of its surface having little or no wood pulp fibers. Another method for forming nonwoven fabrics suitable for wiping is called the Arvell technique and was developed by Teknoweb (Italy). Using this technique, the resulting web typically comprises an intermediate layer containing wood pulp fibers and continuous filaments, and two outer layers made of continuous filaments. The continuous filaments are typically made of polyolefins, and more commonly, of polypropylene. In the case of fabrics, and those made using Arvell technology, when used as wet wipes, the outermost surface has almost no exposed wood pulp fibers and tends to feel undesirably smooth or slippery.

[0006] Moreover, there are situations or applications where wipes (e.g., wet wipes) are desired, at least in their outermost layer. For example, some disinfectant wipes include hygienic detergents that react with cellulose fibers. Wipes used in cleanrooms or medical applications (where linting is highly undesirable) are an additional application where wipes are needed in the absence of cellulose fibers (or at least in the outermost layer). However, wipes made from thermoplastic polymers that have no cellulose fibers on at least one of their surfaces are often associated with poor performance when picking up fine debris and when streaking (i.e., leaving some liquid behind when wiping the surface).

[0007] Therefore, there remains a need in the art for cost-effective nonwoven fabrics suitable for use as wipes (e.g., wet wipes) with a large amount of thermoplastic fibers on exposed surfaces, while exhibiting good wiping performance and comfortable tactile properties. Summary of the Invention

[0008] One or more embodiments of the present invention address one or more of the aforementioned problems. According to certain embodiments of the invention, nonwoven fabrics comprising a core layer and at least one (such as two) outer nonwoven layers are provided. For example, the nonwoven fabric may comprise a core layer located between two nonwoven outer layers, wherein at least one outer layer comprises an elastomeric polyolefin and / or, for example, predominantly lacks cellulose fibers. These nonwoven fabrics are suitable for a wide range of applications, including as dry wipes (e.g., which can be used in a dry state or on-site immersed in a liquid cleaning composition) and wet wipes (e.g., fabrics preloaded or pre-wetted with liquid).

[0009] In one aspect, the present invention provides a nonwoven fabric (e.g., a wipe) comprising a first nonwoven outer layer, a second nonwoven outer layer, and a core layer located directly or indirectly between the first and second nonwoven outer layers. According to certain embodiments of the invention, at least one of the first and second nonwoven outer layers comprises a plurality of blended filaments comprising a mixture of a polymer and an elastomeric polyolefin. According to certain embodiments of the invention, the blended filaments may comprise thermoplastic fibers of continuous length (e.g., spunbond yarn), discontinuous length (e.g., staple fiber), or both. In some embodiments of the invention, for example, the first and second nonwoven outer layers may each comprise blended filaments (e.g., continuous blended filaments and / or a mixture of staple fibers). According to certain embodiments of the invention, the core layer comprises cellulose fibers. In addition to cellulose fibers, according to certain embodiments of the invention, the core layer may also comprise polymer fibers, such as continuous polymer fibers. In this respect, the core layer may comprise a combination of continuous polymer fibers and cellulose fibers. According to certain embodiments of the invention, for example, the core layer may comprise about 25 wt.% to about 100 wt.% of cellulose fibers or about 50 wt.% to about 100 wt.% of cellulose fibers. In an exemplary embodiment of the invention, the nonwoven fabric may comprise a core layer comprising 100 wt.% cellulose fibers (e.g., wood pulp). According to certain embodiments of the invention, the cellulose fibers in the core layer may comprise short fibers and / or chopped fibers. According to certain embodiments of the invention, the core layer may comprise one or more individual or discrete layers containing cellulose fibers. For example, the core layer may comprise about one to five individual layers containing cellulose fibers (e.g., one, two, three, four, or five individual layers).

[0010] According to some embodiments of the invention, the core layer of the nonwoven fabric may comprise a core layer ratio between a weight percentage of cellulose fibers and a weight percentage of polymer fibers of about 4:1 to 1:1. According to some embodiments of the invention, the core layer ratio between the weight percentage of cellulose fibers and the weight percentage of polymer fibers may comprise about 3.5:1 to 2.5:1 (e.g., 3.5:1 to 3:1). According to some embodiments of the invention, the core layer may comprise about 60 wt.% to about 90 wt.% of the nonwoven fabric (e.g., about 70 wt.% to about 90 wt.% of the nonwoven fabric). According to some other embodiments of the invention, the core layer may comprise substantially 100% thermoplastic polymer. In this respect, according to some embodiments of the invention, the core layer may be cellulose-free. According to some embodiments of the invention, the nonwoven fabric may be cellulose-free. According to certain embodiments of the invention, the core layer, the nonwoven fabric, or both may contain an amount of cellulose fibers of no more than about 15 wt.%, no more than about 10 wt.%, no more than 5 wt.%, no more than 3 wt.%, no more than 2 wt.%, no more than 1 wt.%, no more than 0.5 wt.%, or no more than 0.1 wt.%.

[0011] According to certain embodiments of the invention, the nonwoven fabric may comprise at least a first nonwoven outer layer comprising a blended filament (e.g., a continuous blended filament and / or a blend of diced fibers) comprising a mixture of a polymer and an elastomeric polyolefin, wherein the blended filament comprises about 10 wt.% to about 75 wt.% of the elastomeric polyolefin. According to certain embodiments of the invention, the blended filament may comprise about 20 wt.% to about 50 wt.% of the elastomeric polyolefin. According to certain embodiments of the invention, the blended filament may comprise about 30 wt.% to about 40 wt.% of the elastomeric polyolefin (e.g., about 35 wt.% of the elastomeric polyolefin). According to certain embodiments of the invention, each of the first and second nonwoven outer layers comprises a blended filament (e.g., a continuous blended filament and / or a blend of diced fibers) comprising a mixture of a polymer and an elastomeric polyolefin, wherein the blended filament comprises about 10 wt.% to about 75 wt.% of the elastomeric polyolefin (e.g., about 20 wt.% to about 50 wt.% of the elastomeric polyolefin, about 30 wt.% to about 40 wt.% of the elastomeric polyolefin, or about 35 wt.% of the elastomeric polyolefin). According to certain embodiments of the invention, the elastomeric polyolefin comprises a copolymer of propylene and ethylene. In some embodiments of the invention, for example, the elastomeric polyolefin may comprise polypropylene microcrystalline regions and random ethylene amorphous regions.

[0012] According to certain embodiments of the invention, the first nonwoven outer layer, the second nonwoven outer layer, or both may comprise spunbond filaments. For example, the blended filaments may comprise spunbond filaments (e.g., continuous filaments). In some exemplary embodiments of the invention, at least one of the first and second nonwoven outer layers may comprise a plurality of blended filaments (e.g., continuous blended filaments and / or blended diced fibers), the blended filaments comprising a mixture of a polymer and an elastomeric polyolefin, wherein the polymer comprises at least one of polyolefins, polyesters, polyamides, or combinations thereof. According to certain embodiments of the invention, the polymer comprises polypropylene.

[0013] According to certain embodiments of the invention, the first nonwoven outer layer, the second nonwoven outer layer, or both may be substantially lacking in cellulose fibers (e.g., lacking cellulose fibers). According to certain embodiments of the invention, the first nonwoven outer layer, the second nonwoven outer layer, or both may contain an amount of no more than about 15 wt.%, no more than about 10 wt.%, no more than 5 wt.%, no more than 3 wt.%, no more than 2 wt.%, no more than 1 wt.%, no more than 0.5 wt.%, or no more than 0.1 wt.% of cellulose fibers. Additionally or alternatively, the first nonwoven outer layer may define a first outermost surface of the nonwoven fabric, and the second nonwoven outer layer may define a second outermost surface of the nonwoven fabric, wherein the first outermost surface, the second outermost surface, or both may be substantially lacking in cellulose fibers (e.g., lacking cellulose fibers). According to certain embodiments of the invention, the first outermost surface, the second outermost surface, or both may contain an amount of cellulose fibers of no more than about 15 wt.%, no more than about 10 wt.%, no more than 5 wt.%, no more than 3 wt.%, no more than 2 wt.%, no more than 1 wt.%, no more than 0.5 wt.%, or no more than 0.1 wt.%.

[0014] According to certain embodiments of the invention, nonwoven fabrics may contain liquid additives loaded thereon. For example, according to certain embodiments of the invention, the liquid additives may not be particularly limited. In some embodiments of the invention, for example, the liquid additives may include washing solutions, soil-cleaning compositions, skin-cleaning compositions, or antimicrobial compositions. In this regard, some embodiments of the invention may include pre-loaded wet wipes, for example, disposed within a container or package.

[0015] According to some embodiments of the invention, the nonwoven fabric may include a basis weight of about 20 to about 100 gsm. According to some embodiments of the invention, the basis weight of the nonwoven fabric may include about 40 to about 60 gsm. In some embodiments of the invention, for example, the nonwoven fabric may include a basis weight of about 40 gsm to about 50 gsm.

