Nonwoven fabrics comprising fibers formed from post-consumer recycled plastic

Abstract

A nonwoven fabric is provided, comprising a mechanically entangled fiber blend, the mechanically entangled fiber blend comprising (a) post-consumer recycled polymer staple fibers (PCR-staple fibers) and (b) one or more additional fibers, wherein the one or more additional fibers are different from the PCR-staple fibers. The PCR-staple fibers are mechanically entangled with the one or more additional fibers to define a nonwoven fabric.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority under 35 USC §119(e) to U.S. Provisional Application No. 63 / 062,520, filed on August 7, 2020, which is expressly incorporated herein by reference in its entirety. Technical Field

[0003] Embodiments of the presently disclosed invention generally relate to nonwoven fabrics comprising post-consumer recycled polymer staple fibers (PCR-staple fibers) mechanically entangled with one or more additional fibers (e.g., cellulosic fibers, wettable staple fibers, etc.). Embodiments of the presently disclosed invention generally also relate to methods of making such nonwoven fabrics. Background Art

[0004] There is a growing interest in utilizing recycled plastics in a variety of disposable products. Plastic recycling generally involves recovering waste or scrap plastics and reprocessing the material into usable products. Since most plastics are non-biodegradable, recycling is part of a global effort to reduce plastic waste that would otherwise be incinerated, placed in a landfill, or enter one of the world's oceans. In some cases, the use of recycled plastics may be undesirably associated with products that exhibit reduced physical properties compared to products formed entirely from virgin plastics.

[0005] Therefore, there is still a need in the art for nonwoven fabrics, such as wet wipes or dry wipes, comprising fibers formed from post-consumer recycled (PCR) plastics. There is also still a need in the art for methods of making such nonwoven fabrics comprising PCR. Summary of the invention

[0006] One or more embodiments of the present invention can solve one or more of the above problems. According to certain embodiments of the present invention, a nonwoven fabric is provided, the nonwoven fabric comprising a mechanically entangled fiber blend, the mechanically entangled fiber blend comprising (a) post-consumer recycled polymer staple fibers (PCR-staple fibers) and (b) one or more additional fibers; wherein the one or more additional fibers are different from the PCR-staple fibers. According to certain embodiments of the present invention, the PCR-staple fibers are mechanically entangled (e.g., hydroentangled) with one or more additional fibers to define a nonwoven fabric.

[0007] In another aspect, the present invention provides a method for forming a nonwoven fabric. According to certain embodiments of the present invention, the method may include the following: (ia) forming or providing a carded fiber web comprising a fiber blend, the fiber blend comprising (a) post-consumer recycled polymer staple fibers (PCR-staple fibers) and (b) one or more additional fibers, wherein the one or more additional fibers are different from the PCR-staple fibers; or (ib) forming or providing a first layer of post-consumer recycled polymer staple fibers (PCR-staple fibers) and forming or providing a second layer of one or more additional fibers; wherein the first layer is adjacent to the second layer to provide a multi-layer nonwoven web; and (ii) mechanically entangle the PCR-staple fibers with one or more additional fibers to define a nonwoven fabric as described and disclosed herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the 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 so that this disclosure will satisfy applicable legal requirements. Throughout the text, like numbers refer to like elements, and wherein:

[0009] Figure 1 A nonwoven fabric having a three-dimensional pattern according to certain embodiments of the present invention is shown, the three-dimensional pattern comprising a single continuous recessed portion and a plurality of raised portions, the plurality of raised portions comprising islands within the single continuous recessed portion;

[0010] Figure 2 A nonwoven fabric having a three-dimensional pattern according to certain embodiments of the present invention is shown, the three-dimensional pattern comprising a plurality of recessed portions and a plurality of raised portions; and

[0011] Figure 3 A flow chart showing a method of making a nonwoven fabric according to certain embodiments of the present invention is shown. DETAILED DESCRIPTION

[0012] The invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the 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 so that this disclosure will satisfy applicable legal requirements. As used in the specification and in the appended claims, the singular includes plural referents unless the context clearly dictates otherwise.

[0013] The invention disclosed herein generally relates to a nonwoven fabric comprising a plurality of fibers formed from post-consumer recycled (PCR) plastics. According to certain embodiments of the present invention, the nonwoven fabric may comprise PCR-short fibers mechanically entangled (e.g., via hydroentanglement) with one or more additional fibers, the one or more additional fibers being different from the PCR-short fibers. For example, the one or more additional fibers may comprise different polymer compositions, different lengths, different linear densities, and / or different fiber types (e.g., spunbond, meltblown, electrospinning, melt fibrillation, etc.). According to certain embodiments of the present invention, the one or more additional fibers may comprise natural cellulose fibers and / or synthetic cellulose fibers (e.g., pulp, woven fabrics, viscose, rayon, etc.). According to certain embodiments of the present invention, the nonwoven fabric may also comprise an adhesive, such as an adhesive that prevents or mitigates the attachment of disinfectants (e.g., chlorine disinfectants, quaternary ammonium disinfectants, etc.) to the nonwoven fabric. In this regard, according to certain embodiments of the present invention, the nonwoven fabric prevents or mitigates the consumption of the disinfectant concentration of the cleaning or disinfecting composition and / or promotes the release of the disinfectant from the nonwoven fabric or application to the surface to be disinfected.

[0014] The term "substantially" or "essentially" may encompass the entire amount specified according to certain embodiments of the present invention, or may encompass most but not all of the specified amount (e.g., 95%, 96%, 97%, 98% or 99% of the entire amount specified) according to other embodiments of the present invention.

[0015] The term "polymer" or "polymeric" as used interchangeably herein may encompass homopolymers, copolymers, such as block copolymers, graft copolymers, random copolymers and alternating copolymers, terpolymers, etc., and blends and modifications thereof. In addition, unless otherwise specifically limited, the term "polymer" or "polymeric" shall 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 polymers or polymeric materials. These configurations include but are not limited to isotactic, syndiotactic and random configurations of such polymers or polymeric materials. The term "polymer" or "polymeric" shall also include polymers made from various catalyst systems, including but not limited to Ziegler-Natta catalyst systems and metallocene / single-site catalyst systems. According to certain embodiments of the present invention, the term "polymer" or "polymeric" may also include polymers produced by a fermentation process or from a biological source. Additionally or alternatively, the term "polymer" or "polymeric" may include biopolymers, such as polylactic acid (PLA), polyhydroxyalkanoates (PHA) and poly (hydroxycarboxylic acids).

[0016] As used herein, the term "cellulose fibers" may include fibers comprising natural cellulose, regenerated cellulose (e.g., synthetic) and / or combinations thereof or may include fibers formed from natural cellulose, regenerated cellulose (e.g., synthetic) and / or combinations thereof. For example, "cellulose fibers" may be derived from hardwood trees, softwood trees, or a combination of hardwood trees and softwood trees prepared by any known suitable digestion, refining and bleaching operations for use in, for example, papermaking furnishes and / or fluff pulp furnishes. Cellulose fibers may include recycled fibers and / or virgin fibers. Recycled fibers differ from virgin fibers in that the fibers have undergone at least one drying process. In certain 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 certain embodiments of the present invention, the cellulose fibers may include bleached or unbleached pulp fibers, such as high yield pulp and / or mechanical pulp (e.g., thermomechanical pulp (TMP), chemimechanical pulp (CMP), and bleached chemi-thermo-mechanical pulp BCTMP. In this regard, the term "pulp" as used herein may include cellulose that has been processed (e.g., thermally, chemically, and / or mechanically treated). According to certain embodiments of the present invention, the cellulose fibers may include one or more pulp materials. According to certain embodiments of the present invention, the cellulose fibers may include rayon, such as viscose.

