Substrate having surface fiber structure

Abstract

A substrate formed from a nonwoven web and having a microstructured morphology is provided. Multiple short fibers modified with cationic polymers are attached to the nonwoven web using an anionic polymeric adhesive to improve one or more properties of the nonwoven web, such as softness, absorbency, abrasion resistance, and barrier properties. This disclosure also provides a method of forming the substrate, the method comprising printing an adhesive onto the nonwoven web and passing the nonwoven web through an electroplating module.

Description

Background Technology

[0001] Traditional absorbent products, including wiping products, have been made from woven and braided fabrics. These wipes are used in all sorts of industries, such as industrial applications, food service applications, health and medical applications, and for general consumer use. Traditional rags and towels can be reused if washed properly. However, disposable wipes continue to be popular and easily replace many traditional woven or braided products. For example, disposable wipes offer many advantages. They are generally more sterile because they are typically free of lint and contaminants and can be pre-filled with detergent. Washed rags and towels, for instance, can still contain residual lint from previous uses, and this lint can be picked up during the washing process. Furthermore, washing woven or braided wipes is not only costly but also requires large amounts of water and detergents that must be handled properly. Additionally, washed rags and dishcloths require separate solvents or surfactants to be kept on hand, as they are not pre-filled like disposable wipes.

[0002] However, disposable wipes are often constrained by conflicts of interest. For example, industrial wipes, food service wipes, household cleaning wipes, and medical wipes typically require greater strength and should be able to absorb not only water-based solutions but also oily substances. Historically, however, there have been challenges in producing wipes that possess both good water and oil absorption properties. For instance, increasing the oleophilicity of a wipe can result in a more hydrophobic sheet with lower water absorption. Similarly, increasing the hydrophilicity of a wipe can lead to a decrease in the oil absorption of hydrophilic sheets. Furthermore, providing wipes with good abrasion resistance, for example, limits the softness and overall absorbency of the wipe. Similarly, there are conflicts of interest with barrier fabrics (such as those used in masks and performance fabrics). For example, treating barrier fabrics to improve their barrier properties can increase their abrasion resistance, which can cause discomfort when the fabric comes into contact with the user's skin.

[0003] Furthermore, altering the properties of these articles requires changing the composition of the substrate used to form the article, such as by changing the fibers or other components used during the formation of the underlying nonwoven web. This can lead to additional problems, as any change to the substrate composition may result in the trade-offs described above, leading to delays and difficulties during manufacturing, as well as limitations imposed by the fundamental properties of the material.

[0004] Therefore, in one respect, it is advantageous to provide a substrate with overall improved performance. For example, in one respect, it would be advantageous to provide a substrate that exhibits improved performance in one or more aspects of softness, absorbency, abrasion resistance, and barrier properties. Furthermore, it is advantageous to provide an article formed from a substrate, wherein the substrate exhibits improved performance on opposite surfaces of the article. Summary of the Invention

[0005] In one aspect, this disclosure generally relates to a substrate having a microstructured morphology. The substrate comprises a nonwoven web having a first surface and an opposing second surface, extending in a first plane. The substrate also includes an adhesive and a plurality of short fibers extending in one or more second planes not parallel to the first plane, these short fibers being attached to the first surface of the nonwoven web by the adhesive. Furthermore, at least a portion of the short fibers has a length of about 5000 micrometers or less, about 5 deniers or less, or a combination thereof.

[0006] In another aspect, the substrate is a wiping product or an absorbent article. Furthermore, in another aspect, at least a portion of the short fibers has a length of about 1500 micrometers or less and a denier of about 3 or less, or a length of about 1500 micrometers to about 5000 micrometers and a denier of about 3 to about 5.

[0007] Furthermore, in one aspect, the nonwoven web comprises elastic fibers, three-dimensional fibers, degummed cellulose fibers, pulp fibers, or mixtures thereof. Additionally or alternatively, the nonwoven web comprises polyethylene fibers, polyethylene fibers, pulp fibers, or combinations thereof. In another aspect, the nonwoven web is a spunbond nonwoven web. Furthermore, in one aspect, the nonwoven web is embossed.

[0008] In another aspect, the plurality of short fibers comprises polyethylene fibers, polypropylene fibers, rayon fibers, nylon fibers, or combinations thereof. Furthermore, in one aspect, the adhesive comprises anionic components, and the plurality of short fibers comprises cationic components, or combinations thereof. In one aspect, the anionic component and the adhesive are coated on at least a portion of the nonwoven web. Alternatively or additionally, 50% or more of the nonwoven web is coated with the anionic component and the adhesive. In one aspect, the anionic component and the adhesive are applied to the nonwoven web in a pattern including circles, squares, lines, or combinations thereof. Furthermore, in one aspect, the substrate comprises a second plurality of short fibers adhered to a second surface of the nonwoven web by an adhesive. In one aspect, the second plurality of short fibers has a different length, denier, or fiber composition, or combinations thereof, than the first plurality of short fibers.

[0009] Furthermore, in one aspect, the nonwoven mesh exhibits: a water capacity of approximately 200% to approximately 800%; a cup load of less than approximately 100 grams when measured using a 34 gsm nonwoven mesh; a bacterial filtration efficiency of approximately 80% or higher; or a combination thereof. In another aspect, compared to the same nonwoven mesh excluding multiple short fibers, the substrate exhibits a 10% or greater improvement in one or more of the following: water capacity, cup load, or bacterial filtration.

[0010] This disclosure also relates in its entirety to a method of forming a substrate. The method includes forming a nonwoven web extending in a first plane, applying an adhesive to a first surface of the nonwoven web, and adhering a plurality of short fibers to the nonwoven web. In this respect, at least a portion of the plurality of short fibers extends in one or more second planes not parallel to the first plane and has a length of 5000 micrometers or less, a denier of 5 or less, or a combination thereof.

[0011] In another aspect, the adhesive comprises an anionic component, wherein the anionic component and the adhesive are printed onto a nonwoven web. In yet another aspect, the anionic component and the adhesive are printed onto the nonwoven web using a flexographic printing method, and the plurality of short fibers are electrostatically adhered to the nonwoven web. Alternatively or additionally, the substrate is calendered.

[0012] Other features and aspects of this disclosure are discussed in more detail below. Attached Figure Description

[0013] The disclosure, which is comprehensive and enables the implementation of this disclosure, is set forth in more detail in the remainder of the specification and with reference to the accompanying drawings, in which:

[0014] Figure 1 A cross-sectional view of one aspect of the substrate according to this disclosure is shown;

[0015] Figure 2 A cross-sectional view of one aspect of the substrate according to this disclosure is shown; and

[0016] Figure 3 A method for forming a substrate according to this disclosure is shown.

[0017] The repeated use of reference numerals in this specification and the accompanying drawings is intended to indicate the same or similar features or elements of the invention.

[0018] definition

[0019] The terms “about,” “approximately,” or “roughly” used herein to modify values ​​indicate that the value may be increased or decreased by 10% (such as 7.5%, such as 5%, such as 4%, such as 3%, such as 2%, or such as 1%) and remain within the disclosed scope.

[0020] As used herein, the term "fiber" refers to an elongated particle whose apparent length greatly exceeds its apparent width, i.e., whose length-to-diameter ratio is at least about 10. More specifically, as used herein, fiber refers to papermaking fiber. The present invention contemplates the use of various papermaking fibers, such as, for example, natural or synthetic fibers, or any other suitable fibers, and any combination thereof. Papermaking fibers that can be used in the present invention generally include cellulose fibers and more specifically wood pulp fibers.

[0021] The term "nonwoven web" generally refers to a web having a structure of individual fibers or threads arranged in layers but not in an identifiable manner (as in knitted fabrics). Examples of suitable nonwoven fabrics or webs include, but are not limited to, meltblown webs, spunbond webs, bonded carded webs, air-laid webs, co-formed webs, and hydraulically entangled webs.

[0022] The term "meltblown web" broadly refers to a nonwoven web formed by a process in which molten thermoplastic material is extruded as molten fibers through multiple fine, typically circular, die capillaries into a converging, high-speed gas (e.g., air) stream. The air stream reduces the diameter of the molten thermoplastic fibers, which can be microfiber diameters. The meltblown fibers are then carried by the high-speed gas flow and deposited onto a collecting surface to form a web composed of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Patent No. 3,849,241 to Butin et al., the entire contents of which are incorporated herein by reference for all purposes. Generally, meltblown webs can be substantially continuous or discontinuous, typically less than 10 micrometers in diameter, and typically sticky when deposited onto a collecting surface.

[0023] The term "spunbond web" generally refers to a web containing substantially continuous fibers of small diameter. The fibers are formed by extruding molten thermoplastic material from capillaries of multiple fine, typically circular, spinnerets with the diameter of the extruded fibers, and then rapidly thinning it by, for example, eductive drawing and / or other well-known spunbonding mechanisms. Preparation of spunbond webs is described and illustrated, for example, in U.S. Patent Nos. 4,340,563 to Appel et al., 3,692,618 to Dorschner et al., 3,802,817 to Matsuki et al., 3,338,992 to Kinney et al., 3,341,394 to Kinney et al., 3,502,763 to Hartman et al., 3,502,538 to Levy et al., 3,542,615 to Dobo et al., and 5,382,400 to Pike et al., the entire contents of which are incorporated herein by reference for all purposes. Spunbond fibers are generally non-sticky when deposited onto the collection surface. Spunbond fibers can sometimes have a diameter of less than about 40 micrometers, and are typically between about 5 and about 20 micrometers.

[0024] The term "co-forming" generally refers to a composite material comprising a mixture or stabilized matrix of thermoplastic fibers and a second non-thermoplastic material. For example, co-forming materials can be produced by a process in which at least one meltblown die is positioned near a chute through which other materials are added to the web while it is being formed. Such other materials may include, but are not limited to, fibrous organic materials such as wood or non-wood pulp, such as cotton, rayon, recycled paper, pulp fluff, as well as superabsorbent particles, inorganic and / or organic absorbent materials, treated polymer short fibers, etc. Some examples of such co-forming materials are disclosed in U.S. Patent No. 4,100,324 to Anderson et al., U.S. Patent No. 5,284,703 to Everhart et al., and U.S. Patent No. 5,350,624 to Georger et al., each of which is incorporated herein by reference in its entirety for all purposes.

