Tear resistant wipe

Abstract

An improved tear-resistant wipe is provided having a repeating pattern of thin, dense, curved embossed elements adjacent to the leading edge of the wipe, the pattern extending inward for less than one-third of the length of the wipe. The linear embossed elements have a high aspect ratio and narrow width to achieve a high-density embossing, resulting in a small discrete unembossed area within the leading edge region, while the entire unembossed area still occupies at least 70% of the surface area.

Description

[0001] This application is a divisional application of the application with application number 2017800310851, application date June 8, 2017, and invention title "Tear-resistant Wiping Material". Technical Field

[0002] This invention relates to tear-resistant disposable wipes suitable for personal care and hygiene-related cleaning applications. Background Technology

[0003] Disposable wipes, including wet wipes, have long been used in many different personal care and hygiene applications, such as perineal wipes, hand wipes, face wipes, and so on. Users of such wipes expect a wipe with a soft and comfortable feel. Furthermore, users expect a wipe that remains consistently moist, neither too much nor too little moisture. Commonly, such items are provided with multiple wet wipes in a resealable dispenser, allowing the end user to remove the desired number of wipes from the dispenser during use. This helps maintain the desired moisture content of the wipes over a longer period. During use, the wipes rub against a given surface and experience various frictional and torsional forces. However, the dispensing of the wipes also applies frictional and other mechanical forces, which can cause tearing, punctures, or other damage. Achieving the desired tactile properties, as well as the required strength and durability for conversion, dispensing, and use, has proven difficult.

[0004] Therefore, in order to address the unmet needs associated with existing wet wipes, the present invention provides wet wipes with a comfortable feel and tear-resistant edges to provide stronger and more durable wipes that are better able to withstand the forces and stresses typically associated with the switching and dispensing of wipes. Summary of the Invention

[0005] A tear-resistant wipe is provided having a repeating pattern of dense, thin linear embossed elements at least adjacent to the leading edge of the wipe. In this respect, the wipe has a first pattern of embossed elements extending inward along the first edge by less than about 33% of the wipe width, for example, extending towards a (non-adjacent) opposite edge between about 0.6 cm and about 8 cm. When presented in a stacked manner, the first edge or leading edge is oriented such that it is exposed, including the outer portion of the stack. The embossed elements of the first embossed pattern may include linear elements having an aspect ratio of at least 2:1 and a width of less than about 1.5 mm. Furthermore, the linear embossed elements of the first embossed pattern may occupy about 5% to about 30% of the area associated with the first embossed pattern. In some embodiments, the first embossed pattern may produce a plurality of elements having a width of less than about 50 mm. 2The unembossed recesses are substantially discrete in size, such that they occupy most of the area covered by the extension of the first pattern. Additionally, the linear embossed elements of the first embossed pattern may have a length between approximately 2 mm and approximately 40 mm.

[0006] Adjacent to the first embossed pattern, the wiping cloth may have a second embossed pattern without embossing or with embossed elements, the embossed area of ​​the second embossed pattern being smaller than the embossed area of ​​the first embossed pattern. In this respect, the embossed area of ​​the second embossed pattern is preferably at least 25% lower than the embossed area of ​​the first embossed pattern. In some embodiments, the second embossed pattern will primarily comprise an area greater than 100 mm. 2 The area of ​​the unembossed region or element. In various other embodiments, the second embossed pattern may also include linear embossed elements and have an embossed area between about 0.5% and about 10%. Additionally, the wipe may have a third pattern of embossed elements positioned adjacent to the rear edge (opposite to the first edge), wherein the embossing parameters of the third pattern are the same as those of the first pattern.

[0007] Tear-resistant wipes can be provided in a stacked manner, the stack comprising between about 10 and about 250 wipes. In some embodiments, individual wipes within the stack can be provided in an interconnected and / or interleaved folded manner. In a particular embodiment, the stack may include wipes folded to form a first folded panel adjacent to a first edge and a bottom center panel. In some embodiments, individual wipes may be interconnected, for example, by means of removable protrusions or an adhesive connecting the rear and front edges of adjacent wipes. Attached Figure Description

[0008] Figure 1 This is a top view of the wipes of the present invention.

[0009] Figure 2 This is a top plan view of an embossed fabric suitable for conversion to form the wipes of the present invention.

[0010] Figure 3 This is a perspective view of the stack of wipes according to the present invention.

[0011] Figure 4 It has Figure 3 The image depicts a perspective sectional view of an open dispenser with stacked wiping cloths.

[0012] Figure 5A A schematic top view representing a portion of the clip of the interconnected wipes of the present invention.

[0013] Figure 5B An exploded side view schematic diagram of the interconnected folded wipes of the present invention is shown representatively.

[0014] Figure 6 This is a perspective view of an open flexible packaging dispenser with a stack of wipes according to the present invention. Detailed Implementation

[0015] definition

[0016] Throughout this specification and claims, the discussion of the article and / or its individual components shall have the understanding set forth below. As used herein, the term "cellulose" means those materials that comprise or are derived from cellulose, including natural or synthetic cellulose as well as cellulose derived from lignocellulosic and non-lignocellulosic sources.

[0017] As used herein, the terms “comprising,” “including,” or “having” are inclusive or open-ended and do not exclude additional undescribed elements, constituent components, or method steps. Therefore, the terms “comprising,” “including,” or “having” cover the more restrictive terms “substantially consisting of” and “consisting of.”

[0018] As used in this article, "continuous fiber" means fiber formed in a continuous, uninterrupted manner, having an indefinite length and a high aspect ratio (length to diameter) of more than 100:1; in use, the length of such fiber is substantially the same as the length or width of the wiping material itself.

[0019] As used in this article, “short fiber” means long-cut natural or continuous synthetic fiber, which typically has a length between about 0.5 mm and about 200 mm.

[0020] As used herein, unless otherwise expressly indicated, when referring to a material composition, the terms "percent" and "weight percent / percent by weight" each refer to the amount of a component as a percentage of the total amount by weight; for liquid compositions, such total weight percentages are based on dry products, except for dry products.