[0017] As used herein, the terms "nonwoven" and "nonwoven web" may include a web having a structure of individual fibers, filaments and / or threads interwoven but not interwoven in an identifiable repeating manner as in knitted or woven fabrics. According to certain embodiments of the present invention, nonwoven fabrics or nonwoven webs may be formed by any conventional method known in the art (e.g., meltblown, spunbonded, needlepunched, spunlace, airlaid and bonded carded web method). As used herein, "nonwoven web" may include a plurality of individual fibers that have not been subjected to a reinforcement process.

[0018] As used herein, the terms "fabric" and "nonwoven fabric" may include a web of fibers in which a plurality of fibers are mechanically entangled or interconnected, fused together, and / or chemically bonded together. For example, a nonwoven web of individualized web fibers may be subjected to a bonding or consolidation process to bond at least a portion of the individual fibers together to form a coherent (e.g., united) web of interconnected fibers.

[0019] As used herein, the terms "consolidated" and "consolidation" can include bringing together at least some of the fibers of a nonwoven web to achieve a closer proximity or attachment therebetween (e.g., heat fused together, chemically bonded together, and / or mechanically entangled together) to form one or more bonding sites, which increase the resistance to external forces (e.g., friction and tension) compared to an unconsolidated web. One or more bonding sites, for example, can include discrete or localized areas of a web material that have been softened or melted and optionally subsequently or simultaneously pressed to form discrete or localized deformations in the web material. The term "consolidated" can include such an entire nonwoven web: it has been processed so that at least some of the fibers achieve a closer proximity or attachment therebetween (e.g., heat fused together, chemically bonded together, and / or mechanically entangled together), to name just a few examples, such as by thermal bonding or mechanically entangled (e.g., hydroentanglement). According to certain embodiments of the present invention, such a web can be considered a "consolidated nonwoven fabric," "nonwoven fabric," or simply "fabric."

[0020] As used herein, the term "post-consumer recycled material" may include polymeric materials derived from post-consumer sources such as household, distribution, retail, industrial, and demolition. For example, as used herein, "post-consumer recycled fiber" may include fibers obtained from plastic consumer products that are discarded for disposal or recycling after completing their intended use as consumer products, including, for example, plastic containers (e.g., bottles) and plastic bags.

[0021] As used herein, the term "staple fiber" may include cut fibers from filaments. According to certain embodiments, any type of filament material may be used to form staple fibers. For example, staple fibers may include cellulose fibers, polymer fibers and / or elastic fibers. The non-limiting examples of material may include polyolefins (e.g., polypropylene or copolymers containing polypropylene), polyethylene terephthalate and polyamide. The other non-limiting examples of material may include nylon, cotton, rayon and wool. As an example only, the average length of staple fibers may include approximately 2 centimeters to approximately 15 centimeters.

[0022] As used herein, the term "continuous fiber" may include filaments having a high aspect ratio (i.e., length: diameter) such as, for example, greater than about 500,000: 1, greater than about 750,000: 1, or greater than about 1,000,000: 1. According to certain embodiments of the present invention, the term "continuous fiber" may include filaments having substantially endless lengths.

[0023] As used herein, the term "spunbond" may include fibers formed by extruding molten thermoplastic material as filaments from a plurality of thin, usually circular, spinneret capillaries, wherein the diameter of the extruded filaments is then rapidly reduced. According to one embodiment of the present invention, spunbond fibers are generally not tacky when deposited onto a collecting surface and may be generally continuous. Note that spunbond used in certain composite materials of the present invention may include nonwovens described in the literature such as

[0024] As used herein, the term "bicomponent fiber" may include fibers formed of two different polymeric materials or compositions extruded from separate extruders but spun together to form one fiber. The polymeric materials or polymers are arranged in substantially constant positions in different regions across the cross-section of the multicomponent fiber and extend continuously along the length of the multicomponent fiber. The configuration of such multicomponent fibers may be, for example, a sheath / core arrangement in which one polymer is surrounded by another polymer, an eccentric sheath / core arrangement, a side-by-side arrangement, a pie-like arrangement, or an "island in the sea" arrangement, each of which is known in the art of multicomponent fibers (including bicomponent fibers).

[0025] As used herein, the term "microfiber" may include multicomponent fibers that have been partially separated to provide a plurality of smaller fiber portions, wherein the smaller fiber portions may have a dtex of 1.0 or less. In this regard, due to the complete or partial separation or separation of a single segment from a pre-separated multicomponent fiber, the microfiber may include at least a first group of separated fibers or fiber portions and a second group of separated fibers or fiber portions, wherein the "separated fibers or fiber portions" may include portions of a single segment of a multicomponent fiber that has been separated or separated from an original separable multicomponent fiber (e.g., a dtex value lower than 5, 4, 3, 2, etc.). According to certain embodiments of the present invention, a first group of separated staple fibers may include a first polymer material and a second group of separated staple fibers may include a second polymer material different from the first polymer material. In this regard, the microfiber has an increased surface area and a channel and / or pore structure that allows capillary action to promote fluid intake and / or absorption. As disclosed herein, microfibers can be distinguished from the bicomponent staple fibers described herein by one or more of the following: increased porosity due to the presence of micropores and / or microchannels in the microfibers, while the bicomponent staple fibers described herein are free of or substantially free of micropores and / or microchannels.

[0026] As used herein, the term "curl" or "curled" may include two-dimensional or three-dimensional curls or bends, such as folded or compressed portions having an "L" configuration, wave portions having a "zigzag" configuration, or curled portions such as a spiral configuration. According to certain embodiments of the present invention, the term "curl" or "curled" does not include random two-dimensional undulations or fluctuations in the fiber, such as those associated with the normal laydown of the fiber during the melt spinning process.

[0027] As used herein, the term "machine direction" or "MD" includes the direction in which fabrics are produced or transported. As used herein, the term "cross direction" or "CD" includes the direction of fabrics that is substantially perpendicular to the MD.

[0028] As used herein, the term "layer" may include generally identifiable groups of similar material types and / or functions that exist in the XY plane.

[0029] All integer endpoints disclosed herein that can produce a smaller range within a given range disclosed herein are within the scope of certain embodiments of the present invention. For example, the disclosure of about 10 to about 15 includes the disclosure of intermediate ranges, such as: about 10 to about 11; about 10 to about 12; about 13 to about 15; about 14 to about 15; etc., in addition, all single decimals (e.g., reported to the nearest tenth) endpoints that can produce a smaller range within a given range disclosed herein are within the scope of certain embodiments of the present invention. For example, the disclosure of about 1.5 to about 2.0 includes the disclosure of intermediate ranges, such as: about 1.5 to about 1.6; about 1.5 to about 1.7; about 1.7 to about 1.8; etc.

