Foam-shaped wiping product

Abstract

Nonwoven webs that are particularly suitable for use as wiping products are disclosed. The nonwoven web comprises cellulosic pulp fibers blended with synthetic polymer fibers that can be crimped. The web may be produced in a foam forming process that further includes spunlacing. The spunlace step may optionally produce a surface topography. The nonwoven web has an enhanced thickness and is well suited for cleaning grease and oil due to the open configuration.

Description

Background Technology

[0001] Household and industrial wipes are typically used to pick up and absorb both polar and non-polar liquids. Wipes should be constructed with sufficient absorbency to retain the liquid within the wipe's structure. Furthermore, wipes should possess good physical strength and abrasion resistance to withstand the tearing, tensile, and abrasive forces frequently applied during use.

[0002] Conventional wiping products (i.e., "wiping cloths") are made of woven and knitted fabrics. These wiping materials have been used in all different types of industries, such as for industrial applications, food service applications, health and medical applications, and for general consumer use.

[0003] In the past, nonwoven wipes were also made of sizing fibers alone or in combination with synthetic fibers. For example, spunbond webs made of continuous filaments were historically hydroentangled with sizing fibers to produce resilient wipes. In many cases, these webs were used for single-use applications and then discarded. Although these wipes had good strength and absorbency levels, they generally did not possess the same cleaning properties as woven and knitted fabrics, especially when wiping oils and greases.

[0004] In light of the above, there is a current need for disposable nonwoven wipes that possess cleaning properties similar to or superior to conventional textile wipes. In one aspect, there is a current need for disposable nonwoven wipes that are particularly well-suited for picking up and cleaning oils and greases. There is also a need for disposable nonwoven wipes that exhibit excellent cleaning properties at a lower basis weight than conventional textile wipes. Summary of the Invention

[0005] Generally, this disclosure relates to nonwoven fiber webs or substrates that are ideally suited for constructing wiping products and can possess at least one cleaning property that is the same as or better than that of conventional textile wipes. This disclosure also relates to nonwoven fiber webs or substrates configured to pick up and remove oil and grease from surfaces. Nonwoven fiber webs are particularly suitable for use as industrial wipes. While highly suitable for picking up oil and grease, wipes can also be used in a variety of other applications. In particular, wipes exhibit excellent absorption properties and good strength properties.

[0006] For example, in one embodiment, this disclosure relates to a wiping product comprising a nonwoven fiber web having a first surface and an opposing second surface. The nonwoven fiber web comprises cellulose pulp fibers blended with first short fibers and optionally second short fibers. The first and second short fibers may comprise synthetic polymer fibers. The first short fibers may have a size of about 0.3 denier to about 3 denier. When the second short fibers are present, the first short fibers may have a larger denier than the second short fibers. For example, the second short fibers may have a size of about 0.3 denier to about 1.2 denier, and the first short fibers may have a size of about 1.2 denier to about 3 denier. The cellulose pulp fibers comprise about 45% to about 70% by weight of the nonwoven fiber web. The first and second short fibers comprise about 30% to about 55% by weight of the nonwoven fiber web. The nonwoven fiber web may have a basis weight of about 40 gsm to about 120 gsm, such as about 50 gsm to about 70 gsm, such as about 60 gsm to about 70 gsm. In one respect, nonwoven fiber webs can have a basis weight of about 90 gsm to about 120 gsm.

[0007] In one aspect, the morphology pattern may be located on the surface of the nonwoven fiber web. At least a portion of the morphology pattern may include raised pattern elements extending from the substrate surface.

[0008] In one aspect, cellulose pulp fibers and short fibers constitute more than about 90% by weight, such as more than about 95% by weight, of all fibers contained in the nonwoven fiber web. In one specific embodiment, for example, all fibers contained in the nonwoven fiber web comprise cellulose pulp fibers, first short fibers, or second short fibers. In one aspect, the first and second short fibers may be present in the nonwoven fiber web in an amount from about 35% by weight to about 55% by weight, and the cellulose pulp fibers may be present in the nonwoven fiber web in an amount from about 45% by weight to about 65% by weight.

[0009] When a second staple fiber is present, the weight ratio between the first and second staple fibers can be from about 1:3 to about 3:1, such as from about 1.5:1 to about 1:1.5. The first and second staple fibers may comprise polyester. In one aspect, the first and / or second staple fibers may comprise crimped fibers. The first and / or second staple fibers may also comprise bicomponent fibers. The first and second staple fibers may independently have an average fiber length of from about 4 mm to about 25 mm, such as from about 6 mm to about 12 mm.

[0010] Cellulose pulp fibers may include wood fibers or non-wood fibers. In one aspect, cellulose pulp fibers include southern and / or northern softwood kraft paper fibers, hardwood fibers, or combinations thereof. Alternatively, at least some or all of the cellulose pulp fibers may include non-wood fibers.

[0011] In one aspect, the nonwoven fiber web includes a foam-formed fiber web. The foam-formed fiber web can be a non-layered, single-layer sheet fiber web. The foam-formed fiber web can have a volume of about 3 g / cc to about 20 g / cc. The substrate can exhibit a reinforced thickness per basis weight greater than about 0.009 mm / gsm, such as greater than about 0.010 mm / gsm, such as greater than about 0.011 mm / gsm. For example, at a basis weight of about 60 gsm to about 70 gsm, the thickness of the substrate can be greater than about 0.4 mm, such as greater than about 0.6 mm, such as greater than about 0.8 mm and less than about 3 mm.

[0012] In one aspect, the raised pattern elements of the pattern comprise non-interconnected discrete shapes. The basis weight of the nonwoven web in which the raised pattern elements are located may be greater than the basis weight of the nonwoven web in regions where the raised pattern elements are not present (e.g., the basis weight of the substrate surface). For example, the basis weight of the nonwoven web within the raised pattern elements may be greater than about 10%, such as greater than about 20%, such as greater than about 30%, such as greater than about 40%, of the basis weight of the nonwoven web in which the raised pattern elements are not present. In one aspect, the raised pattern elements comprise raised circular elements. The raised pattern elements may have a perimeter of about 0.5 mm to about 20 mm, such as about 0.75 mm to about 10 mm, such as about 1.5 mm to about 5 mm. In one embodiment, the morphological pattern of the nonwoven web may further include a contaminant retention area. The raised pattern elements may, for example, form raised pattern areas adjacent to the contaminant retention areas. The contaminant retention areas may be substantially planar and without raised pattern elements. In one aspect, the contaminant retention areas may comprise non-interconnected discrete areas or may comprise interconnected patterns.