[0021] As used herein, the term “machine direction” or “MD” refers to the direction of travel of fibers deposited onto the forming surface during the formation of the fibrous web; such direction is also the direction of continuous filament extension.

[0022] As used in this article, the term "cross-machine direction" or "CD" refers to a direction that is substantially perpendicular to the machining direction defined above.

[0023] As used herein, the term "nonwoven web" refers to a structure or material web formed without the use of traditional fabric forming processes such as weaving or knitting, to produce a structure of individual fibers or threads that are entangled or interwoven but not in a recognizable repeating pattern. Nonwoven webs can be formed by a variety of processes, including, for example, meltblown, spunbond, hydroentangling, short fiber carding, as well as air-forming and wet-forming processes.

[0024] As used in this article, the term "emboss / embossment" refers to a substantially permanent, localized recess in a substrate sheet.

[0025] As used herein, the term “stack” is used broadly for any collection of sheets in which there are multiple individual sheets having interfaces between surfaces; this includes not only vertically stacked collections of individual sheets, but also horizontally stacked collections of individual sheets, as well as collections of rolled or folded sheets.

[0026] As used herein, “reach-in” dispensing should be understood to mean that a swab must be removed from the dispenser through an opening that extends substantially in common with the walls of the dispenser or through a restricted opening with a perimeter smaller than that defined by the walls. In either case, the top swab for dispensing is placed on top of the remainder of the swab stack, and the top swab needs to be separated from the remainder of the stack whenever a new swab is to be dispensed.

[0027] As used herein, the term “wet wipe” refers to a fibrous sheet having a liquid applied to and retained therein.

[0028] refer to Figure 1The wiping material 10 is provided as defined by: a first edge 12, an opposing second edge 14 extending parallel to the first edge 12, and third and fourth edges 16 and 18 opposing each other and perpendicular to the first and second edges 12 and extending between the first and second edges 14. The size of the wiping material may vary depending on its specific end use and / or desired function. In some embodiments, the wiping material may have a diameter (at its maximum size) between about 5 cm and about 45 cm, and in some embodiments between about 10 cm and about 30 cm. In other embodiments, the wiping material may have a length (extending in the direction of the first and second edges 14) between about 5 cm and about 30 cm or between about 12 cm and about 25 cm. Additionally, the wiping material may have a width (extending in the direction of the third and fourth edges 18) between about 5 cm and about 30 cm or between about 10 cm and about 20 cm. The wiping material may have any of a variety of shapes, such as rectangular, square, elliptical, circular, etc. Furthermore, the edge itself can be cut into straight edges or into more complex or irregular shapes, such as curves; for example, fan-shaped or sinusoidal edges.

[0029] The wipe comprises a series of repeating embossings forming one or more patterns. The embossing will include a permanently compressed area within a base sheet with a significantly reduced thickness and increased density. The wipe 10 comprises a first embossed pattern formed by embossing elements 20. The first embossed pattern extends a distance A (“pattern width”) from a first edge 12 toward an opposing second edge 14. The pattern width A of the first pattern may occupy approximately 33% of the wipe width and ideally approximately 25% of the wipe width, and in some embodiments, may occupy between approximately 5% and approximately 25% of the wipe width or between approximately 5% and approximately 20% of the wipe width. On the other hand, the pattern width A of the first pattern may be between approximately 0.6 cm and approximately 10 cm, or between approximately 1 cm and approximately 8 cm, or even between approximately 2 cm and approximately 5 cm. The first embossed pattern comprises repeating patterns of embossing elements 20, such elements may be identical or different and may have the same or different orientations. The first embossed pattern may have an embossed area (above the area it occupies) between about 30% and about 5%, or between about 5.5% and about 25%, or between about 6% and about 14%.

[0030] refer to Figure 1In the embodiment shown, the first pattern adjacent to the first edge 12 is formed by embossing elements 20a, 20b, and 20c. Embossing elements 20 are linear or curved and have an aspect ratio (L:W) of at least about 2:1, and more ideally at least about 5:1 or at least about 10:1. Furthermore, the linear or curved embossing ideally has a width of less than 1.5 mm, for example, between about 0.005 mm and about 1.5 mm, and in some embodiments, the width of the linear embossing may be between about 0.01 mm and about 1.25 mm, or even between about 0.1 mm and about 1 mm. Regarding patterns employing discrete embossing elements, the embossing-to-embossing spacing is relatively small in the first pattern; in this respect, in some embodiments, the discrete embossing may have a center-to-center spacing between about 1 mm and about 25 mm, or between about 2 mm and about 15 mm, or even between about 2.5 mm and about 11 mm. For the purposes of this paper, the center-to-center distance of the embossed elements is determined based on the midpoint of the linear embossing and is defined as the distance between the closest embossed elements. The size, spacing, and orientation of the linear embossing result in a pattern primarily formed less than approximately 50 mm. 2 And still more ideally smaller than about 45, 35, or even 30 mm 2 The unembossed area or recess 21. For purposes herein, the size of the unembossed recess can be measured by the size of a uniform circle (e.g., having a uniform radius) positioned within the unembossed recess without any embossed elements overlapping it. The first pattern may contain a size greater than 50 mm. 2 60 mm 2 Or even 80 mm 2 Unembossed recesses or areas, however, such large unembossed recesses should comprise less than approximately 33% of the area occupied by the first embossed pattern, and still more ideally less than approximately 25% or even 20% of the area occupied by the first embossed pattern. In some respects, the first embossed pattern may lack any unembossed recesses of any size greater than 90%, 80%, or even 75% of the width of the first pattern. In this respect, the use of thinner, denser embossing allows for a greater increase in edge strength and durability.