[0025] The term "bonded carded web" refers to a web made of short fibers that are fed through a combing or carding unit that separates and aligns the fibers in the machine direction to form a fiber nonwoven web that is generally oriented in the machine direction. Such fibers are typically purchased in bales and then separated in a cotton cleaner or fiber separator before being fed into the carding unit. Once the web is formed, it is bonded using one or more of several known bonding methods.

[0026] The terms "elastomer" and "elasticity" refer to a material that, upon application of a tensile force, can stretch in at least one direction (such as the CD direction) and, upon release of the tensile force, shrink / return to approximately its original size. For example, a stretched material may have an elongation at least 50% greater than its relaxed, unstretched length and will return to at least 50% of its elongated length upon release of the tensile force. A hypothetical example would be a one (1)-inch sample of material that can stretch to at least 1.50 inches and will recover to a length not exceeding 1.25 inches upon release of the tensile force. Advantageously, the material shrinks or recovers at least 50% of its elongated length, and even more advantageously at least 80%.

[0027] The term "hot spot bonding" generally refers to a process performed, for example, by passing material between a patterned roll (e.g., a calendering roll) and another roll, which may or may not be patterned (e.g., an anvil roll). Typically, one or both of these rolls are heated.

[0028] The term "ultrasonic bonding" generally refers to a process performed, for example, by passing material between an ultrasonic amplifier and a patterning roller (e.g., an anvil roller). For example, ultrasonic bonding using a stationary amplifier and a rotating patterning anvil roller is described in U.S. Patent No. 3,939,033 to Grgach et al., U.S. Patent No. 3,844,869 to Rust Jr., and U.S. Patent No. 4,259,399 to Hill, the entire contents of which are incorporated herein by reference for all purposes. Furthermore, ultrasonic bonding using a rotating amplifier and a rotating patterning anvil roller is described in U.S. Patent No. 5,096,532 to Neuwirth et al., U.S. Patent No. 5,110,403 to Ehlert, and U.S. Patent No. 5,817,199 to Brennecke et al., the entire contents of which are incorporated herein by reference for all purposes. Of course, any other ultrasonic bonding technique may also be used in this invention.

[0029] As used in this article, the term "slurry" refers to a mixture containing fiber and water.

[0030] When used herein, the term "absorbent article" or "article" means a product made of a web of fibers, including but not limited to personal care absorbent articles such as baby wipes, mittens, diapers, trouser diapers, open-face diapers, training pants, absorbent underwear, incontinence articles, feminine hygiene products (e.g., sanitary napkins), swimwear, etc.; medical absorbent articles such as clothing, fenestration materials, pads, mattresses, bandages, absorbent sheets, and medical wipes; food service paper towels; garment articles; packaging bags, etc. The materials and methods for forming such articles are well known to those skilled in the art. For example, an absorbent article may include a lining, an outer cover, and an absorbent material or pad formed of a web of fibers located between them.

[0031] As used herein, the term "wiping product" refers to a product made of a fiber web and includes paper towels, industrial wipes, food service wipes, napkins, medical pads, and other similar products. It should be understood that, in one aspect, reference to absorbent articles or absorbent webs according to this disclosure may include wiping products.

[0032] As used herein, the term "basis weight" generally refers to the dry weight of a fiber product per unit area and is usually expressed in grams per square meter (gsm). Basis weight is measured using the TAPPI test method T-220.

[0033] As used in this article, the term "longitudinal" refers to the direction of travel of the shaped surface on which fibers are deposited during the formation of a nonwoven web.

[0034] As used herein, the term "lateral" refers to a direction perpendicular to the longitudinal direction as defined above and within the plane of the shaped surface.

[0035] As used herein, the term "pulp" refers to fibers derived from natural sources such as woody and non-woody plants. Woody plants include, for example, deciduous and coniferous trees. Non-woody plants include, for example, cotton, flax, Spanish grass, milkweed, straw, jute, hemp, and bagasse. Pulp fibers can include hardwood fibers, softwood fibers, and mixtures thereof.

[0036] As used herein, the term "average fiber length" refers to the average length of a fiber, fiber bundle, and / or fibrous material determined by measurement using microscopic techniques. A sample of at least 20 randomly selected fibers is separated from a liquid suspension of the fibers. The fibers are placed on a microscope slide prepared to suspend the fibers in water. A staining dye is added to the suspended fibers to color the cellulose-containing fibers so that they can be distinguished or separated from synthetic fibers. The slide is placed under a Fisher Stereomaster II microscope—S19642 / S19643 series. The 20 fibers in the sample are measured using a 0-20 mil scale at a 20X linear magnification, and the average length, minimum and maximum length, and deviation or coefficient of variation are calculated. In some cases, the average fiber length is calculated as a weighted average length of the fibers (e.g., fibers, fiber bundles, fibrous materials), determined using, for example, a Kajaani Fiber Analyzer model FS-200 from Kajaani OyElectronics, Kajaani, Finland. According to the standard testing procedure, the samples are treated with an impregnation solution to ensure the absence of fiber bundles or debris. Each sample is decomposed and diluted in hot water to a suspension of approximately 0.001%. When testing using the standard Kajaani fiber analysis test procedure, approximately 50 ml to 100 ml of each test sample is drawn from the diluted suspension. The weighted average fiber length can be an arithmetic mean, a length-weighted mean, or a weight-weighted mean, and can be expressed by the following equation:

[0037]

[0038] in

[0039] k = maximum fiber length

[0040] x i =Fiber length

[0041] n i =Number of fibers of length xi

[0042] n = the total number of fibers measured.

[0043] A characteristic of the average fiber length data measured by the Kajaani fiber analyzer is that it does not distinguish between different types of fibers. Therefore, the average length represents the average length based on all different types (if any) of the fibers in the sample.

[0044] The term "short fiber" refers to discontinuous fibers made from synthetic polymers such as polypropylene, polyester, post-consumer recycled (PCR) fibers, nylon, etc., and those that are non-hydrophilic can be treated to become hydrophilic. Short fibers can be cut fibers, etc. Short fibers can have cross-sections such as round, bicomponent, multicomponent, molded, hollow, etc.

[0045] As used herein, the term "abrasive" is intended to describe a surface texture that enables a nonwoven web to scrub surfaces that have been wiped or cleaned with the nonwoven web and to remove dirt, etc. Abrasiveness can vary depending on the polymer used to prepare the abrasive fibers and the degree of texture of the nonwoven web. Detailed Implementation

[0046] Those skilled in the art will understand that this discussion is merely a description of exemplary aspects and is not intended to limit the broader aspects of this disclosure.

[0047] Generally, this disclosure relates to a substrate with a microstructured morphology, said substrate being formed of a nonwoven web and at least a first plurality of short fibers adhered to a first side of the nonwoven web. In particular, this disclosure has found that by carefully selecting the short fibers and adhering them to the nonwoven web such that the short fibers extend in a direction not normally coplanar with the nonwoven web, one or more properties of the substrate can be improved without affecting the properties of the nonwoven web, and without requiring a change in the composition of the nonwoven web. Furthermore, in one aspect, this disclosure has found that a second plurality of short fibers can be adhered to a second side of the nonwoven web. In this aspect, the second plurality of short fibers can differ from the first plurality of fibers in size, shape, or properties (such as water absorption, oil absorption, etc.), thereby providing different properties on each surface of the substrate without requiring a change in the composition or treatment of the nonwoven web.

[0048] For example, in one aspect, first and / or second plurality of short fibers may be selected to improve one or more properties of the nonwoven web, such as water absorption, oil absorption, softness, abrasion resistance, durability, barrier properties, etc. For example, the short fibers may be selected based on the material's ability to improve these properties, and the short fibers may be formed from one or more synthetic fibers. In one aspect, the short fibers may be formed from polypropylene, polyester, post-consumer recycled (PCR) fibers, pre-consumer (e.g., post-industrial) recycled fibers, rayon, polyester, nylon, etc. In another aspect, the fibers may be formed from polypropylene, polyester, rayon, nylon, or combinations thereof. While fibers inherently possessing one or more of the aforementioned properties may be selected, it should be understood that, in one aspect, the selected fibers may be treated to impart or increase their hydrophobicity, absorbency, or other properties known in the art. However, in one aspect, the short fibers may also include cellulosic fibers, such as cotton, including fibers derived from waste and recycled materials, including agricultural, industrial, and textile waste.

[0049] However, in one aspect, one or more of the aforementioned materials may be used to form short fibers, and the length and / or denier of the fibers may be varied to impart additional advantages. For example, shorter and / or finer (e.g., lower denier) fibers may provide a softer surface, while longer and / or coarser (e.g., higher denier) fibers may improve abrasion resistance or durability. Thus, in one aspect, the first and / or second plurality of short fibers may have a denier of about 20 or less, such as about 17.5 or less, such as about 15 or less, such as about 12.5 or less, such as about 10 or less, such as about 8 or less, such as about 6 or less, such as about 5 or less, such as about 4 or less, such as about 3 or less, such as about 2 or less, or any range or value thereof.

[0050] In addition, or alternatively, the fiber may have a length of about 10 micrometers to about 5,000 micrometers, such as about 50 micrometers to about 4,000 micrometers, such as about 100 micrometers to about 3,000 micrometers, such as about 150 micrometers to about 2,000 micrometers, such as about 200 micrometers to about 1,000 micrometers, such as about 250 micrometers to about 750 micrometers, or any range or value therebetween, said length being the longest dimension of a short fiber.

