Non-woven water-soluble composite material structure

Abstract

To provide composites of nonwoven webs including water-soluble fibers including polyvinyl alcohol fiber forming materials.SOLUTION: There are provided nonwoven composite articles including a first layer including a first nonwoven web including a first plurality of fibers having a first diameter, a second layer including a second nonwoven web including a second plurality of fibers having a second diameter, and a first interface including at least a portion of the first nonwoven web and at least a portion of the second nonwoven web, wherein the portion of the first nonwoven web and the portion of the second nonwoven web are fused, and wherein the second diameter is smaller than the first diameter and the first plurality of fibers, the second plurality of fibers, or both include a water-soluble polyvinyl alcohol fiber forming material. There are also provided flushable wipes and absorbent articles including nonwoven webs including fibers including a water-soluble polyvinyl alcohol fiber forming material.SELECTED DRAWING: None

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 62 / 908,310, filed September 30, 2019, the entirety of which is incorporated herein by reference.

[0002] FIELD OF THE INVENTION The present disclosure relates generally to nonwoven composite structures, flushable wipes, and absorbent articles. More particularly, the present disclosure relates to composites of nonwoven webs containing water-soluble fibers, including polyvinyl alcohol fiber-forming materials. [Background technology]

[0003] background Nonwoven webs are traditionally used in many single-use consumer products, including diaper construction, personal care products such as feminine care and adult incontinence products, and single-use wipes in industrial, medical, cleaning, and personal / baby care applications. The traditional chemicals used in such products, such as viscose, polypropylene, or cotton fibers, are generally non-persistent, non-biodegradable, and potential sources of microplastics, and are often disposed of improperly, such as by being flushed down the toilet and entering wastewater treatment and sewage systems. Conventional wipes must be disposed of in the trash, which may be neither hygienic nor convenient for users. Improper disposal of these items can result in clogged home plumbing and the formation of "fatbergs," or aggregates of solidified grease and cooking fats and solidified clumps of biodegradable and non-biodegradable materials composed of disposable wipes, in residential and municipal wastewater systems, potentially contributing to marine microplastics and necessitating changes in consumer behavior.

[0004] It would therefore be advantageous to provide a nonwoven structure using chemicals that are more biodegradable, do not contribute to microplastics, and are even water soluble, with suitable mechanical properties to withstand the stresses applied to a single-use consumer product (e.g., friction from a wipe or the movement of a child while wearing a diaper), and that has a fluid reservoir, for example, for loading lotion into a wipe and / or for retaining liquid in a liquid acquisition layer. Summary of the Invention [Means for solving the problem]

[0005] overview One aspect of the present disclosure provides a nonwoven composite article having: a first layer of a first nonwoven web comprising a first plurality of fibers having a first diameter; a second layer of a second nonwoven web comprising a second plurality of fibers having a second diameter; and a first interface comprising at least a portion of the first nonwoven web and at least a portion of the second nonwoven web, wherein the portion of the first nonwoven web and the portion of the second nonwoven web are fused together, wherein the second diameter is smaller than the first diameter, and the first plurality of fibers, the second plurality of fibers, or both, comprise a water soluble polyvinyl alcohol fiber-forming material.

[0006] Another aspect of the present disclosure provides a wearable absorbent article comprising an absorbent core having a wearer-facing surface and an outer surface, and a liquid acquisition layer, wherein the liquid acquisition layer comprises a nonwoven web comprising a plurality of fibers comprising a water-soluble polyvinyl alcohol fiber-forming material.

[0007] Another aspect of the present disclosure provides an absorbent article comprising a liquid pervious topsheet, a liquid impervious backsheet, an absorbent core and a liquid acquisition layer comprising a nonwoven web comprising a plurality of fibers comprising a water soluble polyvinyl alcohol fiber forming material.

[0008] Another aspect of the present disclosure provides a flushable wet wipe comprising the nonwoven composite article of the present disclosure.

[0009] Another aspect of the present disclosure provides the use of the composite article of the present disclosure in a flushable wet wipe.

[0010] Another aspect of the present disclosure provides the use of a composite article of the present disclosure in a wearable absorbent article.

[0011] Another aspect of the present disclosure provides a method of forming a composite article of the present disclosure, the method comprising depositing a second layer comprising a second nonwoven web onto a first layer comprising a first nonwoven web under conditions sufficient to fuse at least a portion of the first nonwoven web to a portion of the second nonwoven web, thereby forming a first interface.

[0012] Another aspect of the present disclosure provides a liquid-containing nonwoven article comprising: a core nonwoven web comprising a first plurality of fibers comprising a first polyvinyl alcohol fiber-forming material, said core nonwoven web comprising a liquid, said liquid comprising an active agent; and an outer nonwoven web comprising a second plurality of fibers comprising a second polyvinyl alcohol fiber-forming material, wherein the core nonwoven web is encapsulated in the outer nonwoven web.