[0031] Linear embossing can have varied shapes, including, for example, geometric and curved forms. In some embodiments, the embossing may have segments extending primarily along the MD (i.e., at + / -45º to the MD direction) and segments extending primarily along the CD (i.e., at + / -45º to the CD direction). Linear embossing can be discrete embossing or can form continuous embossing, such as cross-shaped or mesh patterns, provided that the embossing pattern satisfies other parameters described herein. Regarding the use of discrete embossing elements, the elements may have lengths of about 2 mm and about 40 mm, or between about 3 mm and about 20 mm, or even between about 3 mm and about 25 mm (the length is measured as the actual length of the linear embossing, e.g., arc length). As a non-limiting example, linear embossing can have S-shaped, Z-shaped, X-shaped, W-shaped, C-shaped, J-shaped, O-shaped, V-shaped, T-shaped, I-shaped, etc. Regarding individual embossings, they may have free ends or form continuous loop shapes (e.g., ellipses, circles, or others). Embossing can include icons such as clouds, dogs, bears, leaves, feathers, flowers, or other recognizable images or characters. (See reference) Figure 1 The embossed element 20c includes an icon.

[0032] In some aspects, the orientation of individual embossing elements may vary relative to the length and width directions and / or MD and CD, ideally positioned with alternating orientations such that adjacent elements extend obliquely relative to the MD or length direction, or in some instances may extend in directions substantially orthogonal to each other. In some embodiments, embossed elements may extend substantially in the length direction or MD, and adjacent elements may extend substantially in the width direction or transverse direction. For example, and referring to Figure 1 In the embodiment shown, the embossed elements 20a and 20b are positioned close to each other in an alternating manner and are oriented substantially perpendicular to each other.

[0033] Furthermore, the series of embossed patterns 20 can be aligned in at least one direction. In this regard, the series of embossed patterns can be aligned along the length direction, the width direction, or skewed relative to said direction (e.g., aligned on the MD and CD, or skewed relative to both the MD and CD). In some embodiments, the series of embossed patterns or continuous embossed patterns can be aligned in a direction at an angle θ relative to the width direction or the CD, said angle being between about 30 degrees and about 60 degrees, or between about 35 degrees and about 55 degrees. Reference Figure 1 The first pattern of a series of linear embossings 20a is aligned at an angle of approximately 45º relative to the MD and CD (length and width of the sheet).

[0034] In one aspect, the area extending inward from the end of the first pattern to the second opposing edge may be unembossed. Alternatively, the wipe may also include a second embossed pattern. In some embodiments, the second embossed pattern may extend across the wipe from the end of the first pattern to the opposing second edge (not shown), or may extend adjacent to the opposing second edge (e.g., ...). Figure 1 The end of the third embossed pattern (as shown in the diagram) is positioned. The embossed area of ​​the second embossed pattern is significantly smaller than that of the first embossed pattern, and in some respects, the second embossed pattern may have an embossed area between about 0.5% and about 10%, or between about 1% and about 6%. Furthermore, ideally, the embossing is discrete and, unlike the first pattern, not dense. The embossed area of ​​the second embossed pattern will be smaller than that of the first embossed pattern; ideally, the embossed area of ​​the second pattern is at least 20% smaller than the first embossed area and still more ideally at least about 30% smaller than the first embossed area. The size, spacing, and orientation of the embossing of the second pattern can be selected such that the pattern is primarily formed to be greater than about 100 mm. 2 And still ideally larger than about 125, 150, or even 200 mm 2 The unembossed recesses. The embossed elements forming the second pattern can also be linear or curved, having parameters (other than area and density) such as those described above with reference to the first embossed pattern. However, in some embodiments, the embossed elements forming the second pattern may optionally have a smaller aspect ratio and a larger width compared to the elements of the first embossed pattern. The second embossed pattern may have a series of small discrete elements and larger elements, such as elements forming icons or images. Reference Figure 1 In the embodiment depicted, the second pattern comprises a repeating pattern formed by widely spaced S-shaped embossed elements 26c and larger elements 26a, 26b, wherein the elements in this particular embodiment include, for example, icons of clouds and leaves.

[0035] refer to Figure 1 The second embossed pattern is formed by embossed elements 26. Individual embossed elements include cloud icons 26a, leaf icons 26b, and S-shaped elements 26c. In the illustrated embodiment, the individual embossed elements 26 of the second pattern are aligned at a 35-degree angle relative to the MD and CD, and in the illustrated embodiment, this angle is slightly smaller than the 45-degree angle shown with respect to the series of first embossed elements 20a of the first embossed pattern. Furthermore, both the first and second embossed patterns include embossed elements 20c and 26a, which are formed identically to each other and also to the icons within the third pattern, i.e., embossed element 24c. This alignment of matching elements and the use of identical icons provides improved manufacturing operations and a more harmonious appearance and form.

[0036] As mentioned above, the third embossed pattern may be positioned adjacent to the second side edge 14. The third embossed pattern and the individual embossings forming the third embossed pattern may be selected according to the parameters described above regarding the first embossed pattern adjacent to the first edge 12. The third embossed pattern may be the same as or different from the first embossed pattern. (See reference) Figure 1 The third embossed pattern is formed by embossing 24 positioned adjacent to the second edge 14. The first and third embossed patterns each include repeating patterns of S-shaped embossed elements 20a, 20b, 24a, 24b and larger elements 20c, 24c, which include, for example, cloud icons that match the icons of the second pattern in this example.

[0037] The wiping cloth of the present invention comprises a porous fibrous substrate sheet. In this respect, the porous material will have individual openings or gaps, which in some embodiments collectively form a path through the thickness of the material via adjacent interconnecting spaces or openings. The fibrous sheet may comprise continuous fibers, short-length fibers, or combinations thereof. The wiping substrate substantially retains its integrity when wet and, in some respects, remains elastically compressible when wet. Furthermore, the fibrous sheet may comprise woven, knitted, or non-woven fabrics, and additionally, the fibrous sheet can be used to form a laminate with one or more additional materials. Suitable fibrous sheets will typically have a strength from about 20 g / m³. 2 Up to approximately 200 g / m 2 The dry basis weight. In some embodiments, the dry basis weight of the fibrous sheet will be approximately 25 g / m². 2 Up to approximately 150 g / m 2 Furthermore, in another embodiment, it can be achieved at approximately 30 g / m 2 Up to approximately 120 g / m 2 Between. This invention is particularly applicable to wipes with fibers of smaller diameter and / or wipes incorporating higher levels of cellulose fibers.