[0051] Furthermore, in one aspect, the short fibers providing softness may have deniers of about 4 or less, such as about 3.5 or less, such as about 3 or less, such as about 2.5 or less, such as about 2 or less, such as about 1.5 or less, such as about 1 or less, such as about 0.9 or less, such as about 0.8 or less, or any range or value therein, and / or lengths of about 2000 micrometers or less, such as about 1750 micrometers or less, such as about 1500 micrometers or less, such as about 1000 micrometers or less, such as about 500 micrometers or less. For example, in one aspect, the soft fibers have deniers of about 2.5 to about 3.5 and lengths of about 1000 micrometers to about 1700 micrometers, deniers of about 1 to about 2 and lengths of about 500 micrometers to about 1500 micrometers, deniers of about 0.5 to about 1 and lengths of about 250 micrometers to about 1000 micrometers, or any range or value therein.

[0052] Similarly, fibers with good abrasion resistance or abrasion-resistant properties may have deniers of about 4 or greater, such as about 5 or greater, such as about 7.5 or greater, such as about 10 or greater, such as about 15 or greater, such as about 20 or greater, such as about 25 or greater, such as about 30 or greater, such as about 35 or greater, such as about 45 or less, such as about 40 or less, such as about 35 or less, such as about 30 or less, such as about 25 or less, or any range or value therein, and / or about 10. The length is millimeters or smaller, such as about 9 millimeters or smaller, such as about 8 millimeters or smaller, such as about 7 millimeters or smaller, such as about 6000 micrometers or smaller, such as about 5000 micrometers or smaller, such as about 4000 micrometers or smaller, such as about 3000 micrometers or smaller, such as about 2000 micrometers or smaller, such as about 1200 micrometers or larger, such as about 1300 micrometers or larger, such as about 1400 micrometers or larger, such as about 1500 micrometers or larger, or any value or range thereof. For example, in one aspect, the abrasive fiber has a length of about 5 to about 7 deniers and about 1250 micrometers to about 4000 micrometers, about 9.5 to about 12 deniers and about 2500 micrometers to about 5500 micrometers, about 19 to about 21 deniers and about 4500 micrometers to about 7500 micrometers, about 38 to about 41 deniers and about 6500 micrometers to about 10,000 micrometers, or any range or value thereof.

[0053] Regardless of the type and size of the fiber selected, the fiber is cationicly treated. In one aspect, the cation is incorporated during the formation of the short fiber; however, it should be understood that the cation can be incorporated into the short fiber after formation, such as by treating the short fiber. In one aspect, the cation is a metal cation, such as an alkali metal cation, and in another aspect, it can be selected from potassium, sodium, lithium, or combinations thereof. In another aspect, suitable cationicly charged fibers can be obtained from Agatex as treated short fibers.

[0054] In particular, in one aspect, as described above, multiple fibers are attached to a nonwoven web by an adhesive after exposure to a magnetic field. As will be discussed in more detail below, various techniques can be used to apply the adhesive to the nonwoven web, including printing, spraying, dipping, etc. Nevertheless, in one aspect, the adhesive can be any adhesive known in the art, but can be anionic. Therefore, as will be discussed in more detail below, multiple fibers can be plated or deposited on the nonwoven web due to the attractive attraction between the cations incorporated into or on the fibers and the anionic components incorporated into the adhesive. While any anion known in the art can be used, in one aspect, the anion is an anion that has a suitable attraction to metal cations (such as alkali metal cations). Therefore, in one aspect, the anion can include mineral anions, such as chloride, bromine, iodine, or fluoride salt anions, such as PF6. − SCN − ClO4 − CF3SO3 − (FSO2)2N − (CF3SO2)2N − (C2F5SO2)2N − and (CF3SO2)3C − And their combinations. In one respect, suitable anionic adhesives are available from Agatex.

[0055] Despite the choice of adhesive, in one respect, the fibers are adhered to one or more surfaces of the nonwoven web by the adhesive. For example, see reference... Figure 1 The nonwoven web 102 may have an adhesive 104 applied thereon, and first plurality of short fibers 106 are attached to the nonwoven web by the adhesive to form a substrate web 100 with a microstructured morphology. Furthermore, refer to... Figure 2 As described above, in one aspect, a first plurality of short fibers are attached to a first side 108 of the nonwoven web, and a second plurality of short fibers 114 are attached to a second side 110 of the nonwoven web 102 by an adhesive 112. In one aspect, as described above, the first plurality of short fibers 106 may be the same as or different from the second plurality of short fibers 114. Similarly, in one aspect, the adhesive 112 may be the same as or different from the adhesive 104. For example, in one aspect, the adhesives themselves may be substantially the same or similar, but the adhesive 104 may be anionicly treated differently from the adhesive 112. However, in one aspect, the adhesive 104 is the same as or substantially the same as the adhesive 112.

[0056] Furthermore, although adhesives 104 and / or 112 are in Figure 1 and Figure 2The image shows the nonwoven web 102 as covering the entire surface; however, it should be understood that in some respects, the adhesive can be applied to about 50% or more of the nonwoven web, such as about 60% or more, such as about 70% or more, such as about 75% or more, such as about 80% or more, such as about 85% or more, such as about 90% or more, such as about 95% or more, such as about 100% or less, such as about 99% or less, such as about 95% or less, such as about 90% or less, such as about 85% or less, such as 80% or less, or any range or value in between. Therefore, in one respect, the adhesive can be applied in a pattern, such as dots, squares, lines, etc.

[0057] Nevertheless, such as Figure 1 and 2 As shown, the first and / or second plurality of short fibers 106 / 114 extend along their lengths (e.g., the maximum dimension from the surface of the nonwoven web to the distal end of the short fiber) in one or more planes that are not coplanar with or parallel to the nonwoven web 102. Specifically, as shown, in one aspect, and by way of example only, the nonwoven web 102 extends in a generally horizontal direction along the x-axis, while the short fibers 106 extend in a plurality of second planes that are not coplanar with or parallel to the x-axis, thereby forming a microstructured morphology on the first and / or second surfaces of the nonwoven web. It should be understood that, due to the process of attaching fibers, which will be discussed in more detail below, some short fibers 106 / 114 may be attached such that their lengths extend generally parallel to the nonwoven web 102; however, at least a portion, such as about 50% or more, such as about 60% or more, such as about 70% or more, such as about 75% or more, such as about 80% or more of the fibers may extend in one or more second planes that are not coplanar with or parallel to the first planes in which the nonwoven web 102 extends. Therefore, the first or second multiple short fibers are further distinguished from the outer layer in the laminate or layered nonwoven configuration.

[0058] Furthermore, this disclosure surprisingly finds that multiple short fibers do not reduce the basic properties of the base web; in fact, they can increase one or more of the following: absorbency, abrasion resistance, softness, and barrier properties.

[0059] For example, in one aspect, the nonwoven web is capable of absorbing between 3.5 grams and 6.0 grams of water per gram of nonwoven web. In some exemplary aspects, the water capacity of the nonwoven web, determined by measuring the increase in weight of the material sample due to liquid absorption, can be between about 200% and about 800%, such as about 250% to about 750%, such as about 300% to about 700%, such as about 350% to about 600%, or any range or value therebetween. Furthermore, the nonwoven web is capable of absorbing between 3.7 grams and 4.3 grams of water in a time interval of about 1 second to about 2 seconds, such as about 1.1 seconds to about 1.9 seconds, such as about 1.2 seconds to about 1.8 seconds, such as about 1.25 seconds to about 1.6 seconds, or any range or value therebetween. Moreover, as mentioned above, it has been unexpectedly found that by forming a substrate according to this disclosure, the properties of the nonwoven web can be maintained at the aforementioned levels, or even increased when selecting fibers that improve absorbency.

[0060] In one respect, nonwoven webs can also exhibit good barrier properties and can filter at least about 70% or more of airborne particles with a diameter of about 0.65 micrometers or larger as determined according to EN 13274-7 (using sodium chloride aerosol with a particle size of 0.65 micrometers and a velocity of 95 liters / minute over a 100 cm² area), such as about 75% or more, about 80% or more, about 85% or more, or about 90% or more of particles with a diameter of about 0.65 micrometers or larger. Similarly, these barrier properties can be maintained while maintaining good air permeability through the nonwoven web. For example, nonwoven webs can exhibit good air permeability according to ASTM D737 (2020, using 38 cm²). 2 The air permeability is measured at approximately 20 cfm or greater, such as approximately 25 cfm or greater, such as approximately 30 cfm or greater, such as approximately 32.5 cfm or greater, such as approximately 35 cfm or greater, such as approximately 40 cfm or greater, or any range or value between these values. Additionally or alternatively, the nonwoven fabric may exhibit a bacterial filtration efficiency (BCE) of approximately 80% or higher, such as approximately 85% or higher, such as approximately 90% or higher, such as approximately 95% or higher, as defined in the test below.

[0061] When the 34 gsm web is tested according to the cupping test described below, the nonwoven web may also have a softness measured in cupping energy of less than about 1500 gm-mm, such as about 1400 gm-mm or less, such as about 1300 gm-mm or less, such as about 1200 gm-mm or less, and a cupping load of less than about 100 g, such as about 95 g, such as about 90 g, such as about 85 g, such as about 80 g, such as about 75 g, such as about 70 g.