[0013] Another aspect of the present disclosure provides a method of forming a liquid-containing nonwoven article of the present disclosure, the method comprising the steps of contacting a core nonwoven web with a liquid comprising an active agent, covering the core nonwoven web with an outer nonwoven web, and sealing the outer nonwoven web to encapsulate the core nonwoven web.

[0014] It is contemplated that for the compositions described herein, optional characteristics including, but not limited to, components and composition ranges thereof, fiber-forming materials, fiber diameter ranges, multi-layer constructions, fiber geometries, and / or mechanical properties may be selected from the various aspects and embodiments provided herein.

[0015] Further aspects and advantages will become apparent to those skilled in the art upon consideration of the following detailed description. While the composite structures, flushable wipes, and absorbent articles of the present disclosure are capable of embodiment in a variety of forms, the description herein below includes specific embodiments with the understanding that the present disclosure is exemplary and is not intended to limit the disclosure to the specific embodiments described herein.

[0016] To further facilitate understanding of the present disclosure, three figures are attached hereto. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 shows cross sections of various fiber shapes, with the lines indicating the fiber diameter.

[0018] [Figure 2] FIG. 2 is a diagram of a nonwoven web, with the outer surfaces of the web designated as 100 and 101.

[0019] [Figure 3] FIG. 3 shows an interface 200 where a first nonwoven web 201 overlaps a second nonwoven web 202 .

[0020] [Figure 4A] FIG. 4A is a diagram of a nonwoven web, with the machine direction shown as 301 and the cross direction shown as 300, including a second nonwoven web 302 having the same length as the nonwoven web in the machine direction 301.

[0021] [Figure 4B] FIG. 4B is an illustration of wrapping a nonwoven web around a second nonwoven web 302 along the machine direction 301.

[0022] [Figure 5A] FIG. 5A is a diagram of a nonwoven web wrapped around and enclosing a second nonwoven web (not shown) having seals 303 at multiple locations along the machine direction and along the lateral edges 304.

[0023] [Figure 5B] FIG. 5B is a diagram of a nonwoven web wrapped around and enclosing a second nonwoven web (not shown) having seals 303 at multiple locations along the machine direction, cut 305 to form unit quantities 306 with flanges 307.

[0024] [Figure 6] FIG. 6 is an illustration of one method of folding a nonwoven web.

[0025] [Figure 7] FIG. 7 is an illustration of one method of folding a nonwoven web.

[0026] [Figure 8] Figure 8 shows various views of the horizontal water absorption test configuration.

[0027] [Figure 9A] FIG. 9A is a plot of the Washburn slope for webs of the present disclosure as a function of the average degree of hydrolysis of the polyvinyl alcohol fiber-forming material in the web.

[0028] [Figure 9B] FIG. 9B is a plot of the water absorption rate of nonwoven webs of the present disclosure as a function of the average degree of hydrolysis of the polyvinyl alcohol fiber-forming material in the web.

[0029] [Figure 9C] FIG. 9C is a plot of absorbency of nonwoven webs of the present disclosure as a function of the average degree of hydrolysis of the polyvinyl alcohol fiber-forming material in the web.

[0030] [Figure 10] FIG. 10 is a plot of the interval of liquid absorbency of nonwoven webs of the present disclosure as a function of the average degree of hydrolysis of the polyvinyl alcohol fiber-forming material in the web.

[0031] [Figure 11A]FIG. 11A is a plot of the Washburn slope for nonwoven webs of the present disclosure as a function of the average degree of hydrolysis of the polyvinyl alcohol fiber-forming material in the multi-layer article.

[0032] [Figure 11B] FIG. 11B is a plot of the water absorption rate of nonwoven webs of the present disclosure as a function of the average degree of hydrolysis of the polyvinyl alcohol fiber-forming material in the multi-layer article.

[0033] [Figure 11C] FIG. 11C is a plot of the absorbency of nonwoven webs of the present disclosure as a function of the average degree of hydrolysis of the polyvinyl alcohol fiber-forming material in the multi-layer article.

[0034] [Figure 12] FIG. 12 is a plot of the interval of liquid absorbency of nonwoven webs of the present disclosure as a function of the average degree of hydrolysis of the polyvinyl alcohol fiber-forming material in the multi-layer article.

[0035] [Figure 13A] FIG. 13A is a plot of the Washburn slope for nonwoven webs of the present disclosure as a function of the average degree of hydrolysis of the polyvinyl alcohol fiber-forming material in the multi-layer article.