[0038] In some embodiments, the fibrous material may comprise fine thermoplastic fibers, such as fibers with an average fiber diameter between about 0.5 micrometers and about 10 micrometers. In some embodiments, the thermoplastic fibers may have an average fiber diameter between about 1 micrometer and about 8 micrometers, or between about 2 micrometers and about 7 micrometers. Such finer fibers are advantageous from the viewpoint of providing a good hand feel and helping to maintain uniform moisture content through sheets and stacks. Thermoplastic polymer fibers may also ideally be continuous or substantially continuous. Polymers suitable for forming such fibers include, but are not limited to, polyolefins, polyesters, polyamides, polyhydroxyalkanoates, polylactic acid, or other fibers that form polymers. Preferred polymer fibers include, but are not limited to, polymer fibers comprising polypropylene and / or polyethylene. Thermoplastic fibers may be formed according to one or more of various processes, including, but not limited to, thermoplastic fibers formed by melt extrusion processes such as meltblowing and other known processes. Methods for manufacturing fine fibers and related webs have been described, for example, in Butin et al. (US3849241), Meitner et al. (US4443513), Win et al. (US4853281), Marmon et al. (US6200669), Haynes et al. (US7150616), Haynes et al. (US7316552), and so on. In this regard, in some embodiments, the fibrous material may comprise between about 100% and 15% thermoplastic fibers, or between about 85% and about 25% thermoplastic fibers, or even between about 45% and 25% thermoplastic polymer fibers.

[0039] The fibrous material may also contain cellulose fibers. In this respect, the fibrous material may contain up to about 85% cellulose fibers, and in some embodiments may include between about 15% and about 75% cellulose fibers, and in other embodiments may include between about 55% and about 75% cellulose fibers. Cellulose fibers may include conventional papermaking fibers, including woody fibers such as those obtained from deciduous and coniferous trees, including but not limited to softwood fibers, such as northern and southern softwood kraft paper fibers; and hardwood fibers such as eucalyptus, maple, birch, and poplar. Other papermaking fibers that may be used in this disclosure include waste or recycled fibers and high-yield fibers. Various pulping processes considered suitable for producing cellulose fibers include bleached chemothermal-mechanical pulp (BCTMP), chemothermal-mechanical pulp (CTMP), pressure / pressure thermomechanical pulp (PTMP), thermomechanical pulp (TMP), thermomechanical chemical pulp (TMCP), high-yield sulfate pulp, and high-yield kraft pulp, all of which result in fibers with high levels of lignin. High-yield fibers are known for their stiffness relative to typical chemically pulped fibers in both dry and wet states. Furthermore, cellulose fibers can include non-wood fibers such as cotton, abaca, bamboo, kenaf, Indian hay, flax, Spanish hay, straw, jute, hemp, bagasse, milkweed fibers, and pineapple leaf fibers, etc. Additionally, cellulose fibers can include synthetic fibers derived from cellulose materials, such as viscose, man-made fibers, lyocell fibers, or other similar fibers. Furthermore, secondary fibers obtained from recycled materials can be used, as needed, such as pulp recovered from sources like newsprint, cardboard, office waste paper, etc. Fibrous sheets can include a single cellulose fiber, or alternatively, a mixture of two or more different cellulose fibers. As is known in the art, the use of fiber mixtures is often desirable, especially when using recycled or secondary fibers.

[0040] Co-formed materials are particularly suitable for this invention. Co-formed nonwoven meshes are formed by combining multiple polymeric fibers and absorbent fibers, such as polyolefin fibers and cellulose fibers, before depositing them onto a forming surface, while these fibers are entrained by a common airflow. Examples of such co-formed substrate sheets and methods of their manufacture are described in Anderson et al. US4100324, Georger et al. US5350624, Schmidt et al. US2011 / 0151196, Jackson et al. US20212 / 171919, etc. In some embodiments, such co-formed sheets may comprise an air-formed matrix of thermoplastic polyolefin meltblown fibers and cellulose or wood pulp fibers. In some embodiments, the meltblown fibers may be continuous fibers.

[0041] Wet-laid or hydrospun nonwoven sheets are also considered suitable for this invention. Hydrospunlace is a process for forming a nonwoven web that typically includes the steps of (i) depositing loose fibers onto a porous tape or patterned mesh, and (ii) subjecting the fibers to one or more rows of fine, high-pressure water jets, causing the fibers to become sufficiently entangled to form a coherent nonwoven web. In some respects, hydrospunlace facilitates the combination of different fiber types, such as combining fibers of different compositions (e.g., polymeric fibers and wood pulp fibers) or fibers of different sizes (e.g., continuous length and short length fibers). As non-limiting examples, suitable hydrospunlace materials and methods of their manufacture are described in more detail in Jeffers et al. US4925722, Everhart et al. US5284703, and Adam et al. US2010 / 0279085. In one embodiment, the fibrous sheet may comprise a mixture of pulp fibers and continuous polyolefin spunbond fibers.

[0042] In another embodiment, the fibrous sheet of the present invention may comprise an air-laid nonwoven web. In an air-laid process, fibers are typically entrained in an airflow by means of a vacuum source, become entangled with each other, and then deposited onto a shaped mesh or wire. The randomly deposited fibers then spontaneously bond together, for example by using heat and / or pressure, or by using an adhesive, such as by including bonding fibers or applying an adhesive to the web. As non-limiting examples, various examples of suitable air-laid nonwoven sheets and methods of their manufacture are described in Ali Kahn et al. US4548856, Close et al. US6811638, Lange et al. US6946413, Gusky et al. US2004 / 0192136, etc.