[0030] In one aspect, the present invention provides a nonwoven fabric comprising a mechanically entangled fiber blend, the fiber blend comprising (a) post-consumer recycled polymer staple fibers (PCR-stub fibers) and (b) one or more additional fibers, wherein the one or more additional fibers are different from the PCR staple fibers. According to certain embodiments of the present invention, the PCR-stub fibers are mechanically entangled (e.g., hydroentangled, needle-punched, air-entangled, etc.) with one or more additional fibers to define a nonwoven fabric. According to certain embodiments of the present invention, the nonwoven fabric includes a unique combination of PCR-stub fibers entangled with, for example, one or more types or groups of additional fibers, the one or more types or groups of additional fibers may contain polymer compositions, lengths, linear densities, and / or fiber types different from the PCR-stub fibers (e.g., spunbond, meltblown, electrospinning, melt fibrillation, etc.). According to certain embodiments of the present invention, one or more additional fibers may include natural cellulose fibers and / or synthetic cellulose fibers (e.g., pulp, woven fabrics, viscose, rayon, etc.). According to certain embodiments of the present invention, the nonwoven fabric may also include an adhesive, such as an adhesive that prevents or mitigates disinfectants (e.g., chlorine disinfectants, quaternary ammonium disinfectants, etc.) from being attached to the nonwoven fabric. In this respect, according to certain embodiments of the present invention, the nonwoven fabric prevents or mitigates the consumption of the disinfectant concentration of the cleaning or disinfecting composition and / or promotes the disinfectant to be released from the nonwoven fabric or applied to the surface to be disinfected. According to certain embodiments of the present invention, the nonwoven fabric may include a three-dimensional pattern on at least one surface of the nonwoven fabric. For example, the three-dimensional pattern may include one or more recessed portions and a plurality of raised portions, wherein the three-dimensional pattern may promote the isolation or capture of loose debris on the surface to be cleaned and / or disinfected.

[0031] According to certain embodiments of the present invention, the nonwoven fabric may include a basis weight of about 20 grams per square meter (gsm) to about 200 gsm, for example, about up to about any of 200 gsm, 175 gsm, 150 gsm, 125 gsm, 100 gsm, 75 gsm, 60 gsm, and 50 gsm, and / or at least about any of 20 gsm, 25 gsm, 30 gsm, 35 gsm, 40 gsm, 45 gsm, 50 gsm, 60 gsm, 70 gsm, 80 gsm, 90 gsm, 100 gsm, and 125 gsm.

[0032] According to certain embodiments of the present invention, the PCR-staple fibers may include synthetic polymers or polymeric materials. For example, the PCR-staple fibers may include polyethylene terephthalate (PET), polyolefins, polyamides, or any combination thereof. For example, the PCR-staple fibers may include polyethylene terephthalate (PET), polyolefins, polyamides, or any combination thereof. For example, the PCR-staple fibers may include polyethylene terephthalate (PCR-PET) recycled after consumption. According to certain embodiments of the present invention, the PCR-staple fibers may include polyolefins. Examples of suitable polyolefin polymers include polyethylene, polypropylene, copolymers thereof, or other forms of those polymers or blends of those polymers. For example, polyethylene may include low-density polyethylene, linear low-density polyethylene, medium-density polyethylene, high-density polyethylene, or copolymers in which ethylene is the main component. In certain embodiments of the present invention, for example, polypropylene may include polypropylene homopolymers and polypropylene copolymers.

[0033] PCR-staple fibers can be provided by collecting, for example, municipal recyclable post-consumer waste (e.g., plastic bottles, synthetic nonwovens, etc.) and sorting the recyclable post-consumer waste into the corresponding polymer type of the waste (e.g., PET in one pile, polypropylene in a second different pile, etc.). The sorted recyclable post-consumer waste can be cleaned (e.g., rinsed with water to remove debris) and / or chemically treated and / or mechanically processed to break the recyclable post-consumer waste into a plurality of smaller components (e.g., a grinding operation is performed to reduce the recyclable post-consumer waste into small pieces). The smaller components of the recyclable post-consumer waste (e.g., small pieces of about 1 / 4 " to about 2") can then be melted and extruded into a plurality of fibers. The extruded fibers can be cut into staple fibers and / or subjected to crimping to impart one or more crimps to the fibers.

[0034] According to certain embodiments of the invention, the average length of the PCR-short fibers can be about 20 mm to about 150 mm, for example at least about any of 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 60 mm, 70 mm, 80 mm and 90 mm, and / or at most about any of 150 mm, 125 mm, 100 mm, 90 mm and 80 mm. The average linear density of the PCR-staple fibers can range from about 1 decitex (dtex) to about 2.5 dtex, for example at least about any of the following: 1 dtex, 1.1 dtex, 1.2 dtex, 1.3 dtex, 1.4 dtex, 1.5 dtex, 1.6 dtex, 1.7 dtex and 1.8 dtex, and / or at most about any of the following: 2.5 dtex, 2.4 dtex, 2.3 dtex, 2.2 dtex, 2.1 dtex, 2.0 dtex, 1.9 dtex and 1.8 dtex.

[0035] According to certain embodiments of the present invention, the PCR-stub may include curled PCR-stub. For example, the curled PCR-stub may include an average of about 3 to about 20 curls per 25 mm fiber length, such as at least about any of 3, 4, 5, 6, 7, 8, 9, 10, 11, and 12 curls per 25 mm fiber length, and / or at most about any of 20, 19, 18, 17, 16, 15, 14, 13, and 12 curls per 25 mm fiber length.

[0036] According to certain embodiments of the present invention, one or more additional fibers include wettable staple fibers; bicomponent staple fibers such as separable bicomponent fibers or inseparable bicomponent fibers; microfiber staple fibers; cellulosic fibers; meltblown fibers; continuous spunbond fibers; or any combination thereof. One or more additional fibers may, for example, include a plurality of wettable staple fibers. The wettable staple fibers may, for example, include hydrophilically modified polyester staple fibers. According to certain embodiments of the present invention, the hydrophilically modified polyester staple fibers include a hydrophilic surface treatment agent coated thereon. According to certain embodiments of the present invention, the wettable staple fibers include hydrophilically modified polyester staple fibers, which are different from PCR-staple fibers of nonwoven fabrics (e.g., PCR-PET staple fibers), which may not have any hydrophilic modification (e.g., no hydrophilic surface treatment coating thereon) and may be generally hydrophobic in nature. The hydrophilically modified polyester staple fibers are available from DAK Americas LLC under the trade name Hydrotec Fiber is commercially available.

[0037] According to certain embodiments of the present invention, one or more other fibers include a plurality of cellulose fibers, such as natural cellulose fibers and / or synthetic cellulose fibers. According to certain embodiments of the present invention, cellulose fibers may include rayon, pulp (such as air-laid pulp), woven fabrics or any combination thereof. For example, nonwoven fabrics may include PCR-short fibers, wettable short fibers and cellulose fibers (such as rayon) mechanically intertwined with each other.