[0013] The raised pattern element may have a height (measured from the substrate surface) greater than about 0.1 mm, such as greater than about 0.2 mm, such as greater than about 0.3 mm, such as greater than about 0.4 mm, such as greater than about 0.5 mm, such as greater than about 0.6 mm, and typically less than about 1.2 mm, such as less than about 1 mm, such as less than about 0.8 mm. The height of the raised pattern element can be measured under a pressure of 0.05 psi.

[0014] The wiping products disclosed herein can be manufactured, packaged, and sold in various forms. In one embodiment, the wiping product comprises individual sheets stacked together. The individual sheets can be folded together if desired. Alternatively, the wiping product may comprise a periodically perforated spiral winding roller. The wiping product may be dry or pre-saturated with a cleaning solvent. In one embodiment, the wiping product comprises industrial wiping materials.

[0015] Other features and aspects of this disclosure are discussed in more detail below. Attached Figure Description

[0016] The full and practical disclosure of this invention is set forth in more detail in the remainder of the specification, including with reference to the accompanying drawings, in which:

[0017] Figure 1 This is a perspective view of one embodiment of a nonwoven material manufactured according to this disclosure;

[0018] Figure 2 This is a schematic diagram of one embodiment of the process for forming nonwoven materials according to this disclosure;

[0019] Figure 3 yes Figure 2 An enlarged partial view of the illustrated schematic diagram; and

[0020] Figure 4 The following is a graph illustrating some of the results obtained in the examples below.

[0021] The repeated use of reference numerals in this specification and drawings is intended to indicate the same or similar features or elements of the invention.

[0022] definition

[0023] As used herein, the term "longitudinal" refers to the direction of travel of the shaped surface on which the fibers are deposited during the formation of the nonwoven fiber web.

[0024] As used in this article, the term "lateral" refers to a direction perpendicular to the longitudinal direction as defined above.

[0025] As used herein, the term "cellulose pulp fiber" 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, fine-stemmed needlegrass, milkweed, rice straw, jute, hemp, and bagasse. "Pulp fiber" refers to delignified cellulose fibers and may include hardwood fibers, softwood fibers, and mixtures thereof.

[0026] As used herein, the term "average fiber length" refers to the average length of fibers, fiber bundles, and / or fibrous materials determined by measurement using microscopic techniques. A sample of at least 20 randomly selected fibers was isolated from a fiber liquid suspension. The fibers were placed on a microscope slide prepared to suspend the fibers in water. A staining dye was added to the suspended fibers to color the cellulose-containing fibers, thereby distinguishing or separating them from synthetic fibers. The slide was placed under a Fisher Stereomaster II microscope—S 19642 / S 19643 series. Measurements were taken of the 20 fibers in the sample using a 0–20 mil scale at 20X linear magnification, and the average length, minimum and maximum length, and deviation or coefficient of variation were 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 by a device such as the Kajaani Fiber Analyzer FS-200, available from Kajaani Oy Electronics, Kajaani, Finland. According to the standard test procedure, the sample is treated with an impregnation solution to ensure the absence of fiber bundles or debris. Each sample is decomposed in hot water and diluted to a suspension of approximately 0.001%. When tested using the standard Kajaani fiber analysis test procedure, each test sample is drawn from the diluted suspension in portions of approximately 50 ml to 100 ml. 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:

[0027]

[0028] in

[0029] k = maximum fiber length

[0030] x i =Fiber length

[0031] n i = The number of fibers with length xi

[0032] n = the total number of fibers measured.

[0033] One characteristic of the average fiber length data measured by the Cajani fiber analyzer is that it does not distinguish between different types of fibers. Therefore, the average length represents the average length of all different types (if any) of fibers in the sample.

[0034] As used herein, the term "short fiber" refers to a discontinuous fiber made from synthetic polymers (such as polypropylene, polyester, post-consumer recycled (PCR) fibers, polyester, nylon, etc.) or cellulosic fibers (such as cotton fibers, bast fibers, regenerated cellulose fibers (e.g., viscose, rayon, etc.)). Short fibers can be diced fibers, etc. Short fibers can have cross-sections that are round, bicomponent, multicomponent, molded, hollow, etc.

[0035] As used herein, the term "nonwoven fiber web or material" refers to a fiber web having a single-fiber structure in which the fibers are interwoven, but not in a identifiable manner as in knitted or woven fabrics. Nonwoven materials include, for example, carded fiber webs, wet-laid fiber webs, air-laid fiber webs, foam-molded fiber webs, etc.

[0036] As used herein, the term "thickness" refers to the representative thickness of a single sheet measured using an EMVECO 200-A Microgage automated micrometer (EMVECO, Inc., Newberg, Oreg.) according to TAPPI test method T402. (The thickness of a sheet product comprising two or more layers is the thickness of a single sheet product comprising all layers.) The micrometer has an anvil diameter of 2.22 inches (56.4 mm) and an anvil pressure of 132 g / cm² (2.0 kPa) per 6.45 cm².

[0037] As used in this article, the term "sheet volume" refers to the quotient of thickness (usually in μm) divided by oven-dry basis weight (usually in gsm).

[0038] As used herein, “void volume” is the amount of space within a nonwoven material that is not occupied by solid materials such as fibers. In one respect, the void volume per surface area can be determined. The void volume can be determined under applied pressure, such as at 0.05 psi or 0.3 psi.

[0039] As used in this article, “height of raised pattern element” refers to the height of the pattern element above the substrate surface of the nonwoven material. The height of the raised pattern element is measured at 0.05 psi. Detailed Implementation

[0040] Those skilled in the art will understand that this discussion is merely a description of exemplary embodiments and is not intended to limit the broader aspects of this disclosure.

[0041] Generally speaking, this disclosure relates to nonwoven fiber webs that are particularly suitable for use as wiping materials. The nonwoven fiber webs not only possess excellent absorbency but also exhibit superior cleaning properties relative to grease and oil. In fact, the nonwoven fiber webs of this disclosure can clean grease and oil from adjacent surfaces as well as conventional textile wipes, but with a much lower basis weight. In addition to having a relatively low basis weight, the nonwoven fiber webs also contain a large amount of cellulose fibers, making the wiping material sustainable and providing additional advantages over conventional textile wipes.

[0042] The nonwoven fiber web manufactured according to this disclosure may include a spunlace fiber web containing fiber blends. The fibers primarily comprise cellulose pulp fibers combined with synthetic polymer fibers. The synthetic polymer fibers may optionally include crimped fibers. In one aspect, the cellulose pulp fibers are combined with a first polymer short fiber and optionally a second polymer short fiber. When the second short fiber is present, the first short fiber may have a denier greater than that of the second short fiber. It has been found that the fiber blends described above provide an excellent balance of strength and wiping properties. In one aspect, the nonwoven fiber web may be a foam-formed fiber web, which is well-suited for accommodating longer polymer synthetic fibers, including crimped fibers.