[0043] To impart an embossed pattern to a substrate sheet, the substrate sheet can be treated using one or more embossing techniques known in the art, which impart localized compression and / or bonding corresponding to the desired pattern. In this regard, the substrate sheet can be embossed by applying localized pressure, heat, and / or ultrasonic energy. In some aspects, the substrate sheet can be embossed using a pair of embossing rollers, as known in the art, wherein at least one of the rollers has a pattern of raised or “needle-like” protrusions corresponding to the desired pattern of the embossed elements to be imparted to the substrate sheet. The two cooperating rollers form a gap through which pressure and, optionally, heat are applied. While suitable embossing can be formed without applying heat, the use of heat and pressure is preferred. Embossing can be performed as known in the art, using a gap formed by a patterning roller and a smoothing support roller (“needle-to-plane”) or by two cooperating patterning rollers (“needle-to-needle”). Regarding the use of smoothing support rollers, such rollers can be coated with an elastic material, such as rubber, to improve the formation of embossing within the mesh. Various embossing methods are shown and described in Hansen et al. (US3855046), Baum (US6036909), Samida et al. (US6165298), and others. As is known in the art, pressure, temperature, residence time, substrate sheet composition and thickness, and other parameters will influence the desired level of pressure and / or heat applied to the substrate sheet to impart the desired embossed pattern. However, in many embodiments, it is desirable to apply pressure at approximately 1400 kg / cm² in the roll gap. 2 (Approximately 20,000 PSI) and approximately 4200 kg / cm² 2 Contact pressure between approximately 60,000 PSI. Furthermore, when incorporating polyolefin fibers such as polypropylene, one or more rollers may have a temperature between approximately 65°C and approximately 90°C.

[0044] In manufacturing, as is known in the field, for the sake of production efficiency and speed, it may often be desirable to emboss multiple series of patterns across the full CD width of the substrate sheet, and then cut the wide substrate sheet on the MD to form wipes of the desired width. (Reference) Figure 2 A wide production sheet 50 is provided, having a repeating series of first embossed patterns 52 and second embossed patterns 54. The first embossed pattern 52 is formed in the wide production sheet 50, the width of which on the CD is twice the width required for the final conversion of the wipes. The wide production sheet is cut along a cutting line 56 extending downwards along the center of the first embossed pattern 52, thereby obtaining a sheet with the desired edge embossing and different center embossed patterns 54. To achieve a variety of different edge embossed patterns in the finished product, it will be readily understood that different edge embossed patterns can replace every other first embossed pattern.

[0045] The wipes can be presented in a stacked form; the stack may, for example, contain between 3 and 250 wet wipes, and in another embodiment may contain between about 10 and about 150 wet wipes, and in another embodiment may contain between about 10 and about 90 wet wipes. In one aspect, the sheets forming the stack can be folded or unfolded and oriented to overlap each other. Various known folding configurations can be used in conjunction with the invention, including, for example, V-folds, Z-folds, W-folds, quarter folds, etc. In some embodiments, the wipe stacks are staggered, whereby a folded panel of one wipe is positioned between two folded panels of one or more adjacent wipes. Apparatus and processes for forming dispensable wipe stacks are known in the art; examples include, but are not limited to, those described in Frick et al. US3401927, Clark et al. US4502675, Yoneyama US5310398, Zander US5964351, Sosalla et al. US6612462, etc. On the other hand, for example, regarding product forms utilizing continuous length sheets, stacks comprising individually separable wet wipes may be provided, the wet wipes having perforations or weakening lines that allow separation into smaller individual sheets of desired shape and size. In this regard, the use of such weakening lines is typically employed in conjunction with stacks in the form of roll forming or trimming.

[0046] refer to Figure 3 A stack 100 comprising a plurality of individual wipes 110 is provided. The individual wipes may be completely separable from each other, or interconnected by means of separable elements such as removable protrusions or by adhesive means as described below. Each wipe 110 has opposing first edges 112 and second edges 114, and opposing third edges 116 and fourth edges 118. Figure 3In the embodiment of the invention depicted, a first embossed pattern 113 is disposed adjacent to a first edge 112, and an identical embossed pattern 114 is disposed adjacent to an opposite second edge 114. As discussed above, a second, more open embossed pattern (not shown for ease of reference) may optionally be disposed between the edge embossed patterns 112, 114. The first edge 112 and the associated first embossed pattern 113 are exposed on the outer surface of the stack, and in this embodiment, on the upper surface of the stack 100. The wipes 110 are presented in a Z-shaped fold, each wipe having a first fold 101 and a second opposing fold 102, the first fold 101 being immediately adjacent to the first edge 112 forming a first panel 103 overlying the center panel 104 of the wipe 110, and the second opposing fold 102 being immediately adjacent to the opposite second edge 114 forming a second panel 105 folded below and resting on the center panel 104 of the wipe 110. The wipes 110 are sequentially folded and oriented such that removal of the outermost or uppermost wipe will similarly reveal and expose the first edge 112 and associated first embossed pattern 113 of the bottom wipe in the stack 100. For example, removal of the uppermost wipe 110a will expose the first edge of the subsequent wipe 110b. Alternatively, in embodiments where both the first and second edges have suitable edge embossed patterns as described above, a folded form can be used, whereby removal of the wipe will, for example, reveal the first or second edge in an alternating manner (not shown). Regarding the forming of the stack, a cleaning agent can be added to it in the desired amount to form a wet wipe stack.

[0047] Furthermore, the wipes of the present invention can be used in combination with a stack of wipes, wherein individual sheets are attached to adjacent sheets using a releasable or easily removable adhesive and are detachable from the adjacent sheets. In this respect, the adhesive connecting adjacent wipes may be placed adjacent to the rear edge of the upper sheet and adjacent to the front edge of the lower or subsequent sheet. Placement adjacent to such edges results in the adhesive being located within and limited to a mesh area having the edge embossing pattern described herein.