[0038] According to certain embodiments of the present invention, one or more other fibers may include continuous fibers, such as continuous spunbond fibers formed by synthetic polymers. As an example only, synthetic polymers may include polyolefins, polyesters, polyamides or any combination thereof. According to certain embodiments, continuous fibers may be more primarily located on one or both outermost surfaces of the nonwoven fabric. Alternatively, one or more continuous fibers may be more primarily located in the middle of the nonwoven fabric in the z direction of the nonwoven fabric, the z direction being perpendicular to the machine direction and the transverse direction of the nonwoven fabric. The nonwoven fabric may, for example, include a plurality of continuous fibers (such as spunbond fibers), which are mechanically intertwined with at least PCR-staple fibers via a spunlace process to define the nonwoven fabric.

[0039] According to certain embodiments of the present invention, the PCR-staple fibers comprise from about 10 wt % to about 90 wt % of the nonwoven fabric, for example, at least about any of 10 wt %, 15 wt %, 20 wt %, 25 wt %, 30 wt %, 35 wt %, 40 wt %, 45 wt %, 50 wt %, 55 wt % and 60 wt % of the nonwoven fabric, and / or at most about any of 90 wt %, 85 wt %, 80 wt %, 75 wt %, 70 wt %, 65 wt % and 60 wt % of the nonwoven fabric.

[0040] According to certain embodiments of the present invention, the wettable staple fibers, if present, comprise from about 10% to about 90% by weight of the nonwoven fabric, for example, at least about any of 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55% and 60% by weight of the nonwoven fabric, and / or at most about any of 90%, 85%, 80%, 75%, 70%, 65% and 60% by weight of the nonwoven fabric.

[0041] According to certain embodiments of the present invention, the plurality of cellulose fibers, if present, comprise from about 10% to about 90% by weight of the nonwoven fabric, for example, at least about any of 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55% and 60% by weight of the nonwoven fabric, and / or at most about any of 90%, 85%, 80%, 75%, 70%, 65% and 60% by weight of the nonwoven fabric.

[0042] According to certain embodiments of the present invention, the bicomponent staple fibers, if present, comprise from about 10% to about 90% by weight of the nonwoven fabric, for example, at least about any of 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55% and 60% by weight of the nonwoven fabric, and / or at most about any of 90%, 85%, 80%, 75%, 70%, 65% and 60% by weight of the nonwoven fabric.

[0043] According to certain embodiments of the present invention, the microfiber staple fibers, if present, comprise from about 10% to about 90% by weight of the nonwoven fabric, for example, at least about any of 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55% and 60% by weight of the nonwoven fabric, and / or at most about any of 90%, 85%, 80%, 75%, 70%, 65% and 60% by weight of the nonwoven fabric.

[0044] According to certain embodiments of the present invention, the first ratio between the PCR-staple fibers in grams per square meter of nonwoven fabric and the plurality of wettable staple fibers in grams per square meter of nonwoven fabric of the nonwoven fabric can be from about 4:1 to about 1:4, for example, at most about any of the following: 4:1, 3.5:1, 3:1, 2.5:1, 2:1, 1.5:1 and 1:1, and / or at least about any of the following: 1:4, 1:3.5, 1:3, 1:2.5, 1:2, 1:1.5 and 1:1.

[0045] According to certain embodiments of the present invention, the second ratio between the plurality of cellulose fibers in grams per square meter of nonwoven fabric and the PCR-staple fibers in grams per square meter of nonwoven fabric of the nonwoven fabric is from about 4:1 to about 1:4, for example, at most about any of the following: 4:1, 3.5:1, 3:1, 2.5:1, 2:1, 1.5:1 and 1:1, and / or at least about any of the following: 1:4, 1:3.5, 1:3, 1:2.5, 1:2, 1:1.5 and 1:1.

[0046] According to certain embodiments of the present invention, the third ratio between the plurality of bicomponent fibers in grams per square meter of nonwoven fabric and the PCR-staple fibers in grams per square meter of nonwoven fabric of the nonwoven fabric is from about 4:1 to about 1:4, for example, at most about any of the following: 4:1, 3.5:1, 3:1, 2.5:1, 2:1, 1.5:1 and 1:1, and / or at least about any of the following: 1:4, 1:3.5, 1:3, 1:2.5, 1:2, 1:1.5 and 1:1.

[0047] According to certain embodiments of the present invention, a fourth ratio between the plurality of microfibers in grams per square meter of nonwoven fabric and the PCR-staple fibers in grams per square meter of nonwoven fabric of the nonwoven fabric is from about 4:1 to about 1:4, for example, at most about any of the following: 4:1, 3.5:1, 3:1, 2.5:1, 2:1, 1.5:1 and 1:1, and / or at least about any of the following: 1:4, 1:3.5, 1:3, 1:2.5, 1:2, 1:1.5 and 1:1.

[0048] According to certain embodiments of the present invention, the nonwoven fabric may include a component weight ratio of PCR-staple fibers in grams per square meter of nonwoven fabric, a plurality of wettable staple fibers in grams per square meter of nonwoven fabric, and a plurality of cellulosic fibers or a plurality of microfiber staple fibers in grams per square meter of nonwoven fabric according to the formula A:B:C, wherein

[0049] (i) 'A' represents grams of PCR-staple fibers per square meter of nonwoven fabric and includes values ​​from about 0.2 to about 0.8, such as at least about any of 0.2, 0.25, 0.3, 0.35, 0.4, and 0.5 and / or at most about any of 0.8, 0.75, 0.7, 0.65, 0.6, 0.55, and 0.5;

[0050] (ii) 'B' represents a plurality of wettable staple fibers in grams per square meter of nonwoven fabric and includes values ​​from about 0.2 to about 0.8, such as at least about any of 0.2, 0.25, 0.3, 0.35, 0.4, and 0.5 and / or at most about any of 0.8, 0.75, 0.7, 0.65, 0.6, 0.55, and 0.5; and

[0051] (iii) 'C' represents a plurality of cellulosic fibers or a plurality of microfiber staple fibers in grams per square meter of nonwoven fabric, and includes values ​​from about 0.2 to about 0.8, such as at least about any of 0.2, 0.25, 0.3, 0.35, 0.4, and 0.5 and / or at most about any of 0.8, 0.75, 0.7, 0.65, 0.6, 0.55, and 0.5.

[0052] According to certain embodiments of the present invention, the microfiber staple fibers, if present, include natural fibers, synthetic fibers, or combinations thereof. For example, the microfiber staple fibers may include denier values ​​of 1 or less, such as up to about any of the following: 1.0, 0.9, 0.8, 0.7, 0.6, and 0.5 and / or at least about any of the following: 0.3, 0.4, 0.5, 0.6, 0.7, and 0.8.