[0043] In one aspect, the nonwoven fiber web may also include a morphological pattern located on the surface of the fiber web. The morphology may include a pattern of raised elements extending from the substrate surface of the nonwoven fiber web. The raised elements, combined with the fiber formulation and the manner in which the fiber web is formed, produce a monolithic sheet product that is well-suited for picking up oil and grease spills in addition to absorbing a variety of other liquids.

[0044] Particularly advantageous is that the nonwoven fiber web made according to this disclosure can be designed to pick up oil and / or grease in the same amount as woven or knitted fabrics but in a basis weight of less than about 20%, such as less than about 30%, such as less than about 40%, such as less than about 50%, such as even less than about 60% of conventional fabric materials.

[0045] The nonwoven fiber web manufactured according to this disclosure comprises a blend of fibers, and it has been found that such a blend of fibers provides various advantages and benefits. For example, the nonwoven fiber web can be made from a blend of cellulose pulp fibers and short fibers.

[0046] Suitable cellulose pulp fibers include, but are not limited to, non-wood fibers such as cotton, abaca, kenaf, sabaigrass, flax, esparto grass, rice straw, jute, bagasse, milkweed fiber, and pineapple leaf fiber; and woody or pulp fibers, such as those obtained from deciduous and coniferous trees, including softwood fibers such as northern and / or southern softwood kraft paper fibers; and hardwood fibers such as eucalyptus, maple, birch, and aspen. Pulp fibers can be prepared in high-yield or low-yield forms and can be pulped by any known method, including kraft paper pulping, sulfite pulping, high-yield pulping methods, and other known pulping methods. Fibers prepared by organic solvent pulping methods may also be used, including the fibers and methods disclosed in U.S. Patent Nos. 4,793,898, 4,594,130, and 3,585,104. Useful fibers can also be produced by anthraquinone pulping, as illustrated in U.S. Patent No. 5,595,628.

[0047] Chemically treated natural cellulose fibers, such as mercerized sizing, chemically hardened or cross-linked fibers, or sulfonated fibers, can be used. For good mechanical properties, it may be desirable for the fibers to be relatively undamaged and substantially unrefined or only lightly refined. Suitable cellulose sizing fibers may also include regenerated fibers, virgin fibers, or mixtures thereof. In some embodiments that enable high volumetric properties and good compressibility, the fibers may have a Canadian standard freeness of at least 200, more specifically at least 300, even more specifically at least 400, and most specifically at least 500.

[0048] Other cellulosic fibers that can be used in this disclosure include high-yield fibers. High-yield pulp fibers are those papermaking fibers produced by pulping methods that provide a yield of about 65% or higher, more specifically about 75% or higher, and even more specifically about 75% to about 95%. Yield is the amount of processed fiber obtained as a percentage of the initial wood mass. Such pulping processes include bleached chemithermomechanical pulp (BCTMP), chemithermomechanical pulp (CTMP), pressure / pressure thermomechanical pulp (PTMP), thermomechanical pulp (TMP), thermomechanical chemical pulp (TMCP), high-yield sulfite pulp, and high-yield kraft pulp, all of which result in fibers with a high lignin content. High-yield fibers are well known for their stiffness in both dry and wet conditions relative to typical chemically pulped fibers.

[0049] Cellulose pulp fibers may be present in the nonwoven fiber web in an amount typically from about 45% to about 70% by weight, including all increments of 1% by weight therein. For example, cellulose pulp fibers may be present in the nonwoven fiber web in an amount of about 48% by weight, such as about 50% by weight, such as about 52% by weight, such as about 55% by weight, such as about 58% by weight, and in an amount less than about 68% by weight, such as less than about 65% by weight, such as less than about 63% by weight.

[0050] According to this disclosure, cellulose pulp fibers are combined with short fibers. In one aspect, the short fibers include synthetic polymer fibers. The short fibers may also optionally include crimped fibers.

[0051] In one aspect, the nonwoven fiber web prepared according to this disclosure comprises two different types of short fibers. For example, the nonwoven fiber web may contain a first short fiber optionally blended with a second short fiber. The first short fiber may have a larger size or a denier greater than that of the second short fiber.

[0052] Generally, the first staple fiber may have a size of about 0.3 denier to about 5 denier. For example, in one aspect, the first staple fiber may have a size of about 0.4 denier to about 1.2 denier. In another aspect, the first staple fiber may have a size of about 1.2 denier to about 3 denier, such as about 1.2 denier to about 2.2 denier.

[0053] When present, the second short fiber can be relatively fine and have a size less than about 1.2 denier, such as less than about 1 denier, such as less than about 0.8 denier, such as less than about 0.7 denier, and greater than about 0.3 denier, such as greater than about 0.4 denier. When the second short fiber is present, the size of the first short fiber can be greater than about 1.2 denier, such as greater than about 1.3 denier, such as greater than about 1.4 denier, and less than about 5 denier, such as less than about 4 denier, such as less than about 3 denier, such as less than about 2.5 denier, such as less than about 2 denier, such as less than about 1.8 denier. In one embodiment, both the first and second short fibers comprise polyester fibers, such as fibers containing (at least partially) polyethylene terephthalate.

[0054] Short fibers may be present in the nonwoven fiber web in an amount from about 20% to about 60% by weight, including all increments of 1% by weight therein. Short fibers may be present in the nonwoven fiber web in an amount greater than about 30% by weight, such as greater than about 33% by weight, such as greater than about 35% by weight, such as greater than about 37% by weight. For example, short fibers may be present in the fiber web in an amount less than about 55% by weight, such as less than about 53% by weight, such as less than about 50% by weight, such as less than about 47% by weight, such as less than about 45% by weight, such as less than about 43% by weight.

[0055] The weight ratio between the first short fiber and the second short fiber (when the second short fiber is present) is typically from about 1:3 to about 3:1, such as from about 1:2 to about 2:1, such as from about 1:1.5 to about 1.5:1, such as from about 1:1.2 to about 1.2:1. In one embodiment, the first short fiber and the second short fiber are present in a 1:1 ratio.

[0056] As described above, the first short fiber, the second short fiber, or both the first short fiber and the second short fiber can include crimped fibers. Creped fibers exhibit a degree of waviness in which the fiber axis deviates from a straight line and follows a simple, complex, or irregular wavy path. In its simplest form, crimp is uniplanar and regular, for example, resembling a sine wave, but is usually much more complex and irregular. An example of three-dimensional crimp is helical crimp. Crepiness can be expressed numerically as the number of crimps per unit length, or as the difference in distance between two points on the fiber when it is relaxed and when it is straightened under appropriate tension.