[0048] In a particular embodiment, and with reference to Figure 5A and 5BA series of interconnected wipes or interconnected wipe clips 134 are provided, comprising a plurality of separable individual sheets 132a, 132b, 132c, etc. The leading edge 131 of the first wipe 132a in the clip 134a is given a first edge embossing pattern 138 according to the teachings described above. The trailing edge of the first wipe 132a and the leading edge of the second wipe 132b are connected along a weakening line 136, which may be achieved, for example, by scribing, perforation, etc. As shown, the weakening line includes a perforation line and has a plurality of individual perforations 137 forming separate, removable protrusions spaced apart and extending across the width of the wipe. Thus, the individual sheets can be easily separated from each other in use. Furthermore, at least the leading edge 131 of the first wipe 132a in the clip 134 and the trailing edge 133 of the last wipe 132h in the individual clip 134 will have the first edge embossing pattern 138 as described above. Alternatively, the front and rear edges of each sheet 132a to 132h may have a first edge embossing pattern as described herein. Referring to the illustrated embodiment, the front edge 131 of the first sheet 132a and the rear edge 133 of the last wipe 123h in the clips 134a and 134b will have a first embossing pattern 138 adjacent to the edge region as described herein.

[0049] The stack 130 of separable individual wipes 132 will also include multiple clips 134a, 134b, etc. The individual clips are interconnected using an adhesive, which may be applied as a thread, bead, or more broadly across selected portions of the wipes. Adhesive 135 is positioned adjacent to the rear edge 133 of the last wipe 132h within the first clip 134a and the front edge 131 of the first wipe 132a in subsequent clips 134b. Thus, the adhesive is positioned across sections of adjacent wipes having an edge embossed pattern applied thereto. Additional details regarding the manufacture of the fan-shaped folded clips of the wipes are described in US6612462 by Sosalla et al., the contents of which are incorporated herein to the extent consistent with this document. The selective use of the embossed pattern described herein provides wipes and / or clips interconnected in an adhesive manner, resulting in a more uniform distribution and a lower frequency of tearing, puncture, and / or other damage to the wipes.

[0050] Cleaning agents

[0051] Liquid cleaning components can be incorporated into sheets to form wet wipes. Ideally, the liquid cleaning components are added to the sheet in additional amounts of about 50% to about 700% (by weight of the dry porous sheet), more ideally from about 75% to about 500% (by weight of the dry porous sheet), even more ideally from about 100% to about 400% (by weight of the dry porous sheet) or from about 100% to about 350% (by weight of the dry porous sheet). Various liquid cleaning formulations are considered suitable for use with the present invention. The choice of a particular cleaning formulation will vary significantly depending on the intended end use of the wipe and other factors known to those skilled in the art. Liquid cleaning components may include solutions, emulsions, or dispersions. As examples, cleaning compositions considered suitable for use with the present invention include, but are not limited to, the cleaning compositions described in Johnson et al. US4772501, Richards US4941995, Cunningham et al. US8563017, Wenzel et al. US8987180, Menard et al. US2010 / 0256033, Park et al. WO2015 / 084880, etc.

[0052] Liquid cleaning compositions contain at least a solvent and a surfactant. The solvent may include water, ethanol (e.g., IPA), or a mixture of water and ethanol. Ideally, the cleaning formulation comprises an aqueous formulation containing more than 50% water and, more preferably, at least about 70% water. In some embodiments, the cleaning formulation may contain between about 70% and about 99% water, or between about 75% and about 98% water, or even between about 85% and about 98% water. In many applications, such as perineal wipes, the use of a higher percentage of water can help reduce skin sensitivity and / or help prevent a sticky or viscous feeling after use of wet wipes.

[0053] The liquid cleaning composition further comprises one or more surfactants. The cleaning composition includes a surfactant comprising less than about 20% by weight of the cleaning composition. In some embodiments, the surfactant may comprise less than about 15% or less than about 10% of the cleaning composition. In some embodiments, the cleaning formulation may comprise a surfactant between about 20% and about 0.5%, or between about 15% and 1%, or even between about 10% and about 2%. Many surfactants are considered suitable for use with the present invention, including nonionic surfactants, anionic, cationic, amphoteric, zwitterionic surfactants, and combinations thereof.

[0054] In some embodiments, the surfactant may include one or more nonionic surfactants. As examples, suitable types of nonionic surfactants include, but are not limited to: alkyl glycosides and alkyl polyglycosides, alkyl glucosides and alkyl polyglucosides, ethoxylated alkylphenols, and ethoxylated fatty acids (C8-C4). 22 Alcohols, ethoxylated and propoxylated fatty alcohols, polyethylene glycol ethers of methyl glucose, polyethylene glycol ethers of sorbitol, ethylene oxide-propylene oxide block copolymers, fatty (C8-C) alcohols, ethoxylated and propoxylated fatty alcohols, methyl glucose, ethylene glycol ethers, sorbitol, ethylene oxide-propylene oxide block copolymers, ethylene glycol (C8-C) alcohol ... 18 Ethoxylated esters of acids, condensation products of ethylene oxide and long-chain amines or amides, condensation products of ethylene oxide and alcohols, and mixtures thereof. One or more anionic, cationic, or amphoteric surfactants may also be used alone or in combination with other surfactants in the cleaning compositions of the present invention. As examples, additional surfactants considered suitable for use in the present invention include, but are not limited to: alkyl sulfates, alkyl ether sulfates, alkyl ether sulfonates, alkylaryl sulfonates, fatty acid amide polyethylene oxide sulfates, aminopropyl alkyl glucosamides, sodium alkyliminodipropionate, carboxybetaine, sulfobetaine, phosphate betaine, phosphite betaine, amine oxides, cocamidopropyl betaine, cocoyl betaine, lauryl hydroxysulfobetaine, alkylamines, dimethyl alkylamines, alkyl betaines, quaternized APG, ethoxylated alkylamines, and combinations thereof.