[0062] Furthermore, this disclosure has found that these properties can be maintained or even improved by incorporating short fibers according to this disclosure. For example, based on the selected fiber, denier, and length, one or more of the above-mentioned properties can be increased by about 10% or more, such as about 20%, such as about 30%, such as about 40%, such as about 50% or more. In addition, in one aspect, by incorporating fibers having one or more of the above-mentioned properties, non-inherent properties of the nonwoven web can be imparted without affecting (e.g., reducing or diminishing) the above-mentioned properties of the nonwoven web. For example, a nonwoven web having the above-mentioned barrier properties can be combined with fibers having high softness, thereby improving the softness of the barrier fabric without affecting the barrier properties. In this aspect, the softness of the substrate can be 10% or more greater than the softness of the same nonwoven web with barrier properties that has not been treated with multiple short fibers, such as about 15% or more, such as about 20% or more, such as about 25% or more. Similarly, in one aspect, absorbent nonwovens can be treated with abrasive fibers, which increase abrasion resistance by about 10% or more, such as about 15% or more, such as about 20% or more, such as about 25% or more, compared to the same absorbent nonwoven without treatment using multiple short fibers. Furthermore, in one aspect, nonwovens with water-absorbing or oil-absorbing properties can contain multiple fibers to improve water-absorbing or oil-absorbing properties, such that a first side of the nonwoven is oil-absorbing, while the opposite side is water-absorbing. For example, absorbent nonwovens can be treated with oil- or water-absorbing fibers, which increase their respective absorbency by about 10% or more, such as about 15% or more, such as about 20% or more, such as about 25% or more, compared to the same absorbent nonwoven without treatment using multiple short fibers. Of course, as mentioned above, it should be understood that the first plurality of fibers can adhere to the first side of the nonwoven web, and the second plurality of fibers can adhere to the second side of the nonwoven web, thereby improving two or more of the aforementioned properties while maintaining (if not improved) the properties of the nonwoven web.

[0063] Nonwoven webs can be formed from one or more polymers available for forming nonwoven web materials, including olefins (e.g., polyethylene and polypropylene), polyesters (e.g., polyethylene terephthalate, polybutylene naphthalate), polyamides (e.g., nylon), polycarbonates, polyphenylene sulfide, polystyrene, polyurethanes (e.g., thermoplastic polyurethane), etc. In one particular embodiment, the fibers of the nonwoven web material may comprise an olefin homopolymer. A suitable olefin homopolymer has a density of 0.91 g / cm³. 3A propylene homopolymer with a melt flow rate of 1200 g / 10 min (230°C, 2.16 kg), a crystallization temperature of 113°C, and a melting temperature of 156°C, was obtained from LyondellBasell Industries in Rotterdam, Netherlands, and is available as the METOCENE MF650X polymer. Another suitable propylene homopolymer has a melt flow rate of 0.905 g / cm³. 3 The polypropylene has a density of 1300 g / 10 min (230°C 2.16 kg) and a melt flow rate of 165°C, and is available as polypropylene 3962 from Total Petrochemicals, Houston, Texas. Another suitable polypropylene is available as ExxtraL. TM 3155 is from ExxonMobil Chemical Company, Houston, Texas.

[0064] In addition, a variety of thermoplastic elastomers and plastisol polymers are commonly used in the nonwoven web materials of the present invention, such as elastomeric polyesters, elastomeric polyurethanes, elastomeric polyamides, elastomeric copolymers, elastomeric polyolefins, etc. In a particular embodiment, elastomeric semi-crystalline polyolefins are used due to their unique combination of mechanical and elastomeric properties. Semi-crystalline polyolefins have or are capable of exhibiting a substantially regular structure. For example, semi-crystalline polyolefins may be substantially amorphous in their undeformed state, but form crystal domains when stretched. The crystallinity of the olefin polymer can be from about 3% to about 60%, from about 5% to about 45% in some embodiments, from about 5% to about 30% in some embodiments, and from about 5% to about 15% in some embodiments. Similarly, semi-crystalline polyolefins can have a latent heat of fusion (ΔH) from about 15 to about 210 joules / gram (“J / g”), from about 20 to about 100 J / g in some embodiments, from about 20 to about 65 J / g in some embodiments, and from 25 to about 50 J / g in some embodiments. f Latent heat of melting is another indicator of crystallinity. Semi-crystalline polyolefins can also have a Vicat softening temperature of about 10°C to about 100°C, in some embodiments about 20°C to about 80°C, and in some embodiments about 30°C to about 60°C. Semi-crystalline polyolefins can have a melting temperature of about 20°C to about 120°C, in some embodiments about 35°C to about 90°C, and in some embodiments about 40°C to about 80°C. Latent heat of melting (ΔH) f The melting temperature can be determined using differential scanning calorimetry (“DSC”) according to ASTM D-3417, as is well known to those skilled in the art. The Vicat softening temperature can be determined according to ASTM D-1525.

[0065] Exemplary semi-crystalline polyolefins include polyethylene, polypropylene, and blends and copolymers thereof. In one specific embodiment, polyethylene is used, which is ethylene and α-olefins (such as C3-C4). 20 α-olefins or C3-C 12 Copolymers of α-olefins. Suitable α-olefins can be linear or branched (e.g., one or more C1-C3 alkyl branches, or aryl groups). Specific examples include 1-butene; 3-methyl-1-butene; 3,3-dimethyl-1-butene; 1-pentene; 1-pentene having one or more methyl, ethyl, or propyl substituents; 1-hexene having one or more methyl, ethyl, or propyl substituents; 1-heptene having one or more methyl, ethyl, or propyl substituents; 1-octene having one or more methyl, ethyl, or propyl substituents; 1-nonene having one or more methyl, ethyl, or propyl substituents; 1-decene substituted with ethyl, methyl, or dimethyl; 1-dodecene; and styrene. Particularly desirable α-olefin comonomers are 1-butene, 1-hexene, and 1-octene. The ethylene content of such copolymers can be from about 60 mol% to about 99 mol%, in some embodiments from about 80 mol% to about 98.5 mol%, and in some embodiments from about 87 mol% to about 97.5 mol%. The content of α-olefins can also be in the range of about 1 mol% to about 40 mol%, in some embodiments from about 1.5 mol% to about 15 mol%, and in some embodiments from about 2.5 mol% to about 13 mol%.

[0066] The density of polyethylene can vary depending on the type of polymer used, but is typically in the range of about 0.85 g / cm³. 3 Approximately 0.96 g / cm³ 3 Within a certain range. Polyethylene "plastics" can, for example, have a range from 0.85 g / cm³. 3 Up to 0.91 g / cm 3 Density within a range. Similarly, "linear low-density polyethylene" (LLDPE) can have densities ranging from approximately 0.91 g / cm³. 3 Approximately 0.94 g / cm³ 3 Density within a range; "Low-density polyethylene" (LDPE) can have densities ranging from approximately 0.91 g / cm³. 3 Approximately 0.94 g / cm³ 3 Density within a range; and "high-density polyethylene" (HDPE) can have densities ranging from 0.94 g / cm³. 3 Up to 0.96 g / cm 3 Density within the specified range. Density can be measured according to ASTM 1505.

[0067] Particularly suitable polyethylene copolymers are those that are "linear" or "substantially linear." The term "substantially linear" means that, in addition to short-chain branches attributable to the incorporation of comonomers, the ethylene polymer also contains long-chain branches in its polymer backbone. "Long-chain branches" refers to chains with a length of at least 6 carbons. Each long-chain branch may have the same comonomer distribution as the polymer backbone and be as long as the polymer backbone to which it is attached. Preferred substantially linear polymers are replaced by 0.01 to 1 long-chain branch per 1000 carbons, and in some embodiments by 0.05 to 1 long-chain branch per 1000 carbons. In contrast to the term "substantially linear," the term "linear" means that the polymer lacks measurable or readily apparent long-chain branches. That is, the polymer is on average replaced by less than 0.01 long-chain branches per 1000 carbons.

[0068] The density of a linear ethylene / α-olefin copolymer is a function of both the length and amount of α-olefin. That is, the longer the α-olefin and the greater the amount of α-olefin present, the lower the copolymer density. While not strictly necessary, a linear polyethylene "plastic" is particularly desirable because the short-chain branching content of the α-olefin allows the ethylene copolymer to exhibit both plastic and elastomeric characteristics, i.e., a "plastic." Because polymerization with the α-olefin comonomer reduces crystallinity and density, the resulting plastid typically has a density lower than that of polyethylene thermoplastic polymers (e.g., LLDPE) but close to and / or overlapping with that of elastomeric polymers. For example, the density of a polyethylene plastid can be 0.91 g / cm³. 3 Or even lower, from about 0.85 g / cm³ in some implementations 3 Approximately 0.88 g / cm 3 And in some implementations, from approximately 0.85 g / cm 3 Approximately 0.87 g / cm 3 Although they have a density similar to that of elastomers, plasmons typically exhibit higher crystallinity and can form non-sticky and relatively free-flowing granules.

[0069] The distribution of α-olefin comonomers within the polyethylene plastid is generally random and uniform across the different molecular weight fractions forming the ethylene copolymer. This uniformity of comonomer distribution within the plastid can be expressed as a comonomer distribution width index (“CDBI”) of 60 or greater in some embodiments, 80 or greater in some embodiments, and 90 or greater in some embodiments. Additionally, the polyethylene plastid can be characterized by a DSC melting point profile, which exhibits a single melting point peak in the 50 to 110°C region (second melt rundown).

[0070] The preferred plastic body used in this invention is an ethylene-based copolymer plastic body, available under the name EXACT™ from ExxonMobilChemical Company, Houston, Texas. Other suitable polyethylene-based plastic bodies are available under the names ENGAGE™ and AFFINITY™ from Dow Chemical Company, Midland, Michigan. Further suitable polyethylene-based plastic bodies are available under the trade name INFUSE. TM Such as INFUSE TM 9807 is an olefin block copolymer obtained from Dow Chemical Company, Midland, Michigan. The polyethylene that can be used in the fibers of this invention is Dow... TM 61800.41. Other suitable ethylene polymers may be named DOWLEX™ (LLDPE), ASPUN, etc. TM (LLDPE) and ATTANE™ (ULDPE) are derived from The Dow Chemical Company. Other suitable ethylene polymers are described in U.S. Patent No. 4,937,299 to Ewen et al., U.S. Patent No. 5,218,071 to Tsutsui et al., U.S. Patent No. 5,272,236 to Lai et al., and U.S. Patent No. 5,278,272 to Lai et al., the entire contents of which are incorporated herein by reference for all purposes.