[0016] In another aspect, the present invention provides a method for forming a nonwoven fabric as disclosed herein. According to certain embodiments of the invention, the method of forming a nonwoven fabric may include the steps of: providing a first nonwoven outer layer, providing a second nonwoven outer layer, providing a core layer, positioning the core layer between the first and second nonwoven outer layers to form a composite web, and bonding the composite web to form a nonwoven fabric; wherein at least one of the first and second nonwoven outer layers comprises a plurality of blended filaments comprising a mixture of a polymer and an elastomeric polyolefin. According to certain embodiments of the invention, the blended filaments may comprise thermoplastic fibers of continuous length (e.g., spunbond filaments), discontinuous length (e.g., diced fibers), or both. According to certain embodiments of the invention, the step of providing the first nonwoven outer layer may include melt-spinning the first nonwoven layer. According to certain embodiments of the invention, the step of providing the second nonwoven outer layer may include melt-spinning the second nonwoven layer. According to certain embodiments of the invention, the step of providing the core layer may include melt-spinning the core layer. According to certain embodiments of the present invention, a method for forming a nonwoven fabric as disclosed herein may include, for example, melting-spinning a first nonwoven layer onto a forming tape, melting-spinning or otherwise forming a core layer onto a first nonwoven outer layer, melting-spinning a second nonwoven layer onto the core layer to form a composite nonwoven fabric, and bonding the composite nonwoven fabric to form a nonwoven fabric as disclosed herein.

[0017] According to certain embodiments of the present invention, nonwoven composite materials can be bonded by various operations, such as thermal bonding, adhesive bonding, mechanical bonding, ultrasonic bonding, or other similar bonding. According to certain embodiments of the present invention, bonding of nonwoven composite materials may include thermal bonding by a calendering machine.

[0018] According to certain embodiments of the invention, at least one of the first and second nonwoven outer layers comprises a plurality of blended filaments (e.g., continuous blended filaments and / or blended diced fibers) comprising a mixture of polymers and elastomeric polyolefins. In some embodiments of the invention, for example, the first and second nonwoven outer layers may each comprise blended filaments (e.g., continuous blended filaments and / or blended diced fibers). According to some embodiments of the invention, the core layer comprises cellulose fibers. According to some embodiments of the invention, in addition to cellulose fibers, the core layer may also comprise polymer fibers, such as continuous polymer fibers. In this respect, the core layer may comprise a combination of continuous polymer fibers and cellulose fibers. According to some embodiments of the invention, for example, the core layer may comprise about 25 wt.% to about 100 wt.% cellulose fibers or about 50 wt.% to about 80 wt.% cellulose fibers. In an exemplary embodiment of the invention, the nonwoven fabric may comprise a core layer comprising 100 wt.% cellulose fibers (e.g., wood pulp). According to some embodiments of the invention, the cellulose fibers of the core layer may comprise short fibers and / or diced fibers. According to certain embodiments of the invention, the core layer may comprise one or more individual or discrete layers containing cellulose fibers. For example, the core layer may comprise about one to five individual layers containing cellulose fibers (e.g., 1, 2, 3, 4, or 5 individual layers). According to certain embodiments of the invention, cellulose fibers may be added to and / or combined with polymer filaments (e.g., melt-spun fibers) to provide polymer fibers and cellulose fibers, wherein the cellulose fibers may be at least partially bonded to and / or at least partially incorporated into the polymer fibers.

[0019] According to certain embodiments of the invention, the core layer of the nonwoven fabric may comprise a core layer ratio between a weight percentage of cellulose fibers and a weight percentage of polymer fibers of about 4:1 to 1:1. According to certain embodiments of the invention, the core layer ratio between the weight percentage of cellulose fibers and the weight percentage of polymer fibers may comprise about 3.5:1 to 2.5:1 (e.g., 3.5:1 to 3:1). According to certain embodiments of the invention, the core layer may comprise about 60 wt.% to about 90 wt.% of the nonwoven fabric (e.g., about 70 wt.% to about 90 wt.% of the nonwoven fabric). According to certain other embodiments of the invention, the core layer may comprise approximately 100 wt.% thermoplastic polymer. In this respect, according to certain embodiments of the invention, the core layer may be cellulose-free. According to certain embodiments of the invention, the nonwoven fabric may be cellulose-free. According to certain embodiments of the invention, the core layer, nonwoven fabric, or both may contain no more than about 15 wt.%, no more than about 10 wt.%, no more than 5 wt.%, no more than 3 wt.%, no more than 2 wt.%, no more than 1 wt.%, no more than 0.5 wt.%, or no more than 0.1 wt.% of cellulose fibers.

[0020] According to certain embodiments of the invention, the resulting nonwoven fabric may comprise at least a first nonwoven outer layer comprising blended filaments (e.g., continuous blended filaments and / or blended diced fibers) comprising a mixture of a polymer and an elastomeric polyolefin, wherein the blended filaments (e.g., continuous blended filaments and / or blended diced fibers) comprise about 10 wt.% to about 75 wt.% of the elastomeric polyolefin. According to certain embodiments of the invention, the blended filaments may comprise about 20 wt.% to about 50 wt.% of the elastomeric polyolefin. According to certain embodiments of the invention, the blended filaments may comprise about 30 wt.% to about 40 wt.% of the elastomeric polyolefin (e.g., about 35 wt.% of the elastomeric polyolefin). According to certain embodiments of the invention, each of the first and second nonwoven outer layers comprises a mixed filament (e.g., a continuous mixed filament and / or a mixed diced fiber) comprising a mixture of a polymer and an elastomeric polyolefin, wherein the mixed filament comprises about 10 wt.% to about 75 wt.% of the elastomeric polyolefin (e.g., about 20 wt.% to about 50 wt.% of the elastomeric polyolefin, about 30 wt.% to about 40 wt.% of the elastomeric polyolefin, or about 35 wt.% of the elastomeric polyolefin). According to certain embodiments of the invention, the elastomeric polyolefin comprises a copolymer of propylene and ethylene. In some embodiments of the invention, for example, the elastomeric polyolefin may comprise polypropylene microcrystalline regions and random ethylene amorphous regions.

[0021] According to certain embodiments of the invention, the first nonwoven outer layer, the second nonwoven outer layer, or both may comprise spunbond filaments (e.g., formed by spunbonding). For example, the blended filaments may comprise continuous spunbond filaments. According to certain embodiments of the invention, at least one of the first and second nonwoven outer layers may comprise a plurality of blended filaments comprising a mixture of a polymer and an elastomeric polyolefin (e.g., continuous blended filaments and / or blended diced fibers), wherein the polymer comprises at least one of polyolefins, polyesters, polyamides, or combinations thereof. According to certain embodiments, the polymer comprises polypropylene.

[0022] According to certain embodiments of the invention, the first nonwoven outer layer, the second nonwoven outer layer, or both may be substantially lacking in cellulose fibers. According to certain embodiments of the invention, the first nonwoven outer layer, the second nonwoven outer layer, or both may contain an amount of no more than about 15 wt.%, no more than about 10 wt.%, no more than 5 wt.%, no more than 3 wt.%, no more than 2 wt.%, no more than 1 wt.%, no more than 0.5 wt.%, or no more than 0.1 wt.% of cellulose fibers. Additionally or alternatively, the first nonwoven outer layer may define a first outermost surface of the nonwoven fabric, and the second nonwoven outer layer may define a second outermost surface of the nonwoven fabric, wherein the first outermost surface, the second outermost surface, or both may be substantially lacking in cellulose fibers. According to certain embodiments of the invention, the first outermost surface, the second outermost surface, or both may contain an amount of cellulose fibers of no more than about 15 wt.%, no more than about 10 wt.%, no more than 5 wt.%, no more than 3 wt.%, no more than 2 wt.%, no more than 1 wt.%, no more than 0.5 wt.%, or no more than 0.1 wt.%.

[0023] According to certain embodiments of the invention, the method may further include adding and / or incorporating a liquid additive loaded onto or on a nonwoven fabric. For example, according to certain embodiments of the invention, the liquid additive may not be particularly limited. In some embodiments of the invention, the liquid additive may, for example, include a washing solution, a dirt-cleansing composition, a skin-cleansing composition, or an antimicrobial composition. In this regard, some embodiments of the invention may include a pre-loaded wet wipe, for example, disposed within a container or package.

[0024] Methods according to certain embodiments of the invention may include forming a nonwoven fabric comprising a basis weight of about 20 to about 100 gsm. According to certain embodiments of the invention, the basis weight of the nonwoven fabric may comprise about 40 to about 60 gsm. In some embodiments of the invention, for example, the nonwoven fabric may comprise a basis weight of about 40 gsm to about 50 gsm. Attached Figure Description

[0025] The invention will now be described more fully below with reference to the accompanying drawings, which illustrate some, but not all, embodiments of the invention. In fact, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for the purpose of this disclosure to satisfy applicable legal requirements. Throughout the text, the same numerals refer to the same elements, and wherein:

[0026] Figure 1 The illustration shows a nonwoven fabric according to an embodiment of the present invention;

[0027] Figure 2 The diagram illustrates a process flow chart for forming a nonwoven fabric according to an embodiment of the present invention; and

[0028] Figure 3 A schematic diagram illustrating the operation of a method for producing a nonwoven fabric according to certain embodiments of the present invention is shown. Detailed Implementation

[0029] The invention will now be described more fully below with reference to the accompanying drawings, which illustrate some, but not all, embodiments of the invention. In fact, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided to satisfy applicable legal requirements for this disclosure. As used in the specification and the appended claims, the singular forms “a” and “the” include the plural indices unless the context clearly indicates otherwise.