[0055] The liquid cleaning composition may optionally contain one or more preservatives or antibacterial agents to extend the shelf life of the wet wipes. Suitable preservatives that can be used in this invention include, but are not limited to, sodium benzoate and other metal salts (e.g., sodium benzoate available under the trade name PUROX S from Emerald Performance Materials); mixtures of methylchloroisothiazolinone and methylisothiazolinone (e.g., KATHON CG from Dow Chemical); methylisothiazolinone (e.g., NELONE 950 from Rohm Haas); DMDM ​​hydantoin and iodopropynyl butylcarbamate (e.g., GLYDANT from Lonza). PLUS); parabens (parabens), such as methylparaben, propylparaben, butylparaben, ethylparaben, benzylparaben, sodium methylparaben, and sodium propylparaben; 2-bromo-2-nitropropane-1,3-diol (e.g., Bronopol from BASF); benzoic acid; sorbic acid and its salts; imidazolidinyl urea (e.g., Germall 115 from Ashlan, Inc.); diazolidinyl urea (e.g., Germall II from Ashland, Inc.), etc. Combinations of one or more different preservatives are also suitable for use in this invention. Ideally, the preservative is present in the cleaning composition in an amount between about 0.001% and about 5% (by weight of the cleaning composition). In some embodiments, the preservative may comprise between about 2.0% and about 0.01% by weight of the cleaning composition, and in other embodiments, it may comprise between about 1.0% and 0.1% by weight of the cleaning composition.

[0056] Liquid cleaning compositions may optionally further include one or more additional components, such as antioxidants, astringents, conditioning agents, emollients, deodorants, topical analgesics, film-forming agents, humectants, water-soluble aids, pH adjusters, rheology modifiers, fragrances, lubricants, surface modifiers, skin care agents, etc.

[0057] Wet wipes can be maintained over time in sealed containers, such as plastic pouches or bags, jars, wide-mouth bottles, boxes, buckets, etc. Ideally, stacked wet wipes should be maintained in resealable containers. The use of resealable containers is particularly desirable when utilizing stacks of wet wipes to limit the evaporation of cleaning components from any remaining unused wet wipes in the container. Exemplary resealable containers and wet wipe dispensers include, but are not limited to, those described in US4171047 by Doyle et al., US4353480 by McFadyen, US4778048 by Kaspar et al., US4741944 by Jackson et al., and US2012 / 0160864 by Shoaf et al., the contents of which are incorporated herein by reference to their consistency with this document. Flexible bag packaging with resealable labels is particularly suitable for use with this invention, and examples include, but are not limited to, those described in Kaufmann's US5264265, Huang et al.'s US6592004, Buck et al.'s US2005 / 0011906, Scott et al.'s US2010 / 0154264, Gerstle et al.'s US2010 / 0155284, and Bushman et al.'s US2014 / 001196, the contents of which are incorporated herein by reference to this invention. For example, dispensers employing protrusions and / or continuous roller-type stacks are disclosed in Niske et al.'s US4651895, Haines et al.'s US6158614, and Tramontina et al.'s US2010 / 0133287, the contents of which are incorporated herein by reference to this invention. Specific stacking heights and sheet counts can vary depending on the intended form and application. As is known in the art, these sheets can be oriented in a stack and the stack can be incorporated into a container in a manner designed to improve use and / or dispensing efficiency. In some embodiments, the wet wipe stack is ideally arranged and combined with a dispenser to facilitate dispensing one at a time, and includes a known “pop-up” dispensing format.

[0058] In one embodiment, and referring to Figure 4A hand-held dispenser 170 is provided, having a housing 172 and a reclosable lid 174 hingedly attached to the housing 172; the housing and lid cooperate to define a sealed interior 175 of the container 170. A stack of wipes 100 is positioned within the housing 172, wherein a first edge 112 and an associated first embossed pattern 113 are presented and exposed, such that when the lid 174 is open, a user can reach into the housing, grasp the first edge 112 of a wipe 110, and remove the wipe 110 from the stack 100. After the top wipe is removed, a subsequent wipe is presented again, with the first edge 112 exposed for the user to grasp. The lid can then return to a closed position (not shown) to prevent evaporation loss of the cleaning components contained in the wipes. In some embodiments, the dispenser may also include a dispensing plate (not shown) between the housing and the lid, which is movable independently relative to the housing in the open and closed positions. The dispensing plate is hinged to a lid or case and provides a rigid member surrounding the periphery of the plate (closely to the case wall) and an internal opening including a contraction orifice (i.e., an orifice smaller than the swab's opening) and / or a cut flexible dispensing membrane across the opening. When a swab is pulled out through the dispensing orifice, the contraction provides resistance or frictional resistance on the swab, such that when the first swab is fully pulled out through the dispensing orifice and the leading edge of a subsequent swab is pulled out through the dispensing orifice, the resistance causes the interconnected swabs to separate, leaving the first edge of the next swab above the stack and partially exposed and / or protruding through the dispensing orifice for easy gripping by the user, providing one-at-a-time pop-out dispensing. Various interactive folding configurations can also be used to provide one-at-a-time pop-out dispensing for both the dispenser and the stack.

[0059] In another embodiment and reference Figure 6 Dispenser 190 is provided by a flexible bag 191 and has a rigid, resealable cap 192 attached thereto to the flexible bag 191. As is known in the art, the flexible bag includes a removable protrusion (not shown) that peels off when the user is ready to withdraw a wipe and provides a dispensing opening 193 upon removal, through which wipes 194 can be withdrawn and removed from a stack (not shown). The size of the dispensing opening or vent can be selected as needed to provide hand-held dispensing or one-at-a-time dispensing and / or pop-up dispensing. A first edge 195 of the wipe having a first embossed pattern 196 is exposed. Removing a wipe from the stack via the dispensing opening 193 causes the underlying subsequent wipes (not shown) to emerge above the stack and be partially exposed through the dispensing opening 193. Individual wipes are oriented such that the edges of the wipes having the edge embossed pattern described above are repeatedly presented for gripping, including in a raised and exposed manner associated with one-at-a-time pop-up dispensing.

[0060] Example

[0061] Example 1: According to US5350624 by Georger et al. and US Application 62 / 381830 by Vater et al., a series of three-piece web forming machines are used to form a nonwoven web. The nonwoven web has a basis weight of 50 gsm and comprises a mixture of 32 wt% polypropylene meltblown fibers and 68 wt% wood pulp fibers. The nonwoven web is embossed and cut to provide a web with properties such as… Figure 1 The embossed wipes shown have an embossed pattern where the edge embossing has 8.5% embossed area and the center bonding pattern has 2.8% embossed area. The embossing rollers are maintained at 75°C and subjected to approximately 26 psi (1.8 kg / cm²). 2 The pressure was measured. Samples with a width of 25.4 mm were taken from the edge portion (with a first embossed pattern) and the center portion (with a second embossed pattern), and the corresponding tensile strength of the samples was tested. The edge sample had an average tensile strength of 261 gf, and the center portion had an average tensile strength of 231 gf.