[0053] According to some embodiments of the present invention, nonwoven fabric can include adhesive applied thereon.For example, according to a desired end use of nonwoven fabric, adhesive can include cationic adhesive, anionic adhesive or nonionic adhesive.Adhesive can include cationic polymer, for example water-soluble cationic polymer.According to some embodiments of the present invention, cationic polymer can include cationic polyamine, and described cationic polyamine includes the main chain containing cationic amine group.According to some embodiments, for example, cationic polyamine can have the main chain containing cationic amine group.In other embodiments, for example, cationic polyamine can have at least one side chain containing cationic amine group.According to some embodiments of the present invention, for example, cationic additive can include cationic polyamine blended with bis(hexamethylene)triamine (for example, from Astro American Chemical Company, 557 South Woods Dr., Fountain Inn, ASTRO of SC29644). 727). According to certain embodiments of the present invention, for example, the cationic polymer may define a cationic coating. According to certain embodiments of the present invention, for example, the adhesive may include a non-ionically modified siloxane additive, which may be hydrophilic. In some embodiments, for example, the non-ionically modified siloxane additive may include a non-ionically modified polyorganosiloxane. In certain embodiments, for example, the non-ionically modified siloxane additive may include a polyoxyalkyl-modified polydimethylsiloxane. In some embodiments, for example, the non-ionically modified siloxane additive may include a polyoxyalkyl (C2-C8) polydimethylsiloxane. In such embodiments, for example, the non-ionically modified siloxane additive may include a polyoxyalkyl (C2-C4) polydimethylsiloxane (e.g., from Schill+Seilacher GmbH, Straβe 205, 71032 Germany 186F). According to certain embodiments of the present invention, by way of example only, the adhesive may be applied to the nonwoven fabric via one or more of a nozzle, a foam applicator, a pad, or a kiss roller. According to certain embodiments of the present invention, non-limiting examples of suitable adhesives that may be used include acrylic adhesives, styrene-butadiene adhesives, ethylene-vinyl acetate adhesives, ethylene vinyl emulsions (e.g., Sunbond 140N, Dur-O-Set E-646, and Unibond 2850), or any combination thereof.

[0054] According to certain embodiments of the present invention, the binder can comprise from about 1 wt % to about 20 wt % of the nonwoven fabric, for example, at least about any of 1 wt %, 3 wt %, 5 wt %, 6 wt %, 8 wt %, 9 wt %, 10 wt % and 12 wt % of the nonwoven fabric, and / or at most about any of 20 wt %, 18 wt %, 16 wt %, 15 wt %, 12 wt % and 10 wt % of the nonwoven fabric.

[0055] According to certain embodiments of the present invention, the nonwoven fabric may also include one or more antimicrobial compounds. For example, the antimicrobial compound may be embedded in an adhesive or adhesive mixture, topically applied to the nonwoven fabric before applying the adhesive, or both. According to certain embodiments of the present invention, as examples only, the antimicrobial compound may include an antimicrobial based on silver, an antimicrobial based on copper, an antimicrobial based on zinc, and any combination thereof.

[0056] According to certain embodiments of the present invention, the nonwoven fabric includes a three-dimensional pattern formed on at least one surface of the nonwoven fabric. For example, the three-dimensional pattern may include at least one concave portion and a plurality of convex portions. For example, Figure 1 As shown, the nonwoven fabric 1 may have a three-dimensional pattern including a single continuous recessed portion 20 and a plurality of raised portions 40, wherein the plurality of raised portions 40 include islands within the single continuous recessed portion. Alternatively, the three-dimensional pattern includes a plurality of recessed portions and a plurality of raised portions. Figure 2 As shown, for example, the nonwoven fabric 1 can have a three-dimensional pattern including a plurality of recessed portions 22 and a plurality of raised portions 42. The plurality of recessed portions can, for example, include a plurality of separate recessed portions that are separate and distinct from each other. For example, the three-dimensional pattern can include alternating ridges and recessed portions.

[0057] According to certain embodiments of the invention, at least one recessed portion comprises an average depth of about 1.0 mm to about 3 mm, for example, at most about any one of 3.0 mm, 2.9 mm, 2.8 mm, 2.7 mm, 2.6 mm, 2.5 mm, 2.4 mm, 2.3 mm, 2.2 mm, 2.1 mm and 2.0 mm and / or at least about any one of 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm and 2.0 mm. According to certain embodiments of the present invention, the average width of the plurality of recessed portions (e.g., the shortest dimension perpendicular to the z-direction of the nonwoven fabric) may include from about 0.25 mm to about 1.8 mm, for example, at most about any one of the following: 1.8 mm, 1.7 mm, 1.6 mm, 1.5 mm, 1.4 mm, 1.3 mm, 1.2 mm, 1.1 mm, 1.0 mm, 0.9 mm and 0.8 mm and / or at least about any one of the following: 0.25 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1.0 mm, 1.1 mm, 1.2 mm and 1.3 mm. According to certain embodiments of the present invention, the average length of the plurality of recessed portions (e.g., the longest dimension perpendicular to the z-direction of the nonwoven fabric) can extend continuously along the entire length of the nonwoven fabric (e.g., in the machine direction or the cross direction) or be at least about 2, 3, 5, 10, 20, 50, or 100 times the average width of the plurality of recessed portions. According to certain embodiments of the present invention, the plurality of recessed portions can be separated by individual ridges (e.g., alternating ridges and recessed portions). For example, individual ridges may have an average ridge width of about 1.5 mm to about 4.0 mm, such as at most about any of 4.0 mm, 3.8 mm, 3.6 mm, 3.4 mm, 3.2 mm, 3.0 mm, 2.9 mm, 2.8 mm, 2.7 mm, 2.6 mm, 2.5 mm, 2.4 mm, 2.3 mm, 2.2 mm, 2.1 mm and 2.0 mm and / or at least about any of 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm and 2.0 mm.

[0058] According to certain embodiments of the present invention, the nonwoven fabric is provided in the form of individual wipes that may be provided in a package or in the form of a continuous wipe having a plurality of perforations representing lines of weakness so that individual wipes may be separated from the continuous wipe.

[0059] According to some embodiments of the present invention, at least one recessed portion can occupy the following recessed top plane area: about 10% to about 70% of the total top plane area of ​​nonwoven fabric, for example, at most about any one of the following: 70%, 60%, 50%, 45%, 40%, 35%, 30%, 25% and 20% of the total top plane area of ​​nonwoven fabric and / or at least about any one of the following: 10%, 12%, 14%, 16%, 18%, 20%, 22%, 24% and 26% of the total top plane area of ​​nonwoven fabric. In this respect, the top view is the positive projection of the position of the 3-dimensional object (for example, described herein and disclosed nonwoven fabric) through the object from the horizontal plane. As used herein, for example, the recessed top plane area includes the 2D area occupied or occupied by a plurality of recessed portions of the total top plane area.

[0060] In another aspect, the present invention provides a method for forming a nonwoven fabric. According to certain embodiments of the present invention, the method may include the following: (ia) forming or providing a carded fiber web comprising a fiber blend, the fiber blend comprising (a) post-consumer recycled polymer staple fibers (PCR-staple fibers) and (b) one or more additional fibers, wherein the one or more additional fibers are different from the PCR-staple fibers; or (ib) forming or providing a first layer of post-consumer recycled polymer staple fibers (PCR-staple fibers) and forming or providing a second layer of one or more additional fibers; wherein the first layer is adjacent to the second layer to provide a multi-layer nonwoven web; and (ii) mechanically entangle the PCR-staple fibers with the one or more additional fibers to define a nonwoven fabric as described and disclosed herein.