[0030] According to some embodiments, the present invention includes a nonwoven fabric that provides desired wiping properties and comfortable tactile properties, wherein a large number of thermoplastic fibers may form one or both exposed surfaces (e.g., the outermost surface) of the nonwoven fabric. The thermoplastic fibers located on the outermost surface(s) of the nonwoven fabric may comprise a mixture of polymeric materials and elastomeric polyolefins. According to some embodiments of the invention, the exposed or outermost surface of the nonwoven fabric may generally be free of cellulose fibers. According to some embodiments of the invention, the nonwoven fabric may comprise a core layer located between two nonwoven outer layers, wherein at least one outer layer comprises an elastomeric polyolefin and / or is predominantly lacking in cellulose fibers. According to some embodiments of the invention, the nonwoven fabric may be suitable for a variety of applications (e.g., end-uses), including as a dry wipe (e.g., which can be used in a dry state or immersed in situ in a liquid cleaning composition) or as a wet wipe (e.g., a wipe structure pre-loaded with liquid).

[0031] According to certain embodiments of the invention, the terms "generally" or "generally" may include the total amount specified, or largely but not including the total amount specified according to other embodiments of the invention.

[0032] As used interchangeably herein, the term "polymer" or "of a polymer" may include homopolymers, copolymers (such as, for example, block, graft, random and alternating copolymers, ternary polymers, etc.), and mixtures and variants thereof. Furthermore, unless otherwise specifically limited, the term "polymer" or "of a polymer" should include all possible structural isomers; stereoisomers, including but not limited to geometric isomers, optical isomers, or enantiomers; and / or any chiral molecular configuration of such polymer or polymeric material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic configurations of such polymer or polymeric material. The term "polymer" or "of a polymer" should also include polymers made from various catalyst systems, including but not limited to, Ziegler-Natta catalyst systems and metallocene / single-site catalyst systems. In some embodiments of the invention, the term "polymer" or "of a polymer" should also include polymers produced by fermentation processes or bio-derived polymers.

[0033] As may be used interchangeably herein, the term "elastic" or "elastic material" can include any material that, upon the application of a biasing force, can stretch to at least 110% or even up to 125% of its relaxed original length without breaking or fracturing (i.e., can stretch to at least 10% or even 25% more than its original length). Upon the release of the applied force, for example, the material can recover at least 40%, at least 60%, or even at least 80% of its elongation. In some embodiments of the invention, the material can recover about 20% to about 100% of its elongation, about 25% to about 95% of its elongation, about 30% to about 90% of its elongation, about 40% to about 80% of its elongation, or about 50% to about 70% of its elongation. For example, a material with an initial length of 100 mm can stretch to at least 110 mm and, upon removal of the force, will retract to a length of 106 mm (e.g., exhibiting 40% recovery). Exemplary elastomers may include Vistamaxx TM Propylene-based elastomers (commercially available from ExxonMobile) are copolymers of propylene and ethylene. For example, Vistamaxx. TM Propylene-based elastomers comprise isotactic polypropylene microcrystalline regions and random amorphous regions.

[0034] As used herein, the term "blended filament" can include filaments formed from a melt mixture comprising one or more polymers (e.g., non-elastomeric polymers) and one or more elastomeric polyolefins. In this respect, the melt mixture can be formed from one or more polymers (e.g., non-elastomeric polymers) and at least one elastomeric polyolefin mixed at temperatures suitable for melt spinning separate filaments consisting of both the polymer and elastomeric components of the melt mixture. According to certain embodiments of the invention, "blended filament" can include continuous lengths, which may be referred to herein as "continuous blended filaments," or discontinuous lengths (e.g., diced fibers), which may be referred to herein as "blended diced fibers."

[0035] As used herein, the terms "nonwoven" and "nonwoven web" can include webs having a structure of individual fibers, filaments, and / or threads that are interlayered but not in a repeating manner as is identifiable in knitted or woven fabrics. According to certain embodiments of the invention, nonwoven fabrics or webs can be formed by any process conventionally known in the art, such as, for example, meltblown, spunbond, hydroentangling, air-laid, and bonded carded web processes.

[0036] As used herein, the term "layer" can include a generally identifiable combination of similar material types and / or functions present in the XY plane.

[0037] As used herein, the term "segmented fiber" can include segmented fibers derived from filaments. According to some embodiments, any type of filament material can be used to form the segmented fiber. For example, the segmented fiber can be formed from cellulose fibers, polymer fibers, and / or elastomer fibers. Examples of materials include cotton, rayon, wool, nylon, polypropylene, and polyethylene terephthalate. By way of example only, the average length of the segmented fiber can range from about 2 cm to about 15 cm.

[0038] As used herein, the term "spunbond" can include fibers formed by extruding molten thermoplastic material as filaments from capillaries of a plurality of fine, generally round, spinnerets, the diameter of which is then rapidly reduced. According to embodiments of the invention, spunbond fibers are generally non-sticky and generally continuous when deposited onto a collection surface. It should be noted that the spunbond in certain composite materials used in the invention can include those described in the literature as... The description refers to nonwoven fabrics.

[0039] As used herein, the term "meltblown" can include fibers formed by extruding molten thermoplastic material through multiple fine die capillaries as molten wires or filaments into a converging high-speed, typically hot, gas (e.g., air) stream, which attenuates the molten thermoplastic material into filaments to reduce their diameter, which, according to certain embodiments of the invention, may be the microfiber diameter. According to embodiments of the invention, the die capillaries may be circular. Subsequently, the meltblown fibers are carried by the high-speed gas stream and deposited on a collection surface to form a randomly distributed web of meltblown fibers. The meltblown fibers may be continuous or discontinuous microfibers and are typically adhesive upon deposition onto the collection surface.

[0040] As used herein, the terms "spunlace" or "hydrospunlace" can include processes for bonding fibers to nonwoven fabrics using high-pressure water jets. Several water jets are directed against a fiber web supported by a movable fabric. Fiber entanglement is introduced through the combined effect of the water jets and the turbulent water generated within the web, which twists adjacent fibers.

[0041] As used herein, the terms “bonded” and “bonded” can include bringing together or attaching (e.g., fusing together) at least a portion of the fibers of a nonwoven web into a closer proximity or attachment therebetween to form bond sites (one or more) that function to increase the nonwoven's resistance to external forces (e.g., abrasion and tension) compared to an unbonded web. For example, bond sites (one or more) can include discrete or localized areas of the web material that have been softened or melted and optionally subsequently or simultaneously compressed to form discrete or localized deformations in the web material. Furthermore, the term “bonded” can include the entire nonwoven web that has been treated to bring together or attach (e.g., fusing together) at least a portion of the fibers into a closer proximity or attachment therebetween, such as by thermal bonding (by way of example only). According to certain embodiments of the invention, such a web can be considered a “bonded nonwoven.” Additionally, specific discrete areas of the fibers that bring together or attach (e.g., fusing together) into a closer proximity or attachment (e.g., fusing together) can be described as “bonded.”

[0042] According to certain embodiments of the invention, consolidation can be achieved, for example, by applying heat and / or pressure to the fiber web (e.g., nonwoven web) via one or more embossing rolls or by using a flow of hot fluid (e.g., through-air bonding). A non-limiting and exemplary method includes thermal bonding. Thermal bonding can be accomplished by passing the fiber web (e.g., nonwoven web) through a pressure nip formed by two rolls, one of which includes an embossing roll that can be heated and has protrusions on its surface having a plurality of raised protrusions having one or more geometries (e.g., dots, rhombuses, circles, ellipses, dog-bone shapes, etc.), which impart or form corresponding discrete thermal bonding sites on the fiber web (e.g., nonwoven web). For example, this operational step can be referred to as “calendering” or “embossing,” wherein the nonwoven web is pulled between the embossing roll and a second roll (e.g., anvil roll), the embossing roll having an embossed pattern that only allows a portion of the web to be exposed to heat and pressure. The degree or extent of consolidation can be expressed as a percentage of the total surface area of ​​a web that has been consolidated or subjected to consolidation, and can be referred to as “bonded area” or “consolidated area.” In other words, the terms “bonded area” and “consolidated area,” as used interchangeably herein, can include the area per unit area occupied by local portions formed by bonding fibers to bonded sites, and can be expressed as a percentage of the total unit area of ​​the consolidated nonwoven fabric. For example, a consolidated nonwoven fabric (e.g., thermally bonded via embossing rollers) can include a plurality of discrete, spaced-apart bonded sites or points (e.g., peripheral and internal bonded sites or points) formed by bonding the fibers of the nonwoven web only in areas of localized energy input. Fibers or portions of fibers away from the localized energy input remain substantially unbonded to adjacent fibers.