[0057] Synthetic fibers can be wound or crimped using a variety of different techniques. In one embodiment, for example, the fiber can be formed from a polymer or polymer mixture that causes the fiber to be wound or crimped when heat-treated. However, in other embodiments, synthetic fibers can be wound or crimped using chemical or mechanical means. Three-dimensional synthetic fibers may include fibers wound in two dimensions and / or helical fibers.

[0058] In one embodiment, the crimped fiber may comprise a multicomponent fiber, such as a bicomponent fiber. Bicomponent fibers may contain different polymers in a side-by-side configuration or an island configuration. The presence of two different polymers can cause the fiber to crimp or coil when heat-treated or subjected to mechanical means. For example, the fiber can be heat-treated by passing it under a hot air knife or hot air diffuser. The crimping may be due to differential cooling of the polymer components of the fiber. After the fiber crimps or coils, it may optionally undergo further heat treatment steps to lock it into a three-dimensional conformation. Synthetic fibers can be made from all different types of polymers, including polyolefin polymers such as polyethylene and / or polypropylene, polyester polymers, polyamide polymers, etc. In one embodiment, the synthetic fiber is a bicomponent fiber made of polyethylene and polypropylene. In one embodiment, the polyethylene may have greater crystallinity, which causes the polyethylene chains to recrystallize upon cooling, resulting in shrinkage of the polyethylene polymer and inducing crimping or coiling into fibers.

[0059] Other multicomponent fibers that can be used according to this disclosure include bicomponent fibers having a skin-core configuration, wherein a polyethylene polymer is used to form the skin, and the core is made of a polyester polymer (such as polyethylene terephthalate polymer). Alternatively, the bicomponent fiber may include a first polyester polymer to form the skin, and the core is made of a second polyester polymer. Both polyester polymers may include polyethylene terephthalate polymers. If desired, many of the above-described bicomponent fibers can also be used as bonding fibers. For example, when subjected to a certain amount of heat, the skin polymer on one fiber can bond to the skin polymer on an adjacent fiber.

[0060] In another embodiment, the crimped fiber may comprise a bicomponent fiber containing a first polymer composition separate from the second polymer composition. The first polymer composition may contain a crimping-reinforcing additive that causes the fiber to crimp. For example, the crimping-reinforcing additive may comprise a polymer having a rapid crystallization rate. For example, in one embodiment, the crimping-reinforcing additive may comprise a polypropylene homopolymer.

[0061] The crimped fibers (first short fibers or second short fibers) according to this disclosure typically contain more than about 1 crimp / cm, such as about 1.5 crimp / cm to about 15 crimp / cm. For example, the fibers may contain more than about 2 crimp / cm, such as more than about 2.5 crimp / cm, such as more than about 2.7 crimp / cm, such as more than about 3 crimp / cm, such as more than about 3.2 crimp / cm, such as more than about 3.5 crimp / cm, such as more than about 3.8 crimp / cm, such as more than about 4 crimp / cm, such as more than about 4.2 crimp / cm, such as more than about 4.5 crimp / cm, such as more than about 4.8 crimp / cm, such as more than about 5 crimp / cm, such as more than about 5.2 crimp / cm, such as more than about 5.5 crimp / cm, such as more than about 5.7 crimp / cm, such as more than about 6 crimp / cm. In other embodiments, the crimped fibers may contain more than about 6.5 crimps / cm, such as more than about 7 crimps / cm, such as more than about 7.5 crimps / cm, such as more than about 8 crimps / cm, and less than about 12 crimps / cm.

[0062] The first and second short fibers contained in the nonwoven fiber web may independently contain crimps per centimeter within any of the aforementioned ranges. The fiber lengths of the first and second short fibers may also be the same or different. Generally, the first and second short fibers may have an average fiber length of about 3 mm to about 100 mm, including all increments of 1 mm therebetween. The first and / or second short fibers may, for example, have an average fiber length greater than about 4 mm, such as greater than about 5 mm, such as greater than about 6 mm. The average fiber length of the first and second short fibers may be less than about 80 mm, such as less than about 60 mm, such as less than about 40 mm, such as less than about 20 mm, such as less than about 15 mm, such as less than about 12 mm.

[0063] The nonwoven fiber web manufactured according to this disclosure can be produced in a variety of different ways. For example, the nonwoven material can be manufactured according to wet web forming process, air-laid web forming process, foam forming process, etc. According to this disclosure, the nonwoven material can also undergo one or more hydroentangling steps during or after the formation of the nonwoven fiber web.

[0064] In one embodiment, for example, the nonwoven material of this disclosure is produced according to a foam forming process. The foam forming process has many advantages and benefits. During the foam forming process, water is replaced by foam, which acts as a carrier for the fibers forming the fiber web. The foam, representing a large amount of air, is blended with cellulose and / or polymer synthetic fibers. Because less water is used to form the fiber web, less energy is required to dry it. Furthermore, the foam forming process is more suitable for producing nonwoven materials containing different types of fibers, especially longer and / or crimped synthetic polymer fibers. Additionally, surface morphology can be incorporated into the nonwoven material, where the raised elements have a larger basis weight than the surrounding area of ​​the fiber web. Furthermore, the foam forming process can produce unique fiber orientations. For example, when a nonwoven material is produced from a combination of shorter fibers (such as pulp fibers) and longer fibers (such as short synthetic polymer fibers), the shorter fibers tend to accumulate in the raised elements, while the longer fibers can have a greater density along the substrate surface. This structure produces a nonwoven material with greater fiber density and absorbency in the raised elements while exhibiting significant strength between the raised elements.

[0065] In a particular implementation scheme, such as Figure 2 and Figure 3 As shown, for illustrative purposes only, the nonwoven materials of this disclosure can be produced using a combination of foam forming processes and hydroentangling steps. For example, the hydroentangling step can occur on a patterned surface that creates a morphology on the nonwoven material.

[0066] Initially, fiber formulations are selected for the production of nonwoven materials. As described above, the fiber formulation may contain cellulose pulp fibers bonded to short fibers. The short fibers may include polymer-synthetic short fibers. In one aspect, the fiber formulation comprises a first short fiber and a second short fiber, wherein the first short fiber has a denier greater than that of the second short fiber. During foam formation, the fiber formulation is combined with foam generated by blending water with a foaming agent.