[0071] Of course, the present invention is by no means limited to the use of ethylene polymers. For example, propylene polymers can also be suitable as semi-crystalline polyolefins. Suitable plastogenic propylene polymers may include, for example, propylene copolymers or terpolymers, including propylene with α-olefins (e.g., C3-C4). 20 The copolymers include ethylene, 1-butene, 2-butene, various pentene isomers, 1-hexene, 1-octene, 1-nonene, 1-decene, 1-undecene, 1-dodecene, 4-methyl-1-pentene, 4-methyl-1-hexene, 5-methyl-1-hexene, vinylcyclohexene, styrene, etc. The comonomer content of the propylene polymer may be about 35% by weight or less, from about 1% by weight to about 20% by weight in some embodiments, and from about 2% by weight to about 10% by weight in some embodiments. Preferably, the density of the polypropylene (e.g., a propylene / α-olefin copolymer) may be 0.91 g / cm³. 3 (or lower, in some embodiments from 0.85 to 0.88 g / cm³) 3 And in some implementation schemes, from 0.85 g / cm 3 Up to 0.87 g / cm 3Suitable propylene-based copolymer plastomers are commercially available under the name VISTAMAXX™ (e.g., 2330, 6202, and 6102) (propylene-ethylene copolymer plastomers) from ExxonMobil Chemical Co., Houston, Texas; under the name FINA™ (e.g., 8573) from Atofina Chemicals, Feluy, Belgium; under the name TAFMER™ from Mitsui Petrochemical Industries; and under the name VERSIFY™ from DowChemical Co., Midland, Michigan. Other examples of suitable propylene polymers are described in U.S. Patent No. 6,500,563 to Datta et al., U.S. Patent No. 5,539,056 to Yang et al., and U.S. Patent No. 5,596,052 to Resconi et al., the entire contents of which are incorporated herein by reference for all purposes.

[0072] Any of a variety of known techniques can generally be used to form semi-crystalline polyolefins. For example, olefin polymers can be formed using radical or coordination catalysts (e.g., Ziegler-Natta). Preferably, the olefin polymer is formed by a single-center coordination catalyst such as a metallocene catalyst. Such catalyst systems produce ethylene copolymers in which the comonomers are randomly distributed within the molecular chain but uniformly distributed in portions of different molecular weights. Metallocene-catalyzed polyolefins are described, for example, in U.S. Patent Nos. 5,571,619 to McAlpin et al., 5,322,728 to Davis et al., 5,472,775 to Obijeski et al., 5,272,236 to Lai et al., and 6,090,325 to Wheat et al., the entire contents of which are incorporated herein by reference for all purposes. Examples of metallocene catalysts include bis(n-butylcyclopentadienyl)titanium chloride, bis(n-butylcyclopentadienyl)zirconia chloride, bis(cyclopentadienyl)scandium chloride, bis(indenyl)zirconia chloride, bis(methylcyclopentadienyl)titanium chloride, bis(methylcyclopentadienyl)zirconia chloride, cobalt diacene, cyclopentadienyl titanium trichloride, ferrocene, hafnium dichlorocene, isopropyl(cyclopentadienyl-1-fluorenyl)zirconia chloride, molybdenum dichlorocene, nickel dichlorocene, silver dichlorocene, ruthenium dichlorocene, titanium dichlorocene, zirconium hydride, zirconium dichlorocene, etc. Polymers prepared using metallocene catalysts typically have a narrow molecular weight range. For example, metallocene-catalyzed polymers can have polydispersity values ​​below 4 (M). w / M n), controlled short-chain branching distribution and controlled isotactic regularity.

[0073] The melt flow index (MI) of semi-crystalline polyolefins can vary, but is generally in the range of about 0.1 g / 10 min to about 100 g / 10 min, in some embodiments from about 0.5 g / 10 min to about 30 g / 10 min, and in some embodiments from about 1 to about 10 g / 10 min, these values ​​being determined at 190°C. The melt flow index is the weight (in grams) of polymer forced through the orifice (0.0825 inch diameter) of an extruder rheometer when subjected to 5000 g of force over 10 minutes at 190°C and can be determined according to ASTM test method D1238-E.

[0074] Of course, other thermoplastic polymers can also be used to form nonwoven web materials. For example, substantially amorphous block copolymers can be used, said copolymers having at least two monoalkenyl aromatic polymer blocks separated by at least one saturated conjugated diene polymer block. The monoalkenyl aromatic blocks can include styrene and its analogues and homologues, such as o-methylstyrene, p-methylstyrene, p-tert-butylstyrene, 1,3-dimethylstyrene, p-methylstyrene, etc., and other monoalkenyl polycyclic aromatic compounds, such as vinylnaphthalene, vinylanthracene, etc. Preferred monovinyl aromatics are styrene and p-methylstyrene. The conjugated diene blocks can include: homopolymers of conjugated diene monomers, copolymers of two or more conjugated dienes, and copolymers of one or more dienes with another monomer, wherein the blocks are primarily conjugated diene units. Preferably, the conjugated diene contains 4 to 8 carbon atoms, such as 1,3-butadiene (butadiene), 2-methyl-1,3-butadiene, isoprene, 2,3-dimethyl-1,3-butadiene, 1,3-pentadiene (pentadiene), 1,3-hexadiene, etc.

[0075] The amount of monoalkenyl aromatic (e.g., polystyrene) blocks can vary, but typically comprises about 8% to about 55% by weight of the copolymer, about 10% to about 35% by weight in some embodiments, and about 25% to about 35% by weight in some embodiments. Suitable block copolymers may comprise monoalkenyl aromatic terminal blocks with a number average molecular weight of about 5,000 to about 35,000 and saturated conjugated diene intermediate blocks with a number average molecular weight of about 20,000 to about 170,000. The total total molecular weight of the block polymers may be about 30,000 to about 250,000.

[0076] Particularly suitable thermoplastic elastomer block copolymers are available under the trade name KRATON™ from Kraton Polymers LLC, Houston, Texas. KRATON™ polymers include styrene-diene block copolymers such as styrene-butadiene, styrene-isoprene, styrene-butadiene-styrene, and styrene-isoprene-styrene. KRATON™ polymers also include styrene-olefin block copolymers formed by the selective hydrogenation of styrene-diene block copolymers. Examples of such styrene-olefin block copolymers include styrene-(ethylene-butene), styrene-(ethylene-propylene), styrene-(ethylene-butene)-styrene, styrene-(ethylene-propylene)-styrene, styrene-(ethylene-butene)-styrene-(ethylene-butene), styrene-(ethylene-propylene)-styrene-(ethylene-propylene), and styrene-ethylene-(ethylene-propylene)-styrene. These block copolymers can have linear, radial, or star molecular configurations. Specific KRATON™ block copolymers include those marketed under the trade names G 1652, G 1657, G 1730, MD6673, MD6703, MD6716, and MD6973. Various suitable styrene block copolymers are described in U.S. Patent Nos. 4,663,220, 4,323,534, 4,834,738, 5,093,422, and 5,304,599, the entire contents of which are incorporated herein by reference for all purposes. Other commercially available block copolymers include S-EP-S and SEEPS elastomer copolymers available under the trade name SEPTON™ from Kuraray Company, Ltd., Okayama, Japan. Other suitable copolymers include SIS and SBS elastomer copolymers available under the trade name VECTOR™ from Dexco Polymers, Houston, Texas. Another suitable polymer is that which is composed of ABAB tetrablock copolymers, such as those discussed in U.S. Patent No. 5,332,613 to Taylor et al., the entire contents of which are incorporated herein by reference for all purposes. An example of such a tetrablock copolymer is a styrene-poly(ethylene-propylene)-styrene-poly(ethylene-propylene) (“S-EP-S-EP”) block copolymer.

[0077] The single polymers discussed above can be used to form fibers constituting the nonwoven web material, and when used, can be used in amounts up to 100% by weight of the total weight of the nonwoven web material, such as about 75% to about 99% by weight, such as about 80% to about 98% by weight, such as about 85% to about 95% by weight. However, in other embodiments, the nonwoven web material may comprise two or more polymers derived from the polymers discussed above. For example, the single-component fibers forming the nonwoven web material may comprise fibers formed from olefin homopolymers in amounts ranging from about 5% to about 80% by weight, such as about 10% to about 75% by weight, such as about 15% to about 70% by weight, based on the total weight of the nonwoven web material. The fibers may also comprise derivatives of the olefin polymer. For example, the nonwoven web material may contain amounts of elastomeric semi-crystalline polyolefins or "plastics" (e.g., ethylene / α-olefin copolymers, propylene / α-olefin copolymers, or combinations thereof), thermoplastic elastomer block copolymers, or combinations thereof, in the range of about 20% to about 95% by weight, such as about 25% to about 90% by weight, such as about 30% to about 85% by weight, based on the total weight of the nonwoven web material.

[0078] In another embodiment, the fibers forming the nonwoven web material can be multi-component and can have a core-sheath arrangement or a side-by-side arrangement. For example, in a core-sheath multi-component fiber arrangement, the sheath can comprise polypropylene and a polypropylene-based plasmon (e.g., VISTAMAXX). TM The blend may contain polyethylene and polyethylene-based plastics (e.g., INFUSE). TM ) blends. On the other hand, the skin may comprise polyethylene and polyethylene-based plastics (e.g., INFUSE). TM The core may comprise a blend of polypropylene and a polypropylene-based plasmon (e.g., VISTAMAXX). TM The core may comprise a blend of polyethylene or polypropylene homopolymer. Alternatively, in other embodiments, the core may comprise 100% polyethylene or polypropylene homopolymer.

[0079] For example, in some embodiments, the fibers forming the nonwoven web material may have a core-sheath arrangement, wherein the core-sheath may contain, by weight of the core-sheath component of the multicomponent fiber, from about 20 wt.% to about 90 wt.%, such as from about 25 wt.% to about 80 wt.%, such as from about 30 wt.% to about 70 wt.% of an olefin homopolymer (e.g., polypropylene or polyethylene). Simultaneously, the core-sheath may also contain, by weight of the core-sheath component of the multicomponent fiber, from about 10 wt% to about 80 wt%, such as from about 20 wt% to about 75 wt%, such as from about 30 wt% to about 70 wt% of an olefin-based plastide (e.g., a polypropylene-based plastide or an ethylene-based plastide).