[0043] As used herein, the term "bicomponent fiber" can include fibers formed from at least two different polymers extruded from separate extruders but spun together to form a single fiber. Bicomponent fibers are also sometimes referred to as conjugated fibers or multicomponent fibers. The polymers are arranged in substantially constant positions across different regions of the cross-section of the bicomponent fiber and extend continuously along the length of the bicomponent fiber. For example, such a configuration of a bicomponent fiber can be a sheath / core arrangement, in which one polymer is surrounded by another, or it can be a side-by-side arrangement, a pie-like arrangement, or an "islands-in-the-sea" arrangement, each known in the field of multicomponent (including bicomponent) fibers. "Bicomponent fiber" can also be a thermoplastic fiber comprising a core fiber made of one polymer enclosed within a thermoplastic sheath made of a different polymer, or a side-by-side arrangement of different thermoplastic fibers. The first polymer often melts at a different (typically lower) temperature than the second polymer. In sheath / core arrangements, these bicomponent fibers provide thermal adhesion due to the melting of the sheath polymer, while maintaining the desired strength properties of the core polymer. In side-by-side arrangements, the fibers shrink and curl, resulting in z-direction expansion.

[0044] As used herein, the term "cellulose fiber" may include fibers derived from hardwood trees, softwood trees, or a combination of hardwood and softwood trees, for example, prepared for papermaking ingredients and / or short-fiber pulp ingredients by any known suitable digestion, refining, and bleaching operation. Cellulose fibers may include recycled fibers and / or virgin fibers. Recycled fibers differ from virgin fibers in that the fiber has undergone a drying process at least once. In some embodiments, at least a portion of the cellulose fibers may be provided by non-woody herbaceous plants, including but not limited to kenaf, cotton, hemp, jute, flax, sisal, or abaca. In some embodiments of the invention, cellulose fibers may include bleached or unbleached pulp fibers, such as high-yield pulp and / or mechanical pulp (such as thermomechanical pulping (TMP), chemimechanical pulping (CMP), and bleached chemimechanical-thermomechanical pulping (BCTMP)). In this respect, the term "pulp" as used herein may include cellulose that has undergone processing (such as thermal, chemical, and / or mechanical treatment). According to some embodiments of the invention, cellulose fibers may include one or more pulp materials.

[0045] According to certain embodiments of the invention, for example, the source of cellulose fibers may include softwood and / or hardwood species. In one embodiment, the source may include softwood. In another embodiment, the source may be softwood based on a total weight of at least 50 wt% (e.g., 50 wt.% to 95 wt%) of the cellulose fibers.

[0046] I. Nonwoven fabrics

[0047] In one aspect, the present invention provides a nonwoven fabric (e.g., a wipe) comprising a first nonwoven outer layer, a second nonwoven outer layer, and a core layer located directly or indirectly (e.g., one or more additional layers may be positioned between a core layer and one or more outer nonwoven layers, if desired) between the first and second nonwoven outer layers. According to certain embodiments of the invention, at least one of the first and second nonwoven outer layers comprises a plurality of blended filaments (e.g., continuous blended filaments and / or blended diced fibers), the plurality of blended filaments comprising a mixture of polymers and elastomeric polyolefins. In some embodiments of the invention, for example, the first and second nonwoven outer layers may each comprise blended filaments (e.g., continuous blended filaments and / or blended diced fibers). According to certain embodiments of the invention, the core layer comprises cellulose fibers. According to certain embodiments of the invention, in addition to cellulose fibers, the core layer may also comprise polymer fibers, such as continuous polymer fibers. In this respect, the core layer may comprise a combination of continuous polymer fibers and cellulose fibers. According to certain other embodiments of the invention, the core layer may lack or substantially lack cellulose fibers. According to certain embodiments of the present invention, nonwoven fabrics may lack cellulose fibers.

[0048] For example, Figure 1 The illustration shows a nonwoven fabric 100 according to one embodiment of the present invention. Figure 1 As shown, the nonwoven fabric 100 includes a first nonwoven outer layer 110 having a first outermost surface 115 and a second nonwoven outer layer 120 having a second outermost surface 125. Figure 1 As shown, the nonwoven fabric 100 includes a core layer 150 positioned directly between a first nonwoven outer layer 110 and a second nonwoven outer layer 120.

[0049] According to certain embodiments of the invention, for example, the core layer may comprise about 25 wt.% to about 100 wt.% of cellulose fibers or about 50 wt.% to about 80 wt.% of cellulose fibers. According to certain embodiments of the invention, the core layer may comprise any of the following: at least about 25 wt.%, 30 wt.%, 40 wt.%, 50 wt.%, 60 wt.%, 70 wt.%, and 75 wt.% of cellulose fibers and / or up to about 100 wt.%, 99 wt.%, 95 wt.%, 90 wt.%, 85 wt.%, and 80 wt.% of cellulose fibers (e.g., about 75-85 wt.% of cellulose fibers, about 60-95 wt.% of cellulose fibers, etc.). In an exemplary embodiment of the invention, the nonwoven fabric may comprise a core layer comprising approximately 100 wt.% cellulose fibers (e.g., wood pulp). According to certain exemplary embodiments of the present invention, the nonwoven fabric may include, for example, two outer spunbond layers and a core layer comprising approximately 100 wt.% cellulose fibers (e.g., wood pulp). For example, one or both outer spunbond layers may include... The core layer may include approximately 100 wt.% cellulose fibers (e.g., wood pulp).

[0050] According to some embodiments of the invention, the cellulose fibers in the core layer may comprise short fibers and / or diced fibers. In this regard, for example, short fibers may comprise lengths of less than 0.01 meters. According to some embodiments of the invention, the core layer may comprise one or more individual or discrete layers containing cellulose fibers. For example, the core layer may comprise about one to five individual layers containing cellulose fibers (e.g., 1, 2, 3, 4, or 5 individual layers). According to some embodiments of the invention, the core layer may comprise more than one individual layer containing cellulose fibers, including a first individual layer containing cellulose fibers and a second individual layer containing cellulose fibers, wherein the fiber composition (e.g., a mixture of thermoplastic fibers and cellulose fibers) may comprise the same or different percentages of cellulose fibers. According to some embodiments of the invention, the core layer may comprise at least three individual layers containing cellulose fibers, wherein one layer has a higher cellulose fiber content relative to the other individual layers containing cellulose fibers and is located at the innermost position of the core layer.

[0051] According to certain embodiments of the invention, the core layer of a nonwoven fabric may comprise a core layer ratio between a weight percentage of cellulose fibers and a weight percentage of polymer fibers of about 4:1 to 1:1. According to certain embodiments of the invention, the core layer ratio between the weight percentage of cellulose fibers and the weight percentage of polymer fibers may comprise about 3.5:1 to 2.5:1 (e.g., 3.5:1 to 3:1). According to certain embodiments of the invention, the core layer ratio between the weight percentage of cellulose fibers and the weight percentage of polymer fibers may comprise any of the following: at least about 1:1, 1.5:1, 2:1, 2.5:1, and 3:1 and / or at most about 5:1, 4.5:1, 4:1, and 3.5:1.

[0052] According to certain other embodiments of the invention, the core layer may comprise approximately 100 wt.% of a thermoplastic polymer. In this respect, according to certain embodiments of the invention, the core layer may be deficient in cellulose fibers. According to certain embodiments of the invention, the nonwoven fabric may be deficient in cellulose fibers. According to certain embodiments of the invention, the core layer, the nonwoven fabric, or both may comprise an amount of no more than about 15 wt.%, no more than about 10 wt.%, no more than 5 wt.%, no more than 3 wt.%, no more than 2 wt.%, no more than 1 wt.%, no more than 0.5 wt.%, or no more than 0.1 wt.% of cellulose fibers. According to certain exemplary embodiments, the nonwoven fabric may comprise a spunbond-meltblown-spunbond structure, wherein the number of meltblown layers positioned between the outer spunbond layers may vary (e.g., from one to about five), and the nonwoven fabric may be deficient in any cellulose fibers.

[0053] According to certain embodiments of the invention, the core layer may comprise about 60 wt.% to about 90 wt.% of the nonwoven fabric (e.g., about 70 wt.% to about 90 wt.% of the nonwoven fabric). According to certain embodiments of the invention, the core layer may comprise at least about 25 wt.%, 40 wt.%, 50 wt.%, 55 wt.%, 60 wt.%, 70 wt.%, and 75 wt.% of the nonwoven fabric and / or at most about 95 wt.%, 90 wt.%, 85 wt.%, and 80 wt.% of the nonwoven fabric.

[0054] According to certain embodiments of the invention, the nonwoven fabric may comprise at least a first nonwoven outer layer comprising blended filaments (e.g., continuous blended filaments and / or blended diced fibers), wherein the blended filaments comprise a mixture of a polymer and an elastomeric polyolefin, wherein the blended filaments comprise about 10 wt.% to about 75 wt.% of the elastomeric polyolefin. According to certain embodiments of the invention, the blended filaments may comprise about 20 wt.% to about 50 wt.% of the elastomeric polyolefin. According to certain embodiments of the invention, the blended filaments may comprise about 30 wt.% to about 40 wt.% of the elastomeric polyolefin (e.g., about 35 wt.% of the elastomeric polyolefin). According to certain embodiments of the invention, each of the first nonwoven outer layer and the second nonwoven outer layer comprises a blended filament (e.g., a continuous blended filament and / or a blend of diced fibers), the blended filament comprising a mixture of a polymer and an elastomeric polyolefin, wherein the blended filament comprises about 10 wt.% to about 75 wt.% of the elastomeric polyolefin (e.g., about 20 wt.% to about 50 wt.% of the elastomeric polyolefin, about 30 wt.% to about 40 wt.% of the elastomeric polyolefin, about 35 wt.% of the elastomeric polyolefin). According to certain embodiments of the invention, the blended filaments (e.g., continuous blended filaments and / or blended diced fibers) of the first nonwoven outer layer and / or the second nonwoven outer layer may independently comprise any of the following: at least about 10 wt.%, 15 wt.%, 20 wt.%, 25 wt.%, 30 wt.%, 35 wt.%, and 40 wt.% of elastomeric polyolefin and / or at most about 85 wt.%, 80 wt.%, 75 wt.%, 70 wt.%, 65 wt.%, 60 wt.%, 55 wt.%, and 50 wt.% of elastomeric polyolefin. According to certain embodiments of the invention, the elastomeric polyolefin comprises copolymers of propylene and ethylene. In some embodiments of the invention, for example, the elastomeric polyolefin may comprise polypropylene microcrystalline regions and random ethylene amorphous regions.