[0067] The blowing agent may, for example, contain any suitable surfactant. In one embodiment, the blowing agent may, for example, comprise sodium lauryl sulfate, also known as sodium lauryl polyoxyethylene ether sulfate or sodium lauryl ether sulfate. In one embodiment, the blowing agent is a nonionic surfactant that may comprise alkyl polyglycosides. For example, the blowing agent may be a C8 alkyl polyglycoside, a C10 alkyl polyglycoside, or a mixture of C8 and C10 alkyl polyglycosides.

[0068] Other blowing agents include sodium dodecyl sulfate or ammonium lauryl sulfate. In other embodiments, the blowing agent may contain any suitable cationic and / or amphoteric surfactants. For example, other blowing agents include fatty acid amines, amides, amine oxides, fatty acid quaternary compounds, etc.

[0069] The foaming agent is typically mixed with water in an amount greater than about 0.1% by weight, such as greater than about 1% by weight, such as greater than about 2% by weight, such as greater than about 3% by weight. One or more foaming agents are typically present in an amount less than about 50% by weight, such as less than about 10% by weight, such as less than about 8% by weight, such as less than about 4% by weight.

[0070] Once the foaming agent and water are mixed, the mixture is either blended or otherwise subjected to forces capable of forming foam. Foam generally refers to a porous matrix, which is an aggregate of hollow units or bubbles that can interconnect to form channels or capillaries.

[0071] Foam density can vary depending on the specific application and various factors, including the fiber composition used. In one embodiment, for example, the foam density may be greater than about 200 g / L, such as greater than about 250 g / L, such as greater than about 300 g / L. Foam density is typically less than about 600 g / L, such as less than about 500 g / L, such as less than about 400 g / L, such as less than about 350 g / L. In one embodiment, for example, a lower density foam is used, whose foam density is typically less than about 350 g / L, such as less than about 340 g / L, such as less than about 330 g / L. The foam will typically have an air content greater than about 30%, such as greater than about 40%, such as greater than about 50%, such as greater than about 60%. The air content is typically less than about 80% by volume, such as less than about 70% by volume, such as less than about 65% by volume.

[0072] To form a nonwoven fiber web, foam is combined with selected fiber ingredients and any auxiliaries. The foamed fiber suspension is then pumped into a tank and fed from the tank into a headbox. For example, Figure 2 and Figure 3 An embodiment of a process for forming a fiber web according to this disclosure is shown. Figure 3 As specifically shown, the foamed fiber suspension can be fed into tank 312 and then into headbox 310. The foamed fiber suspension flows from headbox 310 onto a ring-moving forming fabric 326 supported and driven by rollers 328 to form a fiber web 210. Figure 3 As shown, the forming plate 314 may be located below the fiber web 210, adjacent to the headbox 310. Once formed on the forming fabric 326, the foam forming fiber web may have a consistency of less than about 50%, such as less than about 20%, such as less than about 10%, such as less than about 5%. In fact, the forming consistency may be less than about 2%, such as less than about 1.8%, such as less than about 1.5%. The forming consistency is typically greater than about 0.5%, such as greater than about 0.8%. The forming consistency indicates the ability to produce a fiber web according to this disclosure while minimizing the amount of water required during forming.

[0073] Once the wet fiber web is formed on the shaped fabric 326, the web is conveyed downstream and dehydrated. The process may optionally include multiple vacuum devices 316, such as vacuum chambers and vacuum rollers. Vacuum chambers help remove moisture from the newly formed fiber web 210.

[0074] like Figure 3 As shown, the formed fabric 326 can also be connected to a steam box 318 located above a pair of vacuum rollers 320. For example, the steam box 318 can increase dryness and reduce transverse moisture variation. Steam applied from the steam box 318 heats the moisture in the wet fiber web 210, making it easier for water to drain from the web, especially in conjunction with the vacuum rollers 320. Figure 2 In the illustrated embodiment, the newly formed fiber web 210 is conveyed downstream from the formed fabric 326, undergoes hydroentangling, and is dried on a ventilated dryer.

[0075] After the foam-formed fiber web has been produced, the fiber web is subjected to one or more hydroentangling steps. Figure 3 In the illustrated implementation, for example, the fiber web 210 undergoes two different hydroentangling steps. Specifically, in Figure 3 In this process, the fiber web 210 is hydroentangled on a first surface during a first hydroentangling step, and then hydroentangled on an opposing second surface during a second hydroentangling step. For example... Figure 3 As shown, for example, the process may include a first hydroentangling device 330 and a second hydroentangling device 332. Hydroentangling occurring at each hydroentangling station can be accomplished using conventional hydroentangling equipment. Hydroentangling of the foam-formed fiber web can be performed using any suitable working fluid, such as water. The working fluid flows through a manifold that uniformly distributes the fluid through a series of individual orifices or openings. For example, exemplary orifices or openings may have a diameter of about 0.003 inches to about 0.015 inches. For example, the manifold may include strips of orifices with a diameter of about 0.007 inches. The manifold may contain about 20 to about 40 orifices per inch and may include 1 to 3 rows of orifices. Many other manifold configurations and combinations can be used. For example, in Figure 3 In the illustrated embodiment, the spunlace device 330 includes a plurality of injectors 334, while the spunlace device 332 includes a plurality of injectors 336. The injectors 334 and 336 may be part of a manifold and may be in communication with a working fluid source.

[0076] During the hydroentangling process, the working fluid can pass through the orifice at pressures ranging from approximately 200 psig to approximately 3,500 psig. Within the upper limit of the described pressure range, it is conceivable that the fiber web can be processed at speeds from approximately 500 ft / min to approximately 2000 ft / min. The fluid impingement can be supported on a porous surface or wire, or on a porous drum surface of material or fiber web. Figure 3In the illustrated implementation, for example, hydroentanglement occurs on the first rotating drum 338 and the second rotating drum 340.

[0077] During hydroentangling, the fiber web 210 can be placed directly on the surfaces of the rotating drum 338 and the rotating drum 340. Each rotating drum may include multiple openings or vacuum channels for extracting excess water. These openings or vacuum channels may also form patterns in the fiber web 210 during the hydroentangling process. For example, a pattern may be formed on one surface of the fiber web at a first hydroentangling station, and a pattern may be formed on an opposing second surface of the fiber web at a second hydroentangling station.

[0078] In addition to forming the desired morphology and improving the cleanliness of the nonwoven material 210, one or more hydroentangling stations can significantly improve various physical properties of the fiber web 210, such as the integrity of the fiber web. For example, a columnar jet of working fluid directly impacting the surface of the fiber web is used to entangle and wrap the fibers contained within the fiber web. The hydroentangling process ultimately forms a coherent entangled matrix. The hydroentangling step is also used to further produce a substantially homogeneous fiber mixture within the fiber web. For example, the resulting hydroentangled fiber web is "non-layered" and does not contain distinguishable individual fiber layers in terms of web thickness.