[0080] In addition, the core of the multi-component fiber may contain, by weight, about 30% to about 100% of, such as about 40% to about 95% of, or such as about 50% to about 90% of, an olefin homopolymer (e.g., polypropylene or polyethylene). Furthermore, the core of the fiber may contain, by weight, about 0% to about 70% of, such as about 5% to about 60% of, or such as about 10% to about 50% of, an olefin-based plasticizer (e.g., a polypropylene-based plasticizer or an ethylene-based plasticizer).

[0081] Furthermore, the weight percentage of the sheath, based on the total weight of the fibers, can range from about 10% to about 70% by weight, such as from about 15% to about 65% by weight, such as from about 20% to about 60% by weight. Meanwhile, the weight percentage of the core, based on the total weight of the fibers, can range from about 30% to about 90% by weight, such as from about 35% to about 85% by weight, such as from about 40% to about 80% by weight.

[0082] Furthermore, the fibers forming the nonwoven web material can be arranged side-by-side, with two fibers co-extruded adjacent to each other. In such an embodiment, the first side may comprise polyethylene and a polyethylene-based plastic body, while the second side may comprise polypropylene and a polypropylene-based plastic body. The polyethylene may be present in the first side in an amount ranging from about 30% to about 90% by weight, such as from about 35% to about 80% by weight, or such as from about 40% to about 70% by weight, based on the total weight of the first side. Simultaneously, the polyethylene-based plastic body may be present in the first side in an amount ranging from about 20% to about 80% by weight, such as from about 25% to about 70% by weight, or such as from about 30% to about 60% by weight, based on the total weight of the first side. Furthermore, the polypropylene may be present in the second side in an amount ranging from about 30% to about 90% by weight, such as from about 35% to about 80% by weight, or such as from about 40% to about 70% by weight, based on the total weight of the second side. Meanwhile, the polypropylene-based plastic body may be present in the second side in an amount ranging from about 20% to about 80% by weight, such as from about 25% to about 70% by weight, such as from about 30% to about 60% by weight, based on the total weight of the second side.

[0083] For fiber configurations such as those discussed above, in some embodiments, the propylene-ethylene copolymer can be used in the skin and / or core, or on the first and / or second sides, to act as a compatibilizer and enhance the bond between the skin and the core. For example, the propylene-ethylene copolymer may be present in the skin in an amount ranging from about 0.5 wt% to about 20 wt%, such as from about 1 wt% to about 15 wt%, such as from about 2 wt% to about 10 wt%, based on the total weight of the skin. Alternatively, the propylene-ethylene copolymer may be present in the core in an amount ranging from about 0.5 wt% to about 20 wt%, such as from about 1 wt% to about 15 wt%, such as from about 2 wt% to about 10 wt%, based on the total weight of the core.

[0084] Other additives can also be incorporated into nonwoven materials, such as melt stabilizers, processing stabilizers, heat stabilizers, light stabilizers, antioxidants, heat aging stabilizers, brighteners, anti-caking agents, and viscosity modifiers. Viscosity modifiers, such as polyethylene wax (e.g., EPOLENE™ C-10 from Eastman Chemical), can also be used. Phosphite stabilizers (e.g., IRGAFOS from Ciba Specialty Chemicals, Tarrytown, NY, and DOVERPHOS from Dover Chemical Corp., Dover, Ohio) are exemplary melt stabilizers. Furthermore, hindered amine stabilizers (e.g., CHIMASSORB from Ciba Specialty Chemicals) are exemplary heat and light stabilizers. Additionally, hindered phenols are commonly used as antioxidants in membrane manufacturing. Some suitable hindered phenols include those traded under the name IRAGAANOX. TM Such as IRGANOX TM Those 1076, 1010, or E 201 are derived from Ciba Specialty Chemicals. When used, such additives (e.g., antioxidants, stabilizers, etc.) may each be present in amounts from about 0.001% to about 25% by weight of the nonwoven material, from about 0.005% to about 20% by weight in some embodiments, and from 0.01% to about 15% by weight in some embodiments.

[0085] The polymers discussed above, along with other optional additive components, can form monocomponent or multicomponent fibers, and can be extruded or spun to form the nonwoven web material of the present invention, which can then be used in various products, such as wipes, absorbent articles, wearable articles, etc., and will be discussed in more detail below. Monocomponent fibers can be formed from a single polymer or polymer blend and optional tackifier, which are compounded and then extruded from a single extruder. Meanwhile, multicomponent fibers can be formed from two or more polymers extruded from a separate extruder (e.g., bicomponent fibers), wherein one or more of the polymers can be compounded with a tackifier, but this is not necessary when one of the polymers exhibits inherent adhesiveness, such as VISTAMAXX. TM Polymers and INFUSE TM Polymers. Polymers can be arranged in different zones that are substantially constant throughout the cross-section of the fiber. The components can be arranged in any desired configuration, such as core-sheath type, side-by-side type, sandwich type, island type, three-island type, bullseye type, or various other arrangements known in the art, etc. Various methods for forming multicomponent fibers are described in U.S. Patent Nos. 4,789,592 to Taniguchi et al., 5,336,552 to Strack et al., 5,108,820 to Kaneko et al., 4,795,668 to Kruege et al., 5,382,400 to Pike et al., 5,336,552 to Strack et al., and 6,200,669 to Marmon et al., which are incorporated herein by reference in their entirety for all purposes. Multicomponent fibers with various irregular shapes can also be formed, as described in U.S. Patent Nos. 5,277,976 to Hogle et al., 5,162,074 to Hills, 5,466,410 to Hills, 5,069,970 to Largman et al., and 5,057,368 to Largman et al., the entire contents of which are incorporated herein by reference for all purposes. Furthermore, hollow fibers are also contemplated in this invention, and such fibers can reduce the amount of polymer required and reduce the basis weight of the resulting nonwoven web material.

[0086] In any case, regardless of whether the nonwoven web material is formed by meltblowing, spunbonding, or any other nonwoven web material technology, it should also be understood that, in some embodiments, the core may be a mixture of two or more polymers, such as polypropylene and VISTAMAXX, when tackifiers and / or any optional additives are mixed with one or more polymers. TMPlastic, while the skin can also be a mixture of two or more polymers, such as polyethylene and infusible polymers. TM Plastic body. Generally speaking, the composition of the core can be selected so that the resulting overall material is cloth-like, drapeable and soft, while the composition of the leather can be selected so that the leather provides the required level of adhesion to effectively remove dirt without subjecting the user to a slippery motion and without leaving residue.

[0087] Various embodiments for forming the fibrous and nonwoven web materials of the present invention will now be described in more detail. It should be understood, of course, that the description provided below is merely exemplary, and other methods for forming nonwoven web materials are contemplated in this disclosure. In particular, the nonwoven web material can be formed from meltblown fibers or by methods other than meltblowing, such as spunbonding. One advantage of forming nonwoven web materials by spunbonding is that polymers with higher molecular weights can be used compared to those used to form meltblown nonwoven web materials, because the size of the capillary die used in spunbonding equipment is larger than that in meltblowing equipment. However, it should also be understood that, for the formation of meltblown nonwoven web materials, the size of the capillary of the meltblown die can be increased to accommodate high viscosity (e.g., high molecular weight). However, generally speaking, when subjected to a load of 2160 g at 190°C according to ASTM test method D1238-E, the melt flow rate of the polymers of the present invention can range from about 3 g / 10 min to about 50 g / 10 min. Thus, polymers with high viscosity and crystallinity can be used when forming spunbond nonwoven web materials. For example, polypropylene having a melt flow rate from about 15 g / 10 min to about 50 g / 10 min, such as from about 20 g / 10 min to about 35 g / 10 min, can be used; olefin block copolymer plastomers having a melt flow rate from about 3 g / 10 min to about 20 g / 10 min, such as from about 10 g / 10 min to about 15 g / 10 min, can be used; and polyethylene having a melt flow rate from about 5 g / 10 min to about 30 g / 10 min, such as from about 10 g / 10 min to about 25 g / 10 min, can be used.

[0088] If desired, the nonwoven web material may have a multilayer structure. Suitable multilayer materials may include, for example, spunbond / meltblown / spunbond (SMS) laminates and spunbond / meltblown (SM) laminates, wherein spunbond and meltblown layers are typically formed as described above. However, in one aspect, this disclosure includes nonwoven webs and / or substrates free of SMS laminates. In particular, as mentioned above, the nonwoven web according to this disclosure may be modified to have the property of introducing the nonwoven web through adhered short fibers, thus eliminating the need for any of the conventional benefits associated with SMS laminates.

[0089] Another example of the nonwoven web material envisioned in this invention is a spunbond web produced on a multiple spin bankmachine, where the spin bank deposits fibers onto a layer of fibers deposited by previous spin banks. Such a single spunbond nonwoven web can also be considered a multilayer structure. In this case, the various layers of deposited fibers in the nonwoven web can be identical, or they can differ in basis weight and / or composition, type, size, crimp level, and / or the shape of the produced fibers. Furthermore, a single nonwoven web can be provided as two or more separately produced layers of spunbond webs, carded webs, etc., which are bonded together to form the nonwoven web. These separately produced layers can differ in production method, basis weight, composition, and fibers.