[0055] According to certain embodiments of the invention, the first nonwoven outer layer, the second nonwoven outer layer, or both may comprise filaments (e.g., spunbond filaments). For example, the blended filaments may comprise spunbond filaments. According to certain embodiments of the invention, at least one of the first and second nonwoven outer layers may comprise a plurality of blended filaments (e.g., continuous blended filaments and / or blended diced fibers), the blended filaments comprising a mixture of a polymer and an elastomeric polyolefin, wherein the polymer comprises at least one of a polyolefin, polyester, polyamide, or a combination thereof. According to certain embodiments, the polymer comprises polypropylene, such as isotactic polypropylene.

[0056] According to certain embodiments of the present invention, the first nonwoven outer layer, the second nonwoven outer layer, and / or the core layer of the nonwoven fabric may comprise filaments formed from various processes (e.g., spunbond, meltblown, carding, etc.) and / or various synthetic or natural polymer materials. For example, the first nonwoven outer layer, the second nonwoven outer layer, and / or the core layer of the nonwoven fabric may comprise filaments comprising polypropylene, polyethylene, or both. In some embodiments of the present invention, for example, the polymer material may comprise high-density polypropylene or high-density polyethylene, low-density polypropylene or low-density polyethylene, linear low-density polypropylene or linear low-density polyethylene, copolymers of polypropylene or ethylene, and any combination thereof. In some embodiments of the present invention, the polymer material may comprise at least one of polypropylene, polyethylene, polyester, polyamide, or combinations thereof. According to certain embodiments of the present invention, the polymer material may comprise biopolymers (e.g., polylactic acid (PLA), polyhydroxyalkanoates (PHA), and poly(hydroxycarboxylic) acids).

[0057] According to certain embodiments of the invention, the nonwoven fabric may comprise multicomponent fibers, such as bicomponent fibers having a sheath-core configuration. For example, certain embodiments of the invention may include bicomponent fibers comprising a sheath (by way of example only, comprising polyethylene or propylene) and a core (by way of example only, comprising polypropylene, polyethylene, polyester, or a biopolymer (e.g., at least one of polylactic acid (PLA), polyhydroxyalkanoates (PHA), and polyhydroxycarboxylic acids)). According to certain embodiments of the invention, these bicomponent fibers may be independently incorporated into a first nonwoven outer layer, a second nonwoven outer layer, and / or a core layer.

[0058] According to certain embodiments of the invention, the first nonwoven outer layer, the second nonwoven outer layer, or both may be substantially lacking in cellulose fibers. According to certain embodiments of the invention, the first nonwoven outer layer, the second nonwoven outer layer, or both may contain an amount of no more than about 15 wt.%, no more than about 10 wt.%, no more than 5 wt.%, no more than 3 wt.%, no more than 2 wt.%, no more than 1 wt.%, no more than 0.5 wt.%, or no more than 0.1 wt.% of cellulose fibers. Additionally or alternatively, the first nonwoven outer layer may define a first outermost surface of the nonwoven fabric (e.g., Figure 1 115), and the second nonwoven outer layer may define the second outermost surface of the nonwoven fabric (e.g., Figure 1125), wherein the first outermost surface, the second outermost surface, or both may be substantially lacking in cellulose fibers. According to certain embodiments of the invention, the first outermost surface, the second outermost surface, or both may contain an amount of no more than about 15 wt.%, no more than about 10 wt.%, no more than 5 wt.%, no more than 3 wt.%, no more than 2 wt.%, no more than 1 wt.%, no more than 0.5 wt.%, or no more than 0.1 wt.% of cellulose fibers.

[0059] According to certain embodiments of the invention, nonwoven fabrics may contain liquid additives loaded thereon. For example, according to certain embodiments of the invention, the liquid additives may not be particularly limited. In some embodiments of the invention, for example, the liquid additives may include washing solutions, dirt-cleaning compositions, skin-cleaning compositions, or antimicrobial compositions. In this regard, some embodiments of the invention may include pre-loaded wet wipes, for example, disposed within a container or package.

[0060] According to some embodiments of the invention, the nonwoven fabric may contain a basis weight of about 20 to about 100 gsm. According to some embodiments of the invention, the nonwoven fabric may contain a basis weight of about 40 to about 60 gsm. In some embodiments of the invention, for example, the nonwoven fabric may contain a basis weight of about 40 gsm to about 50 gsm.

[0061] II. Methods for generating nonwoven fabrics

[0062] In another aspect, the present invention provides a method for forming nonwoven fabrics according to embodiments disclosed herein. For example, Figure 2 The illustration shows a process flow diagram for forming nonwoven fabrics according to certain embodiments of the present invention. For example... Figure 2 As shown, according to certain embodiments of the present invention, a method for forming a nonwoven fabric may include the following steps: providing a first nonwoven outer layer in operation 210, the first nonwoven outer layer comprising a plurality of continuous blended filaments, the plurality of continuous blended filaments comprising a mixture of a polymer and an elastomeric polyolefin; providing a second nonwoven outer layer in operation 220; providing a core layer in operation 230; positioning the core layer between the first nonwoven layer and the second nonwoven outer layer in operation 240 to form a composite web; and bonding the composite web in operation 250 to form a nonwoven fabric. It should be noted that operation 210 is only referred to as an example of continuous blended filaments, and operation 210 may include a plurality of continuous blended filaments and / or a mixture of diced fibers. According to certain embodiments of the present invention, for example, the first nonwoven outer layer may be formed from a mixture of diced fibers, continuous blended filaments, or a combination of a mixture of diced fibers and continuous blended filaments.

[0063] According to some embodiments of the present invention, the step of providing a first nonwoven outer layer may include melt-spinning a first nonwoven layer. According to some embodiments of the present invention, the step of providing a second nonwoven outer layer may include melt-spinning a second nonwoven layer. According to some embodiments of the present invention, the step of providing a core layer may include melt-spinning a core layer. According to some embodiments of the present invention, for example, a method of forming a nonwoven fabric as disclosed herein may include melt-spinning a first nonwoven layer onto a forming tape, forming a core layer onto a first nonwoven outer layer, forming a second nonwoven layer onto the core layer to form a composite nonwoven fabric, and bonding the composite nonwoven fabric to form a nonwoven fabric as disclosed herein.

[0064] For example, Figure 3 The illustration shows a schematic diagram 300 illustrating a method for producing a nonwoven fabric according to certain embodiments of the present invention. For example... Figure 3 As shown, 312 provides a first source of molten polymer. Polymer melt from the first molten polymer source 312 is fed to a first warp beam 310, and the polymer melt is melt-spun into a plurality of first warp filaments 315 and deposited onto a moving collection belt 400. The source of the molten polymer can be a typical extrusion system found in most spunbond production lines. The first warp filaments 315 will define a first nonwoven outer layer. A second source of molten polymer 324 and cellulose fibers (e.g., wood pulp fibers) 322 are fed to a second warp beam 320, wherein the molten polymer is spun into continuous filaments and combined with the cellulose fibers (e.g., wood pulp fibers) to form a stream of fibrous material 325 collected on the collection belt 400. The source of the cellulose fibers (e.g., wood fibers) can be a typical air-laid process, where a hammer mill is used to fiberize wood pulp board. At this point, the second warp filaments 325 may include cellulose fibers at least partially bonded to the polymer fibers and / or at least partially incorporated into the polymer fibers. Figure 3 As shown, the second warp filament 325 can be directly deposited onto the first warp filament 315, which has previously been deposited onto the collection belt 400. Figure 3 The illustrated embodiment includes a third warp beam 330 fed from another source of cellulose fibers 332 and a third source of molten polymer 334, wherein the third warp beam 330 provides a third warp beam 335 deposited on top of the second warp beam 325. In this respect, the second and third warp beams can define two separate layers containing cellulose fibers forming the core layer of the nonwoven fabric. Figure 3As shown, a fourth warp beam 340 is provided. The fourth warp beam 340 is fed from a fourth source of molten polymer 342. The fourth source of molten polymer 342 includes a melt mixture comprising one or more polymers (e.g., a non-elastomeric polymer) and at least one elastomeric polyolefin. At this point, the melt mixture from the source of molten polymer 342 is fed into the fourth warp beam, and the melt mixture is melt-spun into a plurality of fourth warp beam filaments 345 and deposited onto a third warp beam filament 335 to define a composite nonwoven web 500. At this point, the fourth warp beam filaments 345 comprise mixed filaments. In this embodiment, the fourth warp beam filaments 345 define a second nonwoven outer layer. The composite nonwoven web 500 enters and / or passes through a thermal calendering apparatus 600, which includes a patterned roll 610 and a smooth counter roll 620, to thermally bond the composite nonwoven web 500 to form a nonwoven fabric 700. The nonwoven fabric 700 includes an embossed side 710 and a smooth side 720 as a result of the embossing roller 610.