[0079] Once the foam-formed fiber web 210 has been hydroentangled once or multiple times, a non-compression drying process can be used to dry the fiber web. For example, as... Figure 2 As shown, a ventilated dryer can be used to dry foam-molded fiber webs.

[0080] See Figure 2 The foam-formed and hydroentangled fiber web 210 is transferred from the drum 340 to the penetrating dry fabric 344 by means of a vacuum transfer roller 346 or a vacuum transfer shoe. If desired, the penetrating dry fabric can run at a slower speed than the fiber web 210 to further enhance stretch. The transfer can be performed with vacuum assistance to ensure that the sheet deforms to conform to the penetrating dry fabric, thereby producing the desired volume and appearance (if desired).

[0081] exist Figure 2 In the illustrated embodiment, the foam-formed fiber web 210 is transferred to the penetrating dryer fabric 344. Alternatively, the foam-formed fiber web may be transferred to a porous metal sleeve forming the circumference of the penetrating dryer 348. Using a metal sleeve instead of fabric offers various advantages. For example, the porous metal sleeve can also create porosity to increase the liquid absorption properties of the fiber web.

[0082] Alternatively, the foam-formed fiber web 210 may be conveyed on a penetrating dry fabric 344 on the circumference of the penetrating dryer 348.

[0083] The vacuum level used for transferring the web can be from about 3 inches to about 15 inches of mercury (75 mm to about 380 mmHg), preferably about 5 inches (125 mm) of mercury. In addition to or as an alternative to using a vacuum to draw the web onto the next fabric, a vacuum shoe or roller (negative pressure) can be supplemented or replaced by using positive pressure from the opposite side of the web to blow the web onto the next fabric.

[0084] Finally, the fiber web is dried to approximately 94% or higher consistency via a penetration dryer 348 and then transferred to carrier fabric 350. The dried substrate 352 is conveyed to a reel 354 using carrier fabric 350 and optionally carrier fabric 356. Optional pressure guide rollers 358 can be used to facilitate the transfer of the fiber web from carrier fabric 350 to fabric 356. Suitable carrier fabrics for this purpose are Albany International 84M or 94M and Asten 959 or 937, all of which are relatively smooth fabrics with fine patterns.

[0085] The process disclosed herein can also produce fiber webs with good volumetric properties. For example, the volume is typically greater than about 3 cc / g, such as greater than about 5 cc / g, such as greater than about 8 cc / g, such as greater than about 10 cc / g, such as greater than about 12 cc / g, and typically less than about 20 cc / g, such as less than about 15 cc / g.

[0086] Nonwoven fiber webs can exhibit enhanced thickness per basis weight greater than about 0.009 mm / gsm, such as greater than about 0.010 mm / gsm, such as greater than about 0.011 mm / gsm. For example, at a basis weight of about 60 gsm to about 70 gsm, the substrate thickness can be greater than about 0.4 mm, such as greater than about 0.5 mm, such as greater than about 0.6 mm, such as greater than about 0.7 mm, such as greater than about 0.8 mm, and less than about 3 mm. It is believed that the process of this disclosure, combined with fiber formulations, produces fiber webs with greater thickness and open structure, resulting in better feel and better cleaning properties.

[0087] exist Figure 2 and Figure 3 In the illustrated embodiment, the foam-formed fiber web can be hydroentangled on a patterned forming surface to create a pattern of raised elements. However, in other embodiments, suction positioned below the forming surface can be used to form the raised elements. These methods produce raised elements with an increased basis weight compared to the base surface of the fiber web. Texture can also be imparted to the fiber web by embossing. However, when the fiber web is embossed, the basis weight of the fiber web remains uniform and no raised elements with increased basis weight are produced.

[0088] Nonwoven fiber webs manufactured according to this disclosure may typically have a smooth surface or may include a pattern of raised elements based on hydroentangling conditions. See also Figure 1 An embodiment of a nonwoven fiber web 10 including a pattern of raised elements is shown. As illustrated, the nonwoven material 10 includes a pattern of raised elements. For example, in Figure 1 In the illustrated embodiment, the pattern includes a first raised pattern element 12 and a second raised pattern element 14. The perimeter of the first raised pattern element 12 is greater than the perimeter of the second raised pattern element 14. In this embodiment, the first raised pattern element 12 is located in a domain consisting of columns and rows. The domain of the first raised pattern element 12 is separated by a grid pattern of the second raised pattern element 14. As will be described in more detail below, this pattern is merely exemplary and may consist of only one of many patterns that can be manufactured according to this disclosure. Furthermore, other patterns may include only a single raised pattern element size or may include more than two raised elements with different sizes.

[0089] like Figure 1 As shown, in one aspect, the protruding elements may include discrete shapes that are not interconnected. Figure 1 In the illustrated embodiment, the protruding element has a cylindrical shape with a generally circular top surface. For example... Figure 1 The circular shape shown offers various advantages and benefits when used for picking up grease and / or oil. However, in other embodiments, the shape of the protruding element can vary. For example, the shape of the protruding element can be irregular, or it can include any suitable geometry, such as rectangles, triangles, ellipses, etc. In one aspect, discrete shapes can be combined with elongated interconnected shapes. For example, discrete individual shapes can be combined with a grid-like protrusion pattern.

[0090] like Figure 1 As illustrated, the pattern of the raised elements forms a void region 16 on the substrate surface 20 of the nonwoven material 10. For example, the void region 16 and the substrate surface 20 can be substantially planar. The raised patterned elements 12 and 14 can extend from the substrate surface 20.

[0091] Between and around the first raised patterned element 12 and the second raised patterned element 14 are void regions 16. These void regions create void surface area volumes between the substrate surface 20 and the tops of the raised patterned elements 12 and 14. The amount and spacing 16 of these void regions can have an influence, and can affect, the ability of the nonwoven material 10 to clean and retain grease and / or oily substances. Figure 1 As shown, the void regions 16 on the substrate surface 20 can have different sizes and shapes. The void regions 16 can provide surface area for retaining and holding contaminants.

[0092] The raised pattern elements 12 and 14 can have any suitable size. Generally, the raised pattern elements can have a perimeter greater than about 0.5 mm, such as greater than about 0.75 mm, such as greater than about 1 mm, such as greater than about 1.5 mm, such as greater than about 2 mm, such as greater than about 2.5 mm, such as greater than about 2.75 mm, such as greater than about 3 mm. The perimeter of the raised pattern elements is typically less than about 20 mm, such as less than about 10 mm, such as less than about 7 mm, such as less than about 5 mm, such as less than about 3 mm, such as less than about 2.5 mm, such as less than about 2 mm, such as less than about 1.75 mm. Figure 1 As shown, the nonwoven material 10 may include raised pattern elements of different sizes. For example, in one aspect, the first raised pattern element 12 may have a perimeter of about 1 mm to about 2.5 mm, while the second raised pattern element 14 may have a perimeter of about 0.5 mm to about 1.5 mm.