[0090] The nonwoven web material envisioned in this invention may also contain additional fiber components, making it a composite. For example, a variety of entanglement techniques known in the art (e.g., hydraulic, air, mechanical, etc.) can be used to entangle the nonwoven web with another fiber component. In one embodiment, a nonwoven web formed of a polymer can be integrally entangled with fibers containing another polymer using a hydraulic entanglement method. Typical hydraulic entanglement processes utilize high-pressure jets of water to entangle fibers to form a highly entangled, consolidated fiber structure, such as a nonwoven web. Hydraulically entangled nonwoven webs, for example, are used in... Evans U.S. Patent No. 3,494,821 and granted Boulton The contents of U.S. Patent No. 4,144,370, which are incorporated herein by reference in their entirety for all purposes, are disclosed herein. The fibrous component of the composite may constitute any desired amount of the resulting composite. For example, the fibrous component may constitute more than about 50% by weight of the composite, and in some embodiments from about 60% by weight to about 90% by weight. Similarly, the nonwoven web may constitute less than about 50% by weight of the composite, and in some embodiments from about 10% by weight to about 40% by weight. In some embodiments, the nonwoven web may comprise a polyolefin-based spunbond web (e.g., polypropylene or polyethylene), while the fibrous component may comprise fibers containing a blend of polypropylene and VISTAMAXX. TM Or any other blend of propylene-based plasmons, or polyethylene and infusible compounds. TM Or any other suitable blend of ethylene-based plastics.

[0091] Spunlace nonwoven materials are also possible. Spunlace nonwovens are disclosed, for example, in U.S. Patent No. 7,779,521 to Topolkaraev et al. In spunlace, layers of fibers are deposited on a perforated support. The perforated support is typically a continuous web, sometimes referred to as a shaped fabric. Shaped fabrics are commonly used in the nonwovens industry, and those skilled in the art will recognize specific types advantageous for spunlace purposes. Alternatively, the perforated support can be the surface of a cylinder, and can generally be any surface that supports the fibers and transports them under a water jet or water curtain that imparts energy to entangle the fibers. Innovent Inc. of Peabody, Mass., USA, Rieter Perfojetand, and Fleissner, mentioned above, sell screens and cylinders suitable for said purposes.

[0092] Typically, perforated supports have holes that allow drainage, but alternatively or additionally, perforated supports may have raised sections or grooves to allow drainage and impart morphological features to the finished fabric. In this context, "water" refers to a fluid that is primarily water but may contain intentional or unintentional additives, including minerals, surfactants, defoamers, and various processing aids.

[0093] When fibers are deposited on a support, they can be completely unbonded; alternatively, the fibers can be slightly bonded as a nonwoven fabric when deposited on a porous support. In other aspects of the invention, unbonded fibers can be deposited on the support, and the fibers can be slightly bonded by heat or other means before hydroentangling. It is generally desirable that the fibers passing under the water jet have sufficient mobility for effective hydroentangling.

[0094] The general conditions for hydroentangling, namely water pressure, nozzle type, and the design of perforated supports, are well known to those skilled in the art. "Hydroentangling" and its derivatives refer to the process of forming fabrics by mechanically wrapping and entangled fibers into a web using a high-speed jet or curtain of water. The resulting hydroentangled fabrics are sometimes referred to in the literature as "spunlace fabric" or "waterwoven fabric."

[0095] Generally, a high-pressure water system delivers water to nozzles or orifices from which high-speed water is discharged. The fiber layer is transferred through at least one high-speed water jet or curtain on a perforated support member. Alternatively, more than one water jet or curtain may be used. The direct impact of the water on the fibers causes them to entangle and twist, forming knots around nearby fibers. Additionally, some water may bounce off the perforated support member, and this bounced water also contributes to the entanglement. The water used for hydroentangling is then typically drained into a manifold from below the support member and is usually recirculated. As a result of the hydroentangling process, the fibers are transformed into a coherent fabric.

[0096] Regardless of the type of nonwoven web material formed, the basis weight of the nonwoven web material can typically vary, such as from about 10 grams per square meter (“gsm”) to about 150 gsm, in some embodiments from about 20 gsm to about 125 gsm, and in some embodiments from about 25 gsm to about 100 gsm. When multiple nonwoven web materials are used, such materials may have the same or different basis weights.

[0097] Furthermore, this disclosure typically includes methods for forming a substrate according to this disclosure. For example, see reference to... Figure 3 The nonwoven web 202, formed using the aforementioned materials or similar materials according to any method known in the art, can be unrolled from the first roller 204. The nonwoven web 202 can undergo various processes known in the art, including embossing (not shown), and has an adhesive 206 applied thereto. Figure 3 As shown in the present disclosure, it has been found that an adhesive can be applied online using a flexographic printing press 208. However, it should be understood that other application methods can be used in some aspects. Nevertheless, a nonwoven web 202 with an adhesive 206 applied thereto enters an electroplating apparatus 210 containing short fibers treated with cationic polymers. As is known in the art, the electroplating module 210 includes electrodes and an electrolyte, such that multiple short fibers are electroplated or deposited onto the anionic adhesive 206. Finally, in one aspect, the nonwoven web 202 containing the electroplated fibers 210 can be calendered 212 to further improve fiber adhesion before being wound onto a roller 214 as a substrate according to the present disclosure.

[0098] Once meltblown nonwoven fabric, spunbond nonwoven fabric, or any other nonwoven fabric is formed, and before or after electroplating and / or calendering, the nonwoven fabric can be further processed to reduce fuzz left when using the nonwoven fabric, minimize the amount of residue or streaks on the surface after contact with the nonwoven fabric, and improve the dust retention capacity of the nonwoven fabric.

[0099] For example, as discussed above, nonwoven web materials can be perforated, bonded post-processed, or both. Perforation can improve the dust retention capacity of nonwoven web materials by forming pockets within them that can trap particles, dust, pathogens, etc. Perforation can be performed by any suitable method known to those skilled in the art, such as laser perforation, slot perforation, needle perforation, or thermal perforation using patterned rollers.

[0100] Simultaneously, post-bonding can reduce fuzzing in nonwoven materials and improve dust retention capacity by forming indentations that trap particles, dust, pathogens, etc. While not strictly necessary, the processes of forming pores and bonding in the nonwoven material can be performed simultaneously. However, it should be understood that other methods of forming pores and bonding, as known to those skilled in the art, can also be used without simultaneous execution.

[0101] To simultaneously create pores and texture elements on a nonwoven web material, patterned bonding techniques (e.g., hot spot bonding, ultrasonic bonding, etc.) are typically used, in which the nonwoven web material is fed into a roll gap defined by at least one patterning roller. Hot spot bonding typically employs a roll gap formed between two rollers, at least one of which is patterned. Ultrasonic bonding, on the other hand, typically employs a gap formed between an ultrasonic amplitude transformer and a patterning roller. Regardless of the chosen technique, the patterning roller includes multiple raised bonding elements to simultaneously bond the nonwoven web material and create pores within it.

[0102] The size of the bonding element can be specifically customized to facilitate the formation of pores in the nonwoven web material and enhance the bonding between the fibers contained in the nonwoven web material. For example, the length dimension of the bonding element can be from about 300 to about 5000 micrometers, in some embodiments from about 500 to about 4000 micrometers, and in some embodiments from about 1000 to about 2000 micrometers. The width dimension of the bonding element can also be in the range of about 20 to about 500 micrometers, in some embodiments from about 40 to about 200 micrometers, and in some embodiments from about 50 to about 150 micrometers. In addition, the "element aspect ratio" (the ratio of the length of the element to its width) can be in the range of about 2 to about 100, in some embodiments from about 4 to about 50, and in some embodiments from about 5 to about 20.

[0103] In addition to the dimensions of the bonding elements, the overall bonding pattern can also be selectively controlled to achieve the desired hole formation. In one embodiment, for example, a bonding pattern is selected in which the longitudinal axis (the longest dimension along the centerline of the element) of one or more of the bonding elements is skewed relative to the machine orientation (“MD”) of the nonwoven web material. For example, one or more of the bonding elements may be oriented relative to the machine orientation of the nonwoven web material at an angle ranging from about 30° to about 150°, in some embodiments from about 45° to about 135°, and in some embodiments from about 60° to about 120°. This results in the bonding elements presenting a relatively large surface area to the nonwoven web material in a direction substantially perpendicular to the direction of movement of the nonwoven web material. This increases the area where shear forces are applied to the nonwoven web material and thus facilitates hole formation.

[0104] The pattern of the bonding elements is typically chosen such that the nonwoven web material has less than about 50% (as measured by conventional optical microscopy methods), less than about 40% in some embodiments, and less than about 25% of the total bonded area in some embodiments. The bonding density is also typically greater than about 50 bonds per square inch and, in some embodiments, from about 75 to about 500 needle bonds per square inch. A suitable bonding pattern used in this invention is called an “S-shaped braid” pattern and is described in U.S. Patent No. 5,964,742 to McCormack et al., the entire contents of which are incorporated herein by reference for all purposes. The S-shaped braid pattern typically has a bonding element density from about 50 to about 500 bonding elements per square inch and, in some embodiments, from about 75 to about 150 bonding elements per square inch. An example of a suitable “S-shaped braid” pattern is shown in Figure 9, which illustrates an S-shaped bonding element 88 having a length dimension “L” and a width dimension “W”. Another suitable bonding pattern is called a "rib knit" pattern and is described in U.S. Patent No. 5,620,779 to Levy et al., the entire contents of which are incorporated herein by reference for all purposes. Rib knit patterns typically have a bonding element density of from about 150 to about 400 bonding elements per square inch, and in some embodiments from about 200 to about 300 bonding elements per square inch. An example of a suitable "rib knit" pattern is shown in Figure 10, which illustrates bonding elements 89 and 91 oriented in different directions. Yet another suitable pattern is a "yarn braid" pattern, which has a bonding element density of from about 200 to about 500 bonding elements per square inch, and in some embodiments from about 250 to about 350 bonding elements per square inch. An example of a suitable "yarn braid" pattern is shown in Figure 11, which illustrates bonding elements 93 and 95 oriented in different directions. Other adhesive patterns that can be used in this invention are described in U.S. Patent No. 3,855,046 to Hansen et al., U.S. Patent No. 5,962,112 to Haynes et al., U.S. Patent No. 6,093,665 to Sayovitz et al., U.S. Patent No. D375,844 to Edwards et al., U.S. Patent No. D428,267 to Romano et al., and U.S. Patent No. D390,708 to Brown, the entire contents of which are incorporated herein by reference for all purposes.