[0061] Figure 3 A flow chart of a method for making a nonwoven fabric according to certain embodiments of the present invention is shown. Figure 3As shown, the method may include a first step option 'a' 110, which includes forming or providing a carded fiber web comprising a fiber blend, the fiber blend comprising (a) post-consumer recycled polymer staple fibers (PCR-staple fibers) and (b) one or more additional fibers, wherein the one or more additional fibers are different from the PCR-staple fibers. Alternatively, the method may include a first step option 'b' 115, which includes forming or providing a first layer of post-consumer recycled polymer staple fibers (PCR-staple fibers) and forming or providing a second layer of one or more additional fibers, wherein the first layer is adjacent to the second layer to provide a multi-layer nonwoven web. The method may also include a subsequent step of mechanically intertwining the PCR-staple fibers with one or more additional fibers to define a nonwoven fabric as described and disclosed herein. According to certain embodiments of the present invention, the step of mechanically intertwining may include hydroentanglement to form a hydroentangled nonwoven fabric, needle punching and / or air entanglement. Optionally, the method may include a coating step 130, which includes applying an adhesive and / or an antimicrobial agent.

[0062] According to certain embodiments of the present invention, wherein a multilayer nonwoven web is formed, the multilayer nonwoven web may include a first layer of PCR-staple fibers, and a second layer of one or more additional fibers, wherein the one or more additional fibers include wettable staple fibers, bicomponent staple fibers, microfiber staple fibers, cellulosic fibers, meltblown fibers, continuous fibers, or any combination thereof. According to certain embodiments of the present invention, the method may also include forming or providing a third layer, wherein the third layer includes a nonwoven web or nonwoven fabric of continuous fibers such as spunbond fibers, and mechanically entangles the continuous fibers with the PCR-staple fibers and the one or more additional fibers.

[0063] According to certain embodiments of the present invention, a carded fiber web comprising a fiber blend comprises PCR-staple fibers, and one or more additional fibers including wettable staple fibers, bicomponent staple fibers, microfiber staple fibers, cellulosic fibers, meltblown fibers, continuous fibers, or any combination thereof are mechanically entangled to form a nonwoven fabric as described and disclosed herein.

[0064] According to some embodiments of the present invention, the method may further include imparting a three-dimensional image to at least the first outermost surface of the nonwoven fabric. For example, the method may further include imparting a three-dimensional image to at least one surface of the nonwoven fabric or in at least one surface of the nonwoven fabric. For example, the method may include directly or indirectly positioning the first outermost surface of the nonwoven fabric to an image transfer device with a three-dimensional pattern, and directly or indirectly applying a jet of fluid to the second outermost surface of the nonwoven fabric to impart the three-dimensional pattern to the nonwoven fabric. For example, according to some embodiments of the present invention, the image transfer device may include one or more cylinders or even one or more sleeves fixed to the corresponding cylinder. According to some embodiments of the present invention, one or more water jets, such as high-pressure water jets, may be applied to the side of the nonwoven opposite to the side of the contact image transfer device. Without being bound by theory, one or more water jets and water directed through the nonwoven fabric cause the fibers of the nonwoven fabric to shift according to the image on the image transfer device (e.g., formed on one or more cylinders or fixed to the image on one or more sleeves of the corresponding cylinder), so that the three-dimensional pattern is imaged according to such an image on the entire nonwoven fabric. Such imaging techniques are further described in, for example, U.S. Pat. No. 6,314,627, entitled "Hydroentangled Fabric having Structured Surfaces"; U.S. Pat. No. 6,735,833, entitled "Nonwoven Fabrics having a Durable Three-Dimensional Image"; U.S. Pat. No. 6,903,034, entitled "Hydroentanglement of Continuous Polymer Filaments"; U.S. Pat. No. 7,091,140, ​​entitled "Hydroentanglement of Continuous Polymer Filaments"; and U.S. Pat. No. 7,406,755, entitled "Hydroentanglement of Continuous Polymer Filaments", each of which is incorporated herein by reference in its entirety. According to certain embodiments of the present invention, the three-dimensional pattern may, for example, include at least one (e.g., a plurality of) recessed portions configured to facilitate capture of loose debris on a surface to be cleaned and / or disinfected.

[0065] Example

[0066] The present disclosure is further illustrated by the following examples, which should not be construed as limiting. That is, the specific features described in the following examples are merely illustrative and not limiting.

[0067] Test Method

[0068] "Basis weight" is reported in ounces per square yard (osy) and is measured according to Berry TM-7027.

[0069] "Size" is reported in mils or inches and is measured according to Berry TM-7015.

[0070] "Wet Machine Direction Tensile Strength" is reported in pounds per inch and is measured according to Berry TM-7012.

[0071] "Wet Machine Direction Elongation" is reported as a percent and is measured according to Berry TM-7012.

[0072] "Wet Transverse Direction Tensile Strength" is reported in pounds per inch and is measured according to Berry TM-t012.

[0073] "Wet Cross Direction Elongation" is reported as a percent and is measured according to Berry TM-7012.

[0074] "Absorption Time" is reported in seconds and is measured according to Berry TM-7023.

[0075] "Absorbency" is reported as a percentage and is measured according to Berry TM-7023.

[0076] "Wet Mullen Burst" is reported in psi and is measured according to Berry TM-7014.

[0077] "Softness" is reported in grams and is measured according to Berry TM-7009.

[0078] "Wash Durability" is reported as the number of cycles and is measured according to Berry TM-7032.

[0079] "Color L" is reported as a number and is measured according to Berry TM-7010.

[0080] "Color a" is reported as a number and is measured according to Berry TM-7010.

[0081] "Color b" is reported as a number and is measured according to Berry TM-7010.

[0082] "Taber" is reported as the cycle number and is measured according to Berry TM-7042.

[0083] "Crush Test" is reported as pass / fail and is measured according to Berry TM-7715.

[0084] The "Friction Test" is reported as pass / fail and is measured according to Berry TM-7715.

[0085] "Wet Crock" is reported as a grade (number) and is measured according to Berry TM-7035.

[0086] Example Group 1

[0087] A control nonwoven fabric (i.e., 6194 control) was formed and had a basis weight of 1.8 ounces per square yard (osy). The control nonwoven fabric contained 47% by weight of PET staple fibers (0.85 osy), 47% by weight of wettable PET staple fibers (0 / 85 osy), and 6% by weight of a binder (0.1 osy). The binder was a nonionic self-crosslinking vinyl acrylic emulsion (i.e., Sunbond 140N from Omnova Solutions (USA)).

[0088] The first example nonwoven fabric (ie, DE1036A) was formed in the same manner as the control nonwoven fabric, except that the PET staple fibers were replaced with PCR-PET staple fibers from Kilop (USA).

[0089] A second example nonwoven fabric (ie, DE1038A) was formed in the same manner as the control nonwoven fabric, except that PCR-PET staple fibers from Stein Fibers (USA) were used in place of the PET staple fibers.