[0065] According to certain embodiments of the present invention, nonwoven composite materials (e.g., from...) Figure 3 The 500) can be bonded by various operations, such as thermal bonding, adhesive bonding, mechanical bonding, ultrasonic bonding, or similar bonding. According to certain embodiments of the invention, bonding of nonwoven composite materials may include thermal bonding via a calender. In this respect, for example, a nonwoven fabric produced by a method according to certain embodiments of the invention may include multiple bonded sites, wherein at least a portion of the fibers at or near the bonded sites may be fused together or alternatively mechanically twisted together by an adhesive component. In this respect, for example, the bonded sites (one or more) may include discrete or localized regions of the nonwoven fabric that have been softened or melted and optionally subsequently or simultaneously compressed to form discrete or localized deformations in the nonwoven fabric.

[0066] although Figure 3 The illustration depicts one specific method for forming a nonwoven fabric according to certain embodiments of the invention; however, some embodiments of the invention may include methods such as... The process, or Arvell process, utilizes and / or forms a nonwoven fabric that combines cellulosic fibers (e.g., pulp) and continuous filaments by thermal bonding (without hydroentangling). In this respect, one or more layers of the nonwoven fabric may comprise a spunbond or carded web, which can be thermally bonded.

[0067] According to certain embodiments of the invention, for example, the core layer may comprise about 25 wt.% to about 100 wt.% of cellulose fibers or about 50 wt.% to about 80 wt.% of cellulose fibers. According to certain embodiments of the invention, the core layer may comprise any of the following: at least about 25 wt.%, 30 wt.%, 40 wt.%, 50 wt.%, 60 wt.%, 70 wt.%, and 75 wt.% of cellulose fibers and / or up to about 100 wt.%, 99 wt.%, 95 wt.%, 90 wt.%, 85 wt.%, and 80 wt.% of cellulose fibers (e.g., about 75-85 wt.% of cellulose fibers, about 60-95 wt.% of cellulose fibers, etc.). In an exemplary embodiment of the invention, the nonwoven fabric may comprise a core layer containing approximately 100 wt.% cellulose fibers (e.g., wood pulp). According to certain exemplary embodiments of the present invention, for example, a nonwoven fabric may include two outer spunbond layers and a core layer comprising approximately 100 wt.% cellulose fibers (e.g., wood pulp). For example, one or both outer spunbond layers may include... The core layer may contain approximately 100 wt.% cellulose fibers (e.g., wood pulp).

[0068] According to certain embodiments of the invention, the cellulose fibers of the core layer may include short fibers and / or diced fibers. In this regard, for example, short fibers may contain lengths of less than 0.01 meters. According to certain embodiments of the invention, the method may include a core layer formed from one or more individual or discrete layers containing cellulose fibers. For example, the core layer may be formed by depositing or stacking about one to five individual layers containing cellulose fibers (e.g., 1, 2, 3, 4, or 5 individual layers) on top of each other. According to certain embodiments of the invention, the core layer may be generated by providing or forming more than one individual layer containing cellulose fibers, including a first individual layer containing cellulose fibers and a second individual layer containing cellulose fibers, wherein the fiber composition (e.g., a mixture of thermoplastic fibers and cellulose fibers) may contain the same or different percentages of cellulose fibers. According to certain embodiments of the invention, the core layer may be generated by forming or providing at least three individual layers containing cellulose fibers, one of which has a higher cellulose fiber content relative to the other individual layers containing cellulose fibers and is located at the innermost part of the core layer.

[0069] According to certain embodiments of the invention, the core layer of a nonwoven fabric may comprise a core layer ratio between a weight percentage of cellulose fibers and a weight percentage of polymer fibers of about 4:1 to 1:1. According to certain embodiments of the invention, the core layer ratio between the weight percentage of cellulose fibers and the weight percentage of polymer fibers may comprise about 3.5:1 to 2.5:1 (e.g., 3.5:1 to 3:1). According to certain embodiments of the invention, the core layer ratio between the weight percentage of cellulose fibers and the weight percentage of polymer fibers may comprise any of the following: at least about 1:1, 1.5:1, 2:1, 2.5:1, and 3:1 and / or at most about 5:1, 4.5:1, 4:1, and 3.5:1.

[0070] According to certain other embodiments of the invention, the core layer may comprise approximately 100 wt.% of a thermoplastic polymer. In this respect, the core layer according to certain embodiments of the invention may be deficient in cellulose fibers. According to certain embodiments of the invention, the nonwoven fabric may be deficient in cellulose fibers. According to certain embodiments of the invention, the core layer, the nonwoven fabric, or both may comprise an amount of no more than about 15 wt.%, no more than about 10 wt.%, no more than 5 wt.%, no more than 3 wt.%, no more than 2 wt.%, no more than 1 wt.%, no more than 0.5 wt.%, or no more than 0.1 wt.% of cellulose fibers. According to certain exemplary embodiments, the nonwoven fabric may comprise a spunbond-meltblown-spunbond structure, wherein the number of meltblown layers positioned between the outer spunbond layers may vary (e.g., from 1 to about 5), and the nonwoven fabric may be deficient in any cellulose fibers.

[0071] According to certain embodiments of the invention, the core layer may comprise about 60 wt.% to about 90 wt.% of the nonwoven fabric (e.g., about 70 wt.% to about 90 wt.% of the nonwoven fabric). According to certain embodiments of the invention, the core layer may comprise any of the following: at least about 25 wt.%, 40 wt.%, 50 wt.%, 55 wt.%, 60 wt.%, 70 wt.%, and 75 wt.% of the nonwoven fabric and / or at most about 95 wt.%, 90 wt.%, 85 wt.%, and 80 wt.% of the nonwoven fabric.

[0072] According to certain embodiments of the present invention, the resulting nonwoven fabric may comprise at least a first nonwoven outer layer, the first nonwoven outer layer comprising blended filaments (e.g., continuous blended filaments and / or blended diced fibers), the blended filaments comprising a mixture of a polymer and an elastomeric polyolefin, wherein the blended filaments comprise about 10 wt.% to about 75 wt.% of the elastomeric polyolefin. According to certain embodiments of the present invention, the blended filaments (e.g., continuous blended filaments and / or blended diced fibers) may comprise about 20 wt.% to about 50 wt.% of the elastomeric polyolefin. According to certain embodiments of the present invention, the blended filaments (e.g., continuous blended filaments and / or blended diced fibers) may comprise about 30 wt.% to about 40 wt.% of the elastomeric polyolefin (e.g., about 35 wt.% of the elastomeric polyolefin). According to certain embodiments of the invention, each of the first nonwoven outer layer and the second nonwoven outer layer comprises a blended filament (e.g., a continuous blended filament and / or a blend of diced fibers) comprising a mixture of a polymer and an elastomeric polyolefin, wherein the blended filament (e.g., a continuous blended filament and / or a blend of diced fibers) comprises about 10 wt.% to about 75 wt.% of an elastomeric polyolefin (e.g., about 20 wt.% to about 50 wt.% of an elastomeric polyolefin, about 30 wt.% to about 40 wt.% of an elastomeric polyolefin, about 35 wt.% of an elastomeric polyolefin). According to certain embodiments of the invention, the blended filaments (e.g., continuous blended filaments and / or blended diced fibers) of the first nonwoven outer layer and / or the second nonwoven outer layer may independently comprise any of the following: at least about 10 wt.%, 15 wt.%, 20 wt.%, 25 wt.%, 30 wt.%, 35 wt.%, and 40 wt.% of elastomeric polyolefin and / or at most about 85 wt.%, 80 wt.%, 75 wt.%, 70 wt.%, 65 wt.%, 60 wt.%, 55 wt.%, and 50 wt.% of elastomeric polyolefin. According to certain embodiments of the invention, the elastomeric polyolefin comprises copolymers of propylene and ethylene. In some embodiments of the invention, for example, the elastomeric polyolefin may comprise polypropylene microcrystalline regions and random ethylene amorphous regions.

[0073] According to certain embodiments of the invention, the first nonwoven outer layer, the second nonwoven outer layer, or both may comprise continuous filaments (e.g., spunbond filaments). For example, the blended filaments may comprise filaments formed by spunbonding. According to certain embodiments of the invention, at least one of the first and second nonwoven outer layers may comprise a plurality of blended filaments (e.g., continuous blended filaments and / or blended diced fibers), the blended filaments comprising a mixture of a polymer and an elastomeric polyolefin, wherein the polymer comprises at least one of polyolefins, polyesters, polyamides, or combinations thereof. According to certain embodiments, the polymer comprises polypropylene, such as isotactic polypropylene.