[0062] Example 2. A series of three-piece web forming machines were used to form a nonwoven web according to Georger et al. (US5350624). The nonwoven web had a basis weight of 50 gsm and comprised a mixture of 32 wt% polypropylene meltblown fibers and 68 wt% wood pulp fibers. The nonwoven web was embossed and cut to provide a web with the following characteristics: Figure 1 The embossed wipes shown have an embossed pattern where the edge embossing has 8.5% embossed area and the center bonding pattern has 2.8% embossed area. The embossing rollers are maintained at 75°C and subjected to approximately 26 psi (1.8 kg / cm²). 2 The pressure was measured. Samples with a width of 25.4 mm were taken from the edge portion (with a first embossed pattern) and the center portion (with a second embossed pattern), and the corresponding tensile strength of the samples was tested. The edge sample had an average tensile strength of 237 gf, and the center portion had an average tensile strength of 218 gf.

[0063] It should be understood that although the invention has been described in detail with respect to specific embodiments and / or examples thereof, it will be apparent to those skilled in the art that various changes, modifications, and other alterations can be made to the invention without departing from its spirit and scope. Therefore, it is intended that the claims cover or encompass all such modifications, alterations, and / or changes.

Claims

1. A stack of wiping wipes, comprising: The wiping cloth has a width defined by opposing first and second edges and a length defined by opposing third and fourth edges; The wipe further has a first embossed pattern with embossed elements, the first embossed pattern extending inward along the first edge by less than 33% of the width of the wipe, and extending toward the second edge between 0.6 cm and 8 cm; The total area occupied by the embossed elements of the first embossed pattern is between 5% and 30% of the area occupied by the first embossed pattern, and includes linear or curved elements with an aspect ratio of at least 2:1 and a width of less than 1.5 mm, wherein the area occupied by the first embossed pattern mainly comprises elements with a size of less than 50 mm. 2 The unembossed recesses; and Adjacent to the first embossed pattern, the wipe (i) has no embossing or (ii) has a second embossed pattern with embossed elements, wherein the area occupied by the embossed elements of the second embossed pattern is at least 20% smaller than the area occupied by the embossed elements of the first embossed pattern; and Additionally, the outer portion of the stack includes the first edge of the wiping cloth.

2. The wipe stack of claim 1, wherein a series of embossed elements of the first embossed pattern are aligned along a line extending at an angle between 30 and 60 degrees to the width direction of the wipe.

3. The swab stack of claim 1, wherein the embossing element of the first embossed pattern comprises discrete curved segments having a length between 2 mm and 40 mm and an aspect ratio of at least 5:1, and wherein the curved embossing element has segments extending substantially in both the length and width directions.

4. The swab stack according to claim 3, wherein the embossed elements have an average center-to-center spacing between 1 mm and 25 mm.

5. The wipe stack of claim 3, wherein the wipes have a second embossed pattern adjacent to and extending inwardly from the first embossed pattern, and wherein the first embossed pattern further includes embossed elements forming an icon, and the second embossed pattern includes elements forming an icon, and wherein the icons are identical.

6. The swab stack according to claim 5, wherein the icons in the first embossed pattern and the second embossed pattern are aligned.

7. The swab stack of claim 1, wherein the swab has a second embossed pattern adjacent to and extending inwardly from the first embossed pattern, and wherein the second embossed pattern includes embossed elements having an aspect ratio of at least 5:1, has an embossed area between 0.5% and 10%, and has an embossed area that is at least 25% lower than the embossed area of ​​the first embossed pattern.

8. The wipe stack of claim 7, wherein the second embossed pattern extends inward from the first embossed pattern, and wherein the area occupied by the second embossed pattern primarily comprises a size greater than 150 mm. 2 The unembossed recessed area.

9. The wipe stack of claim 7, wherein the first embossed pattern of the embossed element further extends along the second edge and inwardly extends less than 33% of the width of the wipe, and wherein the second embossed pattern extends between the first embossed patterns.

10. The wipe stack of claim 9, wherein adjacent sheets are interconnected with an adhesive, and wherein the adhesive is located only in the area having the first embossed pattern.

11. The swab stack of claim 9, wherein adjacent sheets are interconnected by removable protrusions positioned adjacent to the opposing first and second edges.

12. The wipe stack of claim 1, wherein the wipe comprises between 15% and 75% cellulose fibers and between 85% and 25% thermoplastic fibers, and wherein the wipe is impregnated with an aqueous cleaning composition, and wherein the wipe contains between 50% and 600% of the aqueous cleaning composition based on the weight of the dried substrate sheet.

13. The swab stack of claim 3, wherein the stack comprises interconnected adjacent swabs, and wherein a plurality of adjacent swabs are interconnected with an adhesive and the plurality of adjacent swabs are interconnected by removable protrusions.

14. The swab stack of claim 13, wherein the first pattern comprises adjacent embossed elements that are substantially orthogonal to each other and oriented.

15. A swab dispenser comprising: A container defining an internal space, the dispenser having a dispensing opening and further having a closing mechanism associated with the dispensing opening, wherein in a closed position the dispensing opening is closed and in an open position the dispensing opening is exposed and a swab can be removed from the dispensing opening; According to claim 1, the swab stack is located inside the container, and wherein the first edge of the outermost swab is accessible or exposed through the dispensing opening.

16. The swab dispenser of claim 15, wherein the dispensing opening includes a constricting opening.

17. The wipe dispenser of claim 15, wherein the wipe stack is configured such that removal of the outermost wipe causes the subsequent wipe to be partially pulled out through the dispensing opening and exposes the first edge of the wipe having the first embossed pattern.

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