[0090] Tables 1 and 2 provide a summary of the physical properties of the control nonwoven fabric and each of the example nonwoven fabrics.

[0091]

[0092] Table 1

[0093]

[0094] Table 2

[0095] Example Group 2

[0096] A control nonwoven fabric (i.e., 6198 control) was formed and had a basis weight of 1.2 ounces per square yard (osy). The control nonwoven fabric contained 46.7 weight percent PET staple fibers (0.56 osy), 46.7 weight percent wettable PET staple fibers (0.56 osy), and 6.7 weight percent binder (0.08 osy). The binder was a nonionic self-crosslinking vinyl acrylic emulsion (i.e., Sunbond 140N from Omnova Solutions (USA)).

[0097] The first example nonwoven fabric (ie DE1036B) was formed in the same manner as the control nonwoven fabric, except that PCR-PET staple fibers from Kilop (USA) were used instead of PET staple fibers.

[0098] A second example nonwoven fabric (ie, DE1038B) was formed in the same manner as the control nonwoven fabric, except that PCR-PET staple fibers from Stein Fibers (USA) were used in place of the PET staple fibers.

[0099] Tables 3 and 4 provide a summary of the physical properties of the control nonwoven fabric and each of the example nonwoven fabrics.

[0100]

[0101] Table 3

[0102]

[0103] Table 4

[0104] Example Group 3

[0105] A control nonwoven fabric (i.e., M165 control) was formed and had a basis weight of 2.1 ounces per square yard (osy). The control nonwoven fabric contained 57% by weight of rayon fibers (1.22 osy), 34.7% by weight of PET staple fibers (0.73 osy), and 6.7% by weight of a binder (0.15 osy). The binder was an anionic self-crosslinking vinyl acrylic emulsion (i.e., Dur-O-Set E-646 from Celanese (USA)). An antimicrobial agent (i.e., Microban Z06 from Microban (USA))

[0106] The first example nonwoven fabric (ie, DE1036C) was formed in the same manner as the control nonwoven fabric, except that the PET staple fibers were replaced with PCR-PET staple fibers from Kilop (USA).

[0107] A second example nonwoven fabric (ie, DE1038C) was formed in the same manner as the control nonwoven fabric, except that PCR-PET staple fibers from Stein Fibers (USA) were used in place of the PET staple fibers.

[0108] Tables 5 and 6 provide a summary of the physical properties of the control nonwoven fabric and each of the example nonwoven fabrics.

[0109]

[0110] Table 5

[0111]

[0112] Table 6

[0113] Example Group 4

[0114] A control nonwoven fabric (i.e., 6186 Control) was formed and had a target basis weight of 2.1 ounces per square yard (osy). The control nonwoven fabric contained 66% by weight of rayon fibers (1.39 osy), 25% by weight of PET staple fibers (0.53 osy), and 9% by weight of a binder (0.18 osy). The binder was a cationic self-crosslinking ethylene vinyl acetate emulsion (i.e., Unibond 2850).

[0115] The first example nonwoven fabric (ie, DE1036D) was formed in the same manner as the control nonwoven fabric, except that the PET staple fibers were replaced with PCR-PET staple fibers from Kilop (USA).

[0116] A second example nonwoven fabric (ie, DE1038D) was formed in the same manner as the control nonwoven fabric, except that PCR-PET staple fibers from Stein Fibers (USA) were used in place of the PET staple fibers.

[0117] Tables 7 and 8 provide a summary of the physical properties of the control nonwoven fabric and each of the example nonwoven fabrics.

[0118]

[0119] Table 7

[0120]

[0121] Table 8

[0122] Example Group 5

[0123] For the control nonwoven fabric from embodiment group 1 and each embodiment nonwoven fabric, the ability of preventing the control solution containing quaternary ammonium compound (quat) from being consumed was evaluated. The concentration of the control solution was 215ppm. Each nonwoven fabric was immersed in the corresponding disinfectant composition containing quaternary ammonium compound, wherein the concentration of quaternary ammonium compound was 215ppm. As shown in Table 9, the concentration of the corresponding disinfectant composition was tested in the process of 96 hours. In this respect, each embodiment nonwoven fabric performed as well as the control nonwoven fabric. For example, after 96 hours, all nonwoven fabrics only consumed the quaternary ammonium compound concentration from 215ppm to 200ppm (for example, the quaternary ammonium compound concentration decreased by 7%).

[0124]

[0125] Table 9

[0126] Without departing from the spirit and scope of the present invention, those of ordinary skill in the art may implement these and other modifications and variations of the present invention, the spirit and scope of the present invention being more particularly set forth in the appended claims. In addition, it should be understood that the aspects of the various embodiments may be interchangeable in whole or in part. In addition, those of ordinary skill in the art will appreciate that the foregoing description is only by way of example and is not intended to limit the present invention as further described in the appended claims. Therefore, the spirit and scope of the appended claims should not be limited to the exemplary description of the versions contained herein.

Claims

1. A nonwoven fabric comprising: A mechanically entangled fiber blend comprising (a) post-consumer recycled polymer staple fibers (PCR-staple fibers) formed from a synthetic polymer material, wherein the PCR-staple fibers are free of a hydrophilic surface treatment coating; and (b) one or more additional fibers selected from the group consisting of a plurality of wettable staple fibers, a plurality of cellulosic fibers, or a combination thereof, wherein the plurality of wettable staple fibers include hydrophilically modified polyester staple fibers having a hydrophilic surface treatment coated thereon, and wherein the PCR-staple fibers include polyethylene terephthalate (PET), a polyolefin, or a polyamide; wherein the PCR-staple fibers are mechanically entangled with the one or more additional fibers to define the nonwoven fabric, and wherein the PCR-staple fibers are formed from recycled post-consumer waste that has been chemically treated and / or mechanically processed to break up the recycled post-consumer waste prior to being melted and extruded into the PCR-staple fibers, Wherein the one or more additional fibers comprise a plurality of wettable staple fibers.

2. The nonwoven fabric of claim 1, wherein the PCR-staple fibers comprise post-consumer recycled polyethylene terephthalate (PCR-PET).

3. The nonwoven fabric according to claim 1, wherein the PCR-staple fibers have one or more of the following: The average length is 20mm to 150mm; The average linear density of the PCR staple fibers is from 1 dtex to 2.5 dtex; and The average value is 3 to 20 crimps per 25 mm of fiber length.

4. The nonwoven fabric of claim 1, wherein the PCR-staple fibers have one or more of the following: The average length is at least any one of the following: 20mm, 25mm, 30mm, 35mm, 40mm, 45mm, 50mm, 60mm, 70mm, 80mm and 90mm; The average linear density of the PCR-short fibers is at least any one of 1 dtex, 1.1 dtex, 1.2 dtex, 1.3 dtex, 1.4 dtex, 1.5 dtex, 1.6 dtex, 1.7 dtex, and 1.8 dtex; and The average is at least any of the following: 3 curls, 4 curls, 5 curls, 6 curls, 7 curls, 8 curls, 9 curls, 10 curls, 11 curls and 12 curls per 25 mm fiber length.