[0074] According to certain embodiments of the present invention, the first nonwoven outer layer, the second nonwoven outer layer, and / or the core layer of the nonwoven fabric may comprise filaments formed by various processes (e.g., spunbond, meltblown, carding, etc.) and / or various synthetic or natural polymer materials. For example, the first nonwoven outer layer, the second nonwoven outer layer, and / or the core layer of the nonwoven fabric may comprise filaments comprising polypropylene, polyethylene, or both. In some embodiments of the present invention, for example, the polymer material may comprise high-density polypropylene or high-density polyethylene, low-density polypropylene or low-density polyethylene, linear low-density polypropylene or linear low-density polyethylene, copolymers of polypropylene or ethylene, and any combination thereof. In some embodiments of the present invention, the polymer material may comprise at least one of polypropylene, polyethylene, polyester, polyamide, or combinations thereof. According to some embodiments of the present invention, the polymer material may comprise biopolymers (e.g., polylactic acid (PLA), polyhydroxyalkanoates (PHA), and polyhydroxycarboxylic acids).

[0075] According to certain embodiments of the invention, the nonwoven fabric may comprise multicomponent fibers, such as bicomponent fibers having a sheath-core configuration. For example, certain embodiments of the invention may include bicomponent fibers comprising a sheath (by way of example only, comprising polyethylene or propylene) and a core (by way of example only, comprising polypropylene, polyethylene, polyester, or a biopolymer (e.g., at least one of polylactic acid (PLA), polyhydroxyalkanoate (PHA), and polyhydroxycarboxylic acid). According to certain embodiments of the invention, these bicomponent fibers may be independently incorporated into a first nonwoven outer layer, a second nonwoven outer layer, and / or a core layer.

[0076] According to certain embodiments of the invention, the first nonwoven outer layer, the second nonwoven outer layer, or both may be substantially devoid of cellulose fibers. According to certain embodiments of the invention, the first nonwoven outer layer, the second nonwoven outer layer, or both may contain an amount of cellulose fibers not exceeding about 15 wt.%, not exceeding about 10 wt.%, not exceeding 5 wt.%, not exceeding 3 wt.%, not exceeding 2 wt.%, not exceeding 1 wt.%, not exceeding 0.5 wt.%, or not exceeding 0.1 wt.%. Additionally or alternatively, the first nonwoven outer layer may define a first outermost surface of the nonwoven fabric (e.g., Figure 1 115), and the second nonwoven outer layer may define the second outermost surface of the nonwoven fabric (e.g., Figure 1125), wherein the first outermost surface, the second outermost surface, or both may be substantially lacking in cellulose fibers. According to certain embodiments of the invention, the first outermost surface, the second outermost surface, or both may contain an amount of no more than about 15 wt.%, no more than about 10 wt.%, no more than 5 wt.%, no more than 3 wt.%, no more than 2 wt.%, no more than 1 wt.%, no more than 0.5 wt.%, or no more than 0.1 wt.% of cellulose fibers.

[0077] According to certain embodiments of the invention, the method may further include adding and / or incorporating a liquid additive loaded onto or on a nonwoven fabric. For example, according to certain embodiments of the invention, the liquid additive may not be particularly limited. In some embodiments of the invention, the liquid additive may, for example, include a washing solution, a dirt-cleansing composition, a skin-cleansing composition, or an antimicrobial composition. In this regard, some embodiments of the invention may include a pre-loaded wet wipe, for example, disposed within a container or package.

[0078] According to some embodiments of the invention, the nonwoven fabric may include a basis weight of about 20 to about 100 gsm. According to some embodiments of the invention, the basis weight of the nonwoven fabric may include about 40 to about 60 gsm. In some embodiments of the invention, for example, the nonwoven fabric may include a basis weight of about 40 gsm to about 50 gsm.

[0079] III. Examples

[0080] The present disclosure is further illustrated by the following embodiments, which should not be construed as limiting. That is, the specific features described in the following embodiments are merely illustrative and not restrictive.

[0081] It is well known that tactile properties related to the smooth or slippery feel of a wet wipe can be predicted by testing the fabric's coefficient of friction (COF) against itself. It is also believed that some wiping properties, including those with stripes, can be predicted at least in part by the COF for a given wipe.

[0082] Use such as Figure 3 The process shown produced a sample of a nonwoven fabric (e.g., a composite material). In this process, a warp beam 1 (e.g., from...) was used to fabricate a sample of a nonwoven fabric. Figure 3 310) and 4 (e.g., from Figure 3 The continuous filaments generated by warp beams 2 and 3 (e.g., from warp beams 340) form the outermost layer of the fabric, while the continuous filaments generated by warp beams 2 and 3 (e.g., from warp beams 340) form the outermost layer of the fabric. Figure 3Continuous filaments (320 and 330) are combined with wood fibers to form the core layer of the fabric. This process is also considered an Armell technique and involves blending and slightly bonding wood fibers with continuous filaments to form an intermediate layer or absorbent core (i.e., the “product” from warp beams 2 and 3), while the layering of continuous filaments traps or sandwiches the core layer between them as an outer sheath. Sandwiching the core layer between the outermost layers of continuous filaments helps reduce wood fiber shedding. All samples were made using a spinneret that produces thermoplastic filaments with a bilobal cross-section. The resulting structures (e.g., composite webs from warp beams 1 to 4) were then thermally bonded using a low-bond-area calendering process.

[0083] Sample 1

[0084] Sample 1 has a basis weight of 50 gsm and is produced by the process described above, by first making warp shaft 1 (e.g., from...) Figure 3 310) deposits a layer of 4.75 gsm continuous filaments made of 25 MFR (ISO 1133, 230°C / 2.16 kg) polypropylene on the collecting belt. On top of this layer, through warp shafts 2 and 3 (e.g., from... Figure 3 The core layers of warp shafts 320 and 330 are deposited, wherein each of these warp shafts generates a layer made of 4.75 gsm of propylene-based polyolefin and 15.5 gsm of wood pulp fiber. Finally, warp shaft 4 (e.g., from...) is used... Figure 3 340) was deposited from 35 wt.% Vistamaxx TM Another layer of continuous filaments made of VM-2125 (sold by ExxonMobil) and 65 wt.% spunbond grade polypropylene. The composite web, then formed by warp beams 1 to 4, is bonded by calendering. It should be noted that during bonding via the calender, the top layer of the composite web (e.g., including Vistamaxx)... TM The VM-2125 layer is positioned against the embossing roller of the calender, while the other side of the composite mesh (without Vistamaxx) TM VM-2125) is positioned against the smoothing roller. From warp shafts 1 and 4 (e.g., from...) Figure 3 The continuous filaments (310 and 340) are made from spinnable grade propylene-based polyolefins selected for their adhesion to wood fibers. Finally, filaments are provided to warp shafts 2 and 3 (e.g., from...). Figure 3 The wood fibers (320 and 330) are composed of wood fibers made from Stora Fluff ECF cork sulfate treated pulpboard (sold by Stora EnsoBiomaterials, POBox 12386 NL-1100 AJ Amsterdam).

[0085] Sample 2

[0086] Sample 2 was produced by accelerating the collection process used to produce Sample 1 by reducing the basis weight of the nonwoven fabric to 45 gsm. The weight ratios between layers or between components remained the same as those described in Sample 1.

[0087] Compare sample 1 (C1)

[0088] This comparative sample was also produced using the process described above. The material throughput and belt speed were set to generate a nominal basis weight of 50 gsm. For this comparative sample, the outer layers (warp beams 1 and 4) consisted of continuous filaments spun from a mixture comprising 92% 25 MFR (ISO 1133, 230°C / 2.16 kg) polypropylene and 8% calcium carbonate masterbatch (80% calcium carbonate loading). Each of these layers had a basis weight of approximately 4.75 gsm, or approximately 9.5% of the total basis weight of the nonwoven fabric. Warp beams 2 and 3 (e.g., from...) Figure 3 The compositions of 320 and 330 consist of approximately 4.75 gsm of continuous propylene-based polyolefin filament and 15.5 gsm of wood pulp fiber, respectively. The structure produced by this process has two outer layers, each representing 9.5% of the total basis weight of the nonwoven fabric, while the warp beams 2 and 3 (e.g., from...) Figure 3 The cores generated by the combination of 320 and 330 accounted for 81% by weight of this comparative sample.

[0089] Compare sample 2 (C2)

[0090] Comparative Sample 2 was prepared by accelerating the collection process used to prepare Comparative Sample 1 in a manner that reduced the basis weight to 45 gsm. The weight ratios between layers or between components remained the same as those in Comparative Sample 1.

[0091] Compare sample 3 (C3)

[0092] Comparative sample 3 was prepared by accelerating the collection process used to prepare comparative sample 1 in a manner that reduced the basis weight to 40 gsm. The weight ratios between layers or between components remained the same as those in comparative sample 1.

[0093] Compare sample 4 (C4)

[0094] Comparative sample 4 has a basis weight of approximately 50 gsm and was manufactured using a process quite similar to that used for the previous comparative samples; however, for this comparative sample, while the core layer is a mixture of wood fiber and polyolefin filaments, the two outer layers of the continuous filament are made of spunbond-grade polypropylene. This comparative sample includes the absence of Vistamaxx on both exposed surfaces of the material. TM Or a baseline sample of calcium carbonate.