[0093] Within each patterned area, the raised patterned elements may be spaced at a distance that creates a sufficient gap area 16 while also creating sufficient edges for the raised patterned elements. The spacing can be measured along a line intersecting the center of each raised element from the edge of one raised element to the edge of the adjacent raised element. The spacing between raised elements within a region or patterned area is typically greater than about 0.2 mm, such as greater than about 0.3 mm, such as greater than about 0.5 mm, such as greater than about 0.7 mm, such as greater than about 0.9 mm, such as greater than about 1.1 mm, such as greater than about 1.3 mm, such as greater than about 1.5 mm, such as greater than about 1.7 mm, such as greater than about 1.9 mm, such as greater than about 2.1 mm, such as greater than about 2.3 mm. The spacing between adjacent pattern elements is typically less than about 5 mm, such as less than about 4 mm, such as less than about 3 mm, such as less than about 2.75 mm, such as less than about 2.5 mm, such as less than about 2.25 mm, such as less than about 2 mm, such as less than about 1.8 mm, such as less than about 1.6 mm, such as less than about 1.4 mm, such as less than about 1.2 mm, such as less than about 1 mm, such as less than about 0.8 mm.

[0094] The height of the raised pattern element can be measured at a pressure of 0.05 psi and can be measured from the top of the pattern element to the substrate surface 20. The height of the raised element can be uniform or variable on the surface of the nonwoven fiber web. Generally, the height of the raised element can be greater than about 0.2 mm, such as greater than about 0.5 mm, such as greater than about 0.7 mm, such as greater than about 0.9 mm, such as greater than about 1.1 mm. The height of the raised element is typically less than about 2 mm, such as less than about 1.7 mm, such as less than about 1.5 mm, such as less than about 1.3 mm, such as less than about 1.2 mm, such as less than about 1.1 mm, such as less than about 1 mm, such as less than about 0.9 mm, such as less than about 0.8 mm, such as less than about 0.7 mm.

[0095] like Figure 1 As shown, the raised pattern elements 12 and 14 occupy a certain amount of surface area relative to the void region 16. The surface area can be varied and controlled based on the type of application to which the nonwoven fiber web 10 will be used. Generally, the raised pattern elements 12 and 14 occupy more than about 8% of the total surface area, such as more than about 10% of the total surface area, such as more than about 15% of the total surface area, such as more than about 20% of the total surface area, such as more than about 25% of the total surface area, such as more than about 30% of the total surface area, such as more than about 35% of the total surface area, such as more than about 40% of the total surface area, such as more than about 45% of the total surface area, such as more than about 50% of the total surface area, such as more than about 55% of the total surface area, such as more than about 60% of the total surface area, such as more than about 65% of the total surface area. The protruding elements typically occupy less than about 80% of the total surface area of ​​the nonwoven material 10, such as less than about 75% of the total surface area, such as less than about 70% of the total surface area, such as less than about 65% of the total surface area, such as less than about 60% of the total surface area, such as less than about 55% of the total surface area, such as less than about 50% of the total surface area, such as less than about 45% of the total surface area, such as less than about 40% of the total surface area.

[0096] As described above, using hydroentangling to create a pattern of raised elements produces a basis weight difference throughout the nonwoven web. Specifically, the basis weight of the raised areas is greater than the basis weight of the base surface of the web.

[0097] For example, the basis weight of the raised area can be greater than about 10%, such as greater than about 20%, such as greater than about 30%, such as greater than about 40%, such as greater than about 50%, such as greater than about 60% of the basis weight of the nonwoven material substrate surface. The basis weight of the raised area can be up to about 100% greater than the basis weight of the substrate surface, such as up to about 90% greater than the basis weight of the substrate surface.

[0098] When tested at a pressure of 0.05 psi, the nonwoven material manufactured according to this disclosure typically exhibits a strength greater than about 0.1 g / cm³.3 The density. For example, the density of a nonwoven fiber web can be greater than about 0.12 g / cm³. 3 And less than approximately 2g / cm 3 Such as greater than approximately 1.8 g / cm³ 3 And less than approximately 0.14 g / cm³ 3 .

[0099] The basis weight of the nonwoven materials manufactured according to this disclosure can be any value from about 20 gsm to about 200 gsm, including all increments of 1 gsm therebetween. However, in many applications, the basis weight can be less than that of conventional fabric materials while still having the same cleaning ability relative to many contaminants, such as grease and oil. For example, in one aspect, the basis weight can be less than about 100 gsm, such as less than about 90 gsm, such as less than about 80 gsm, such as less than about 70 gsm, such as less than about 68 gsm. The basis weight is typically greater than about 40 gsm, such as greater than about 50 gsm, such as greater than about 55 gsm, such as greater than about 60 gsm, such as greater than about 62 gsm. However, in one aspect, heavier fiber webs with a basis weight of about 90 gsm to about 120 gsm can be produced.

[0100] As described above, the nonwoven fiber web manufactured according to this disclosure typically comprises cellulose pulp fibers combined with short fibers. The short fibers may include two different sizes of fibers, including a first short fiber having a larger denier than the second short fiber. In one aspect, the cellulose pulp fibers and short fibers substantially constitute all the fibers contained in the nonwoven fiber web. For example, the cellulose pulp fibers and short fibers may account for more than about 90% by weight, such as more than about 95% by weight, or such as more than about 98% by weight of the fibers contained in the nonwoven fiber web. In this respect, the nonwoven fiber web may be configured not to contain any other synthetic polymer short fibers, such as binder fibers, etc. The nonwoven fiber web may also be configured not to contain any regenerated cellulose fibers.

[0101] The present disclosure can be better understood by referring to the following embodiments.

[0102] Example 1

[0103] According to this disclosure, a nonwoven fiber web was manufactured, and various properties were tested compared with conventional cloth wipes.

[0104] Nonwoven fiber webs are similar in appearance to Figure 1 The illustrated implementation scheme is manufactured using a combination of foam molding and hydroentangling processes. For example, by using... Figure 2 and Figure 3The process illustrated above is similar to that used to manufacture nonwoven fiber webs. The fiber formulation used to produce the web contains 60% by weight cork pulp fiber and 40% by weight crimped polyester fiber. The crimped polyester fiber comprises 50% by weight 0.5 denier crimped fiber and 50% by weight 1.5 denier crimped fiber. The nonwoven fiber web has a basis weight of 65 gsm.