5. The nonwoven fabric according to claim 1 or 4, wherein the PCR-short fibers have one or more of the following: The average length is at most any of the following: 150 mm, 125 mm, 100 mm, 90 mm and 80 mm; The average linear density of the PCR-staple fibers is at most any of the following: 2.5 dtex, 2.4 dtex, 2.3 dtex, 2.2 dtex, 2.1 dtex, 2 dtex, 1.9 dtex, and 1.8 dtex; and The average is at most any of: 20 curls, 19 curls, 18 curls, 17 curls, 16 curls, 15 curls, 14 curls, 13 curls, and 12 curls per 25 mm fiber length.

6. The nonwoven fabric according to claim 1, wherein the PCR-staple fibers account for 10 to 90 weight % of the nonwoven fabric.

7. The nonwoven fabric of claim 1, wherein the PCR-staple fibers account for at least any of: 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt% and 60 wt% of the nonwoven fabric.

8. The nonwoven fabric of claim 1 or 7, wherein the PCR-staple fibers account for up to any of: 90 wt%, 85 wt%, 80 wt%, 75 wt%, 70 wt%, 65 wt% and 60 wt% of the nonwoven fabric.

9. The nonwoven fabric of claim 1 , wherein the plurality of wettable staple fibers comprise 10 to 90 weight percent of the nonwoven fabric, and wherein the first ratio of the nonwoven fabric between grams of the PCR-staple fibers per square meter of the nonwoven fabric and grams of the plurality of wettable staple fibers per square meter of the nonwoven fabric is from 4:1 to 1:

4.

10. The nonwoven fabric of claim 9, wherein the plurality of wettable staple fibers comprises at least any of: 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55% and 60% by weight of the nonwoven fabric.

11. The nonwoven fabric of claim 9 or 10, wherein the plurality of wettable staple fibers comprises at most any of: 90%, 85%, 80%, 75%, 70%, 65% and 60% by weight of the nonwoven fabric.

12. The nonwoven fabric of claim 9, wherein a first ratio of the nonwoven fabric between the PCR-staple fibers in grams per square meter of the nonwoven fabric and the plurality of wettable staple fibers in grams per square meter of the nonwoven fabric is at most any one of: 4:1, 3.5:1, 3:1, 2.5:1, 2:1, 1.5:1, and 1:

1.

13. The nonwoven fabric according to claim 9 or 12, wherein a first ratio between the PCR-staple fibers in grams per square meter of the nonwoven fabric and the plurality of wettable staple fibers in grams per square meter of the nonwoven fabric is at least any one of: 1:4, 1:3.5, 1:3, 1:2.5, 1:2, 1:1.5 and 1:

1.

14. The nonwoven fabric of claim 1, wherein the one or more additional fibers further comprise a plurality of cellulosic fibers, and wherein the nonwoven fabric comprises a composition weight ratio of the PCR-stab fibers in grams per square meter of the nonwoven fabric, the plurality of wettable staple fibers in grams per square meter of the nonwoven fabric, and the plurality of cellulosic fibers in grams per square meter of the nonwoven fabric according to the formula A:B:C, wherein (i) 'A' represents the amount of said PCR-staple fibers in grams per square meter of said nonwoven fabric, and Includes the following values: 0.2 to 0.8; (ii) 'B' represents the plurality of wettable staple fibers in grams per square meter of the nonwoven fabric, and Includes the following values: 0.2 to 0.8; as well as (iii) 'C' represents the plurality of cellulosic fibers or the plurality of microfiber staple fibers in grams per square meter of the nonwoven fabric, and Includes the following values: 0.2 to 0.

8.

15. The nonwoven fabric of claim 14, wherein 'A' comprises the following values: at least any one of the following: 0.2, 0.25, 0.3, 0.35, 0.4, and 0.

5.

16. The nonwoven fabric of claim 14 or 15, wherein 'A' comprises the following values: at most any of the following: 0.8, 0.75, 0.7, 0.65, 0.6, 0.55 and 0.

5.

17. The nonwoven fabric of claim 14, wherein 'B' comprises the following values: at least any one of the following: 0.2, 0.25, 0.3, 0.35, 0.4, and 0.

5.

18. The nonwoven fabric of claim 14 or 17, wherein 'B' comprises the following values: at most any of the following: 0.8, 0.75, 0.7, 0.65, 0.6, 0.55 and 0.

5.

19. The nonwoven fabric of claim 14, wherein 'C' comprises the following values: at least any one of the following: 0.2, 0.25, 0.3, 0.35, 0.4, and 0.

5.

20. The nonwoven fabric of claim 14 or 19, wherein 'C' comprises the following values: at most any of the following: 0.8, 0.75, 0.7, 0.65, 0.6, 0.55, and 0.

5.

21. The nonwoven fabric of any one of claims 1 to 4, further comprising a binder, an antimicrobial compound, or a combination thereof.

22. The nonwoven fabric according to any one of claims 1 to 4, wherein the nonwoven fabric comprises a three-dimensional pattern formed on at least one surface of the nonwoven fabric, the three-dimensional pattern comprising at least one concave portion and a plurality of convex portions.

23. The nonwoven fabric of any one of claims 1 to 4, wherein the nonwoven fabric is provided in the form of a plurality of individual wipes disposed within a package.

24. A method of forming a nonwoven fabric, comprising: (ia) forming or providing a carded fiber web comprising a fiber blend comprising (a) post-consumer recycled polymer staple fibers (PCR-staple fibers) formed from a synthetic polymer material, wherein the PCR-staple fibers are free of a coating of a hydrophilic surface treatment agent; and (b) one or more additional fibers selected from: a plurality of wettable staple fibers, a plurality of cellulosic fibers, or a combination thereof, wherein the plurality of wettable staple fibers comprises hydrophilically modified polyester staple fibers coated with a hydrophilic surface treatment agent, and wherein the PCR-staple fibers comprise polyethylene terephthalate (PET), a polyolefin, or a polyamide; or (ib) forming or providing a first layer of post-consumer recycled polymer staple fibers (PCR-staple fibers) formed from a synthetic polymer material, wherein the PCR-staple fibers are free of a coating of a hydrophilicity rendering treatment agent; and forming or providing a second layer of one or more additional fibers selected from: a plurality of wettable staple fibers coated with a hydrophilic surface treatment, a plurality of cellulosic fibers, or a combination thereof, and wherein the PCR-staple fibers comprise polyethylene terephthalate (PET), a polyolefin, or a polyamide; wherein the first layer is adjacent to the second layer to provide a multi-layer nonwoven web; and (ii) mechanically entangling the PCR-staple fibers with the one or more additional fibers to define a nonwoven fabric; wherein the PCR-staple fibers are formed from recycled post-consumer waste that has been chemically treated and / or mechanically processed to break up the recycled post-consumer waste before being melted and extruded into the PCR-staple fibers, wherein in (ia) or (ib), the one or more additional fibers comprise a plurality of wettable staple fibers.

25. The method of forming a nonwoven fabric of claim 24, wherein in (ia) or (ib), the PCR-staple fibers comprise post-consumer recycled polyethylene terephthalate (PCR-PET).

Images