[0095] The test and comparison samples were tested for the following properties: basis weight according to ASTM D 3776; tensile strength and peak elongation according to ASTM D 5035 using a 50 mm wide strip; and static and kinetic coefficients of friction (“COF”) according to ASTM D1894. For testing, a sled was wound around the test or comparison sample, and the flat surface was also covered by the test or comparison sample. Notably, both sides of the test or comparison sample were tested against themselves: the side facing the pattern roll (P) against the same side (itself), and the side facing the smooth roll (S) against itself. Furthermore, the test or comparison sample used for wet testing was saturated by immersion in water and hung to drip for 1 minute before testing.

[0096] The test results can be found in Tables 1, 2 and 3.

[0097]

[0098]

[0099] The first observation of dynamic COF for dry or wet samples is for the same sample, on the "P" side (i.e., containing Vistamax for samples 1 and 2). TM VM-2125 and the nonwoven fabric positioned against the embossing roller on one side) is different from the "S" side (i.e., lacking Vistamaxx). TM VM-2125 (the outermost part of the nonwoven fabric positioned against the smooth roller) exhibits significantly higher values. For example, for dry testing, an average gain of approximately 45% was achieved for the "P" side relative to the "S" side. For wet testing, this gain was approximately 27% for the "P" side relative to the "S" side. For example, a second observation is that the "P" side for samples 1 and 2 also exhibited higher dry or wet dynamic COF when compared to the "P" or "S" side for the baseline sample (i.e., C4). A third observation from the data summarized above includes the addition of Vistamaxx. TM VM-2125 increases dry or wet dynamic COF more than when calcium carbonate filler is added.

[0100]

[0101] The results of static COF summarized in Table 3 also illustrate the effect of adding Vistamaxx. TMThe benefits of VM-2125. For example, the gain on the "P" side relative to the "S" side for samples 1 and 2 was approximately 23% for the dry test and 28% for the wet test. The gain was even more pronounced when comparing the "P" side of samples 1 and 2 with both sides of the comparative sample C4. In summary, these results clearly demonstrate that adding elastomeric polyolefins to the filaments forming the outer layer of a nonwoven fabric (e.g., a wet wipe) increases the COF of this wipe against itself, and we know that this higher COF is expected to reduce the slipperiness of such a wipe and improve some aspects of its wiping performance. In this respect, incorporating elastomeric polyolefins into the filaments forming the outer layer helps the user perceive them as significantly (notably) close to cellulose-containing wipes on their exposed sides (i.e., the outermost sides).

[0102] Based on previous tests on wet wipe samples, it should be clear that, according to certain embodiments of the invention, adding elastomeric polyolefins to the polypropylene-based composition of the thermoplastic filaments forming the majority of the outer layer of the wet wipe significantly improves the COF on that side relative to the wipe side excluding elastomeric polyolefins.

[0103] These other modifications and variations can be made to the invention by those skilled in the art without departing from the spirit and scope of the invention, the spirit and scope of which are more specifically set forth in the appended claims. Furthermore, it should be understood that aspects of the various embodiments may be interchanged, in whole or in part. Moreover, those skilled in the art will understand that the foregoing description is merely illustrative and is not intended to limit the invention as further described in such appended claims. Therefore, the spirit and scope of the appended claims should not be limited to the exemplary descriptions contained herein.

Claims

1. Nonwoven fabrics, including: A first nonwoven outer layer, wherein the first nonwoven outer layer lacks cellulose fibers; A second nonwoven outer layer, wherein the second nonwoven outer layer lacks cellulose fibers; and A core layer, located between the first nonwoven outer layer and the second nonwoven outer layer, the core layer comprising a combination of continuous non-elastomeric polymer spunbond fibers and cellulose fibers, wherein the core layer comprises 50 wt.% to 99 wt.% cellulose fibers, and wherein the cellulose fibers are at least partially bonded to and at least partially incorporated into the continuous non-elastomeric polymer spunbond fibers; At least one of the first nonwoven outer layer and the second nonwoven outer layer is composed of a plurality of mixed filaments, which are formed from a single melt mixture of (i) a non-elastomeric polymer and (ii) an elastomeric polyolefin mixed with each other. The blended filament contains 10 wt.% to 75 wt.% of the elastomeric polyolefin.

2. The nonwoven fabric of claim 1, wherein the blended filament comprises continuous blended filament, blended diced fibers, or both.

3. The nonwoven fabric according to any one of claims 1-2, wherein the first nonwoven outer layer and the second nonwoven outer layer each comprise continuous blended filaments.

4. The nonwoven fabric according to any one of claims 1-2, wherein the core layer comprises 50 wt.% to 95 wt.% cellulose fibers.

5. The nonwoven fabric of claim 4, wherein the core layer comprises 50 wt.% to 80 wt.% cellulose fibers.

6. The nonwoven fabric of claim 4, wherein the core layer comprises 1 to 5 separate layers containing cellulose fibers.

7. The nonwoven fabric of claim 6, wherein the cellulose fibers comprise diced fibers.

8. The nonwoven fabric of any one of claims 1-2, wherein the core layer comprises a core layer ratio between a weight percentage of cellulose fibers of 4:1 and a weight percentage of non-elastomeric polymer spunbond fibers of 1:

1.

9. The nonwoven fabric of claim 8, wherein the core layer comprises a core layer ratio between a weight percentage of cellulose fibers of 3.5:1 and a weight percentage of non-elastomeric polymer spunbond fibers of 2.5:

1.

10. The nonwoven fabric according to any one of claims 1-2, wherein the core layer accounts for 60 wt.% to 90 wt.% of the nonwoven fabric.

11. The nonwoven fabric of claim 10, wherein the core layer comprises 70 wt.% to 90 wt.% of the nonwoven fabric.

12. The nonwoven fabric of claim 1, wherein the blended filament comprises 20 wt.% to 50 wt.% of the elastomeric polyolefin.

13. The nonwoven fabric of claim 1, wherein the blended filament comprises 30 wt.% to 40 wt.% of the elastomeric polyolefin.

14. The nonwoven fabric of claim 1, wherein the blended filament comprises 35 wt.% of the elastomeric polyolefin.

15. The nonwoven fabric of any one of claims 1-2, wherein the elastomeric polyolefin comprises a copolymer of propylene and ethylene.

16. The nonwoven fabric of claim 15, wherein the elastomeric polyolefin comprises polypropylene microcrystalline regions and random ethylene amorphous regions.

17. The nonwoven fabric of any one of claims 1-2, wherein the first nonwoven outer layer, the second nonwoven outer layer, or both comprise spunbond yarn.

18. The nonwoven fabric of any one of claims 1-2, wherein the non-elastomeric polymer comprises at least one of polyolefin, polyester, polyamide, or combinations thereof.

19. The nonwoven fabric of claim 18, wherein the non-elastomeric polymer comprises polypropylene.

20. The nonwoven fabric of any one of claims 1-2, wherein the nonwoven fabric comprises a basis weight of 20 to 100 gsm.

21. The nonwoven fabric of claim 20, wherein the nonwoven fabric comprises a basis weight of 40 to 60 gsm.

22. A method for forming a nonwoven fabric, comprising: A first nonwoven outer layer is provided, wherein the first nonwoven outer layer lacks cellulose fibers; A second nonwoven outer layer is provided, wherein the second nonwoven outer layer lacks cellulose fibers; A core layer is formed comprising a combination of continuous non-elastomeric polymer spunbond fibers and cellulose fibers, wherein, while the continuous non-elastomeric polymer spunbond fibers are in a molten state, the continuous non-elastomeric polymer spunbond fibers are embedded with the cellulose fibers to at least partially incorporate the cellulose fibers into the continuous non-elastomeric polymer spunbond fibers, and wherein the core layer comprises 50 wt.% to 99 wt.% of cellulose fibers, and wherein the cellulose fibers are at least partially bonded to and at least partially incorporated into the continuous non-elastomeric polymer spunbond fibers; The core layer is positioned between the first nonwoven outer layer and the second nonwoven outer layer to form a composite material web; and The composite mesh is bonded to form the nonwoven fabric; At least one of the first and second nonwoven outer layers is composed of a plurality of hybrid filaments, said hybrid filaments being formed from a single melt mixture of (i) a non-elastomeric polymer and (ii) an elastomeric polyolefin; and The blended filament contains 10 wt.% to 75 wt.% of the elastomeric polyolefin.

23. The method of claim 22, further comprising the steps of forming the melt mixture and melt-spinning the melt mixture to form the first nonwoven outer layer, the second nonwoven outer layer, or both.

24. Nonwoven fabrics, including: First nonwoven outer layer; The second nonwoven outer layer; and A core layer, located between the first nonwoven outer layer and the second nonwoven outer layer, the core layer being composed of 100% by weight cellulose fibers; At least one of the first and second nonwoven outer layers is composed of a plurality of hybrid filaments, said hybrid filaments being formed from a single melt mixture of (i) a non-elastomeric polymer and (ii) an elastomeric polyolefin, and The blended filament contains 10 wt.% to 75 wt.% of the elastomeric polyolefin.

25. The nonwoven fabric of claim 1 or 24, wherein the non-elastomeric polymer comprises polylactic acid, polyhydroxyalkanoate, or a combination thereof.

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