[0105] Choosing an appropriate bonding temperature (e.g., the temperature of the heated roller) will help melt and soften the nonwoven material in the area adjacent to the bonding element. The softened nonwoven material can then flow and displace during the bonding process, such as by the pressure applied by the bonding element.

[0106] To achieve simultaneous pore formation and bonding without significantly softening the polymer of the nonwoven fabric material, bonding temperature and pressure can be selectively controlled. For example, one or more rollers can be heated to surface temperatures of about 50°C to about 160°C, about 60°C to about 140°C in some embodiments, and about 70°C to about 120°C in some embodiments. Similarly, the pressure applied by the rollers during thermal bonding (“roll gap pressure”) can range from about 75 to about 600 pounds per linear inch (about 1339 to about 10,715 kg per meter) in some embodiments, from about 100 to about 400 pounds per linear inch (about 1786 to about 7143 kg per meter) in some embodiments, and from about 120 to about 200 pounds per linear inch (about 2143 to about 3572 kg per meter) in some embodiments. Of course, the residence time of the material can affect the specific bonding parameters employed.

[0107] Another factor affecting the simultaneous formation of pores and bonding is the tension in the nonwoven web material. An increase in tension in the nonwoven web material as it passes over the bonding element is typically associated with an increase in pore size, for example. Of course, excessive tension can adversely affect the integrity of the nonwoven web material, which may negatively impact the ability to form a fabric with sufficient adhesion and minimal fuzzing. Therefore, in most embodiments of the invention, a draw ratio of about 1.5 or higher, in some embodiments from about 2.5 to about 7.0, and in some embodiments from about 3.0 to about 5.5 is used to achieve the desired tension in the film during lamination. The draw ratio can be determined by dividing the final length of the film by its original length.

[0108] Generally, the size and / or pattern of the holes obtained in the nonwoven mesh material corresponds to the size and / or pattern of the aforementioned adhesive elements. That is, the holes can have the length, width, aspect ratio, and orientation described above. For example, the length dimension of the hole can be from about 200 to about 5000 micrometers, in some embodiments from about 350 to about 4000 micrometers, and in some embodiments from about 500 to about 2500 micrometers. Similarly, the width dimension of the hole can be in the range from about 20 to about 500 micrometers, in some embodiments from about 40 to about 200 micrometers, and in some embodiments from about 50 to about 150 micrometers. Furthermore, the aspect ratio (the ratio of the length of the hole to its width) can be in the range from about 2 to about 100, in some embodiments from about 4 to about 50, and in some embodiments from about 5 to about 20. Similarly, one or more longitudinal axes (the longest dimension along the centerline of the hole) in the hole may be skewed relative to the machine orientation of the nonwoven fabric material, such as from about 30° to about 150° relative to the machine orientation of the nonwoven fabric material, from about 45° to about 135° in some embodiments, and from about 60° to about 120° in some embodiments.

[0109] Furthermore, certain aspects of this disclosure can be better understood through the following embodiments, which are intended to be non-limiting and exemplary in nature.

[0110] Example:

[0111] Cupping: The softness of nonwoven fabrics can be measured using the "cupping" test. The cupping test evaluates fabric stiffness by measuring the peak load (also known as "cupping load" or simply "cupping") required to crush a 23 cm × 23 cm fabric sheet into an inverted cup approximately 6.5 cm in diameter × 6.5 cm high using a hemispherical presser foot with a 4.5 cm diameter, while the cupped fabric is surrounded by a cylinder of approximately 6.5 cm diameter to maintain uniform deformation. The average of 10 readings is used. The presser foot and cup are aligned to avoid contact between the cup wall and the presser foot, which would affect the readings. The peak load is measured as the presser foot descends at a rate of approximately 0.25 inches / second (380 mm / min) and is measured in grams. The cupping test also produces a value for the total energy required to crush the sample ("cupping energy"), which is the energy from the start of the test to the peak loading point, i.e., the area under the curve formed by the load in grams on one axis and the distance the presser foot moves in millimeters on the other axis. Therefore, cupping energy is reported in gm-mm. Lower cupping values ​​indicate a softer layer. A suitable device for measuring cupping values ​​is the FTD-G-500 force sensor (500 g range), available from Schaevitz Company, Pennsauken, NJ.

[0112] Example 1

[0113] A spunbond / spunbond nonwoven web with a basis weight of approximately 23 gsm and barrier properties is formed. A water-based adhesive treated with an anionic reagent provided by Agatex is applied to the nonwoven web in a thickness of 100 micrometers by flexographic printing. Short polyethylene fibers with a denier of approximately 1.5 and a length of 500 micrometers, treated with cationic reagent provided by Agatex, are then adhered to the nonwoven web using the aforementioned electroplating equipment to form a substrate. The substrate exhibits improved flexibility while maintaining good barrier properties. For example, after attaching the short fibers, the substrate exhibits a bacterial filtration efficiency of 98.2% as measured according to Annex B of UNE-EN 14683:2019, an air permeability of 14.1 Pa / cm² as measured according to Annex C of UNE-EN 14683:2019, and a splash resistance of less than 10.6 kPa as measured according to ISO 22609:2004 ASTM F1862.

[0114] Example 2

[0115] A polypropylene nonwoven web co-molded with pulp fibers and having a basis weight of approximately 82 gsm was prepared. A water-based adhesive treated with anionic reagents provided by Agatex was applied to the nonwoven web at a thickness of 100 micrometers via flexographic printing. Polyethylene short fibers with a denier of approximately 1.5 and a length of 500 micrometers were treated with cationic reagents provided by Agatex and adhered to the nonwoven web using the aforementioned electroplating equipment, thereby forming a substrate of 150 gsm, which exhibited 15% improved abrasion resistance compared to the same nonwoven web without multiple short fibers.

[0116] These and other modifications and variations of the invention can be practiced by those skilled in the art without departing from the spirit and scope of the invention as more specifically described in the appended claims. Furthermore, it should be understood that aspects of each figure may be interchanged, in whole or in part. Moreover, those skilled in the art will recognize that the above description is merely illustrative and is not intended to limit the invention further described in the appended claims.

Claims

1. A substrate having a microstructured topography comprising: a nonwoven web comprising a first surface and an opposing second surface, wherein the nonwoven web extends in a first plane; an adhesive; and a first plurality of staple fibers attached to the first surface of the nonwoven web by the adhesive, wherein at least a portion of the first plurality of staple fibers extends in one or more second planes, wherein the one or more second planes are not parallel to the first plane, and wherein at least a portion of the staple fibers have a length of 5000 microns or less, a denier of 5 or less, or a combination thereof; and wherein the nonwoven web has: a water capacity of 200% to 800% measured as an increase in weight of the nonwoven web due to absorbed water, a pressure cup load of less than 100 grams when measured using a 34 gsm nonwoven web, a bacterial filtration efficiency of 80% or more, or a combination thereof.

2. The substrate of claim 1, wherein the substrate is a wiping product or an absorbent article.

3. The substrate of claim 1 or 2, wherein at least a portion of the staple fibers have a length of 1500 microns or less and a denier of 3 or less.

4. The substrate of claim 1 or 2, wherein at least a portion of the staple fibers have a length of 1500 microns to 5000 microns and a denier of 3 to 5.

5. The substrate of claim 1 or 2, wherein the nonwoven web comprises elastomeric fibers, decorticated cellulose fibers, pulp fibers, or a mixture thereof.

6. The substrate of claim 1 or 2, wherein the nonwoven web comprises polyethylene fibers, pulp fibers, or a combination thereof.

7. The substrate of claim 1 or 2, wherein the nonwoven web is a spunbond nonwoven web.

8. The substrate of claim 1 or 2, wherein the first plurality of staple fibers comprises polyethylene fibers, polypropylene fibers, rayon fibers, nylon fibers, or a combination thereof.

9. The substrate of claim 1 or 2, wherein the adhesive comprises an anionic component, the first plurality of staple fibers comprises a cationic component, or a combination thereof.

10. The substrate of claim 9, wherein the adhesive is coated on at least a portion of the nonwoven web.

11. The substrate of claim 10, wherein the adhesive is coated on 50% or more of the nonwoven web.

12. The substrate of claim 10, wherein the adhesive is applied on the nonwoven web in a pattern comprising a circle, a square, a line, or a combination thereof.

13. The substrate of claim 1 or 2, wherein nonwoven web is embossed.

14. The substrate of claim 1 or 2, further comprising a second plurality of staple fibers adhered to the second surface of the nonwoven web by an adhesive.

15. The substrate of claim 14, wherein the second plurality of staple fibers has a different length or denier than the first plurality of staple fibers.

16. The substrate of claim 1, wherein the substrate exhibits 10% or greater improvement in one or more of water capacity, pressure cup load, or bacterial filtration compared to the same nonwoven web excluding the first plurality of short fibers.

17. A method for forming a substrate, comprising: A nonwoven web extending in the first plane is formed; Apply the adhesive to the first surface of the nonwoven web; and The first plurality of short fibers are adhered to the nonwoven web. At least a portion of the first plurality of short fibers extends in one or more second planes. The one or more second planes are not parallel to the first plane, and At least a portion of the said short fibers has a length of 5000 micrometers or less, a denier of 5 or less, or a combination thereof; and The nonwoven web described herein has: The water capacity is 200% to 800%, measured as the increase in the weight of the nonwoven web due to the absorbed water. When measuring with a 34 gsm nonwoven fabric, the pressure cup load is less than 100 grams. 80% or higher bacterial filtration efficiency, or Their combination.

18. The method of claim 17, wherein the adhesive comprises an anionic component, and wherein the adhesive is printed onto the nonwoven web.

19. The method of claim 18, wherein the adhesive is printed onto the nonwoven web in a flexographic manner, and the first plurality of short fibers are electrostatically adhered to the nonwoven web.

20. The method of any one of claims 17 to 19, wherein the substrate is calendered.

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