[0105] The textile wipes used during testing were product number WCA40-42W, obtained from RagLady, Stevensville, Maryland. The textile wipes were made from recycled cotton, optionally containing polymer synthetic fibers.

[0106] Usage tests were conducted on the nonwoven fiber web and textile wiping cloth manufactured according to this disclosure. The results are illustrated graphically. Figure 4 As shown in the figure, the nonwoven fiber web manufactured according to this disclosure is as good as or better than textile cloths in cleaning oil and grease. The nonwoven fiber web is superior to textile cloths in water wiping and non-cleaning tasks. During testing, it was found that the nonwoven fiber web manufactured according to this disclosure is not as durable as textile cloths, which is predictable because textile cloths are designed for heavier materials to be washed, while the nonwoven fiber web of this disclosure is designed for single-use applications.

[0107] 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, which are more specifically set forth in the appended claims. Furthermore, it should be understood that aspects of the various embodiments are interchangeable in whole or in part. Moreover, those skilled in the art will understand that the foregoing description is merely illustrative and is not intended to limit the invention further described in the appended claims.

Claims

1. A wiping product, comprising: A spunlace nonwoven fiber web having a first surface and an opposing second surface, the nonwoven fiber web comprising cellulose pulp fibers blended with first short fibers and optionally second short fibers, the first short fibers comprising synthetic polymer fibers, the first short fibers having a size of about 0.3 denier to about 3 denier, the cellulose pulp fibers comprising about 45% to about 70% by weight of the nonwoven fiber web, the short fibers comprising about 30% to about 55% by weight of the nonwoven fiber web, and the nonwoven fiber web having a basis weight of about 40 gsm to about 120 gsm.

2. The wiping product of claim 1 further includes a morphology pattern on the surface of the nonwoven fiber web, at least a portion of the morphology pattern including raised pattern elements extending from the substrate surface.

3. The wiping product according to any one of the preceding claims, wherein the nonwoven fiber web comprises the first short fiber and the second short fiber, the first short fiber having a fiber size of about 1.2 denier to about 3 denier, and the second short fiber comprising synthetic polymer fibers and having a fiber size of about 0.3 denier to about 1.2 denier, such as about 0.4 denier to about 1.1 denier.

4. The wiping product according to claim 3, wherein the first short fiber and the second short fiber comprise polyester fibers.

5. The wiping product according to any one of the preceding claims, wherein the cellulose pulp fibers and the short fibers account for more than 90% by weight, such as more than 95% by weight, of the fibers contained in the nonwoven fiber web.

6. The wiping product according to any one of the preceding claims, wherein the nonwoven fiber web has a basis weight of about 55 gsm to about 75 gsm, such as about 60 gsm to about 70 gsm.

7. The wiping product according to any one of the preceding claims, wherein the nonwoven fiber web comprises about 35% to about 55% by weight of the first short fibers and the second short fibers, and comprises about 45% to about 65% by weight of the cellulose pulp fibers.

8. The wiping product according to claim 3, wherein the weight ratio of the first short fiber to the second short fiber is from about 1:3 to about 3:1, such as from about 1:1.5 to about 1.5:

1.

9. The wiping product of claim 2, wherein the raised pattern element has a basis weight, and the substrate surface has a basis weight, and wherein the basis weight of the raised pattern element is greater than about 10% of the basis weight of the substrate surface.

10. The wiping product according to claim 2 or 9, wherein the raised pattern elements of the pattern comprise discrete shapes that are not interconnected.

11. The wiping product according to claim 2, 9 or 10, wherein the raised pattern element comprises a raised circular element.

12. The wiping product according to claim 2, 9, 10 or 11, wherein at least a portion of the raised pattern element has a height greater than about 0.1 mm, such as greater than about 0.2 mm, such as greater than about 0.3 mm, such as greater than about 0.4 mm, such as greater than about 0.5 mm, such as greater than about 0.6 mm, and generally less than about 1.2 mm, such as less than about 1 mm, such as less than about 0.8 mm.

13. The wiping product according to any one of the preceding claims, wherein the substrate exhibits a thickness per basis weight greater than about 0.009 mm / gsm, such as greater than about 0.010 mm / gsm, such as greater than about 0.011 mm / gsm.

14. The wiping product according to any one of the preceding claims, wherein the nonwoven fiber web has a thickness greater than about 0.4 mm, such as greater than about 0.6 mm, such as greater than about 0.8 mm, and less than about 2 mm, such as less than about 1.5 mm, such as less than about 1.2 mm, at a basis weight of about 60 gsm to about 70 gsm.

15. The wiping product according to any one of the preceding claims, wherein the nonwoven fiber web comprises a foam-formed fiber web.

16. The wiping product of claim 2, wherein the raised pattern element occupies about 15% to about 80% of the surface area of ​​the first surface, such as about 20% to about 60% of the surface area of ​​the first surface.

17. The wiping product according to claim 2, wherein the morphological pattern includes a first raised pattern element and a second raised pattern element, the effective diameter of the first raised pattern element being smaller than the effective diameter of the second raised pattern element.

18. The wiping product of claim 1, wherein the first short fiber comprises crimped fiber.

19. The wiping product of claim 3, wherein the first short fiber and the second short fiber comprise crimped fibers.

20. The wiping product according to any one of the preceding claims, wherein the first short fiber and the second short fiber have an average fiber length of about 4 mm to about 20 mm, such as about 6 mm to about 12 mm.

21. The wiping product according to any one of the preceding claims, wherein the foam-formed fiber web has a first surface and an opposing second surface, and wherein the first surface has been hydroentangled, and the second surface has been hydroentangled.

22. The wiping product according to any one of the preceding claims, wherein the nonwoven fiber web is a single-layer sheet fiber web and is non-layered.

23. The wiping product according to any one of the preceding claims, wherein the nonwoven fiber web has a volume of about 3 g / cc to about 20 g / cc.

24. The wiping product according to any one of claims 1 to 5, wherein the nonwoven fiber web has a basis weight of about 90 gsm to about 120 gsm.

25. The wiping product according to any one of the preceding claims, wherein the wiping product includes industrial wiping materials.

26. The wiping product according to any one of the preceding claims, wherein the wiping product comprises individual sheets stacked together.

27. The wiping product according to any one of claims 1 to 25, wherein the wiping product comprises a spiral wound roller.

28. The wiping product according to any one of the preceding claims, wherein the wiping product is pre-saturated with a cleaning solvent.

Images