[0036] [Figure 13B] FIG. 13B is a plot of the water absorption rate of nonwoven webs of the present disclosure as a function of the average degree of hydrolysis of the polyvinyl alcohol fiber-forming material in the multi-layer article.

[0037] [Figure 13C] FIG. 13C is a plot of absorbency of nonwoven webs of the present disclosure as a function of the average degree of hydrolysis of the polyvinyl alcohol fiber-forming material in the multi-layer article.

[0038] [Figure 14]FIG. 14 is a plot of the interval of liquid absorbency of nonwoven webs of the present disclosure as a function of the average degree of hydrolysis of the polyvinyl alcohol fiber-forming material in the multi-layer article. DETAILED DESCRIPTION OF THE INVENTION

[0039] Detailed Description The present disclosure provides nonwoven composite articles, flushable wipes, absorbent articles, and liquid-containing nonwoven articles, as well as methods of making and using the same. The nonwoven composite articles of the present disclosure include: a first layer including a first nonwoven web including a first plurality of fibers having a first diameter; a second layer including a second nonwoven web including a second plurality of fibers having a second diameter; and a first interface including at least a portion of the first nonwoven web and at least a portion of the second nonwoven web, where the portion of the first nonwoven web and the portion of the second nonwoven web are fused together, wherein the second diameter is smaller than the first diameter, and the first plurality of fibers, the second plurality of fibers, or both, comprise a water-soluble polyvinyl alcohol fiber-forming material.

[0040] Nonwoven composite articles of the present disclosure may provide one or more advantages including, but not limited to, improved liquid acquisition compared to single-layer nonwoven articles, improved lotion load and retention compared to single-layer nonwoven articles, improved biodegradability compared to traditional nonwoven articles, improved flushability compared to traditional nonwoven articles, improved softness compared to traditional nonwoven articles, improved mechanical properties (e.g., modulus, tensile strength, elongation, toughness, and / or breaking strength) compared to single-layer carded nonwovens comprising the same water-soluble fibers, and / or improved dispersion and dissolution compared to traditional nonwoven articles. Flushable wipes of the present disclosure may provide one or more advantages including, but not limited to, improved lotion load and retention compared to traditional wipes, improved liquid acquisition compared to traditional wipes, improved softness compared to traditional wipes, improved flushability compared to traditional wipes, and / or improved biodegradability, dispersion, and / or dissolution compared to traditional wipes. The absorbent articles of the present disclosure may provide one or more advantages including, but not limited to, improved liquid acquisition compared to traditional liquid acquisition layers in absorbent articles, improved liquid retention compared to traditional liquid acquisition layers in absorbent articles, improved softness compared to traditional liquid acquisition layers, and / or improved biodegradability, dispersion and / or dissolution compared to traditional wipes.

[0041] As used herein, unless otherwise specified, the term "nonwoven web" refers to a web or sheet comprising, consisting of, or consisting essentially of fibers arranged (e.g., by carding) and bonded to one another. Furthermore, as used herein, "nonwoven web" includes any structure comprising a nonwoven web or sheet, including, for example, a nonwoven web or sheet having a film laminated to its surface. Methods for preparing nonwoven webs from fibers are well known in the art and are described, for example, in "Nonwoven Fabrics Handbook," prepared by Ian Butler, edited by Subhash Batra et al., Printing by Design, 1999, the entire contents of which are incorporated herein by reference. As used herein, unless otherwise specified, the term "film" refers to a continuous film or sheet prepared, for example, by a casting or extrusion process.

[0042] As used herein, unless otherwise specified, the term "water-soluble" refers to any fiber, nonwoven web, nonwoven composite article, or film having a dissolution time of 300 seconds or less at a particular temperature, as determined according to MSTM-205 as set forth herein. For example, the dissolution time can be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds or less at temperatures of about 80°C, about 70°C, about 60°C, about 50°C, about 40°C, about 20°C, or about 10°C, as appropriate. In embodiments where a dissolution temperature is not specified, the water-soluble fiber, nonwoven web, or nonwoven composite article has a dissolution time of 300 seconds or less at a temperature of about 80°C or less. As used herein, unless otherwise specified, the term "cold water-soluble" refers to any fiber, nonwoven web, or nonwoven composite article having a dissolution time of 300 seconds or less at 10°C, as determined according to MSTM-205. For example, the dissolution time can be 200 seconds or less, 100 seconds or less, 60 seconds or less, or 30 seconds at 10° C., as appropriate. In embodiments, a "water-soluble film" means that at a thickness of 1.5 mils, the film dissolves in 300 seconds or less at a temperature of 80° C. or less. For example, a 1.5 mil (about 38 μm) thick water-soluble film can have a dissolution time of 300 seconds or less, 200 seconds or less, 100 seconds or less, 60 seconds or less, 30 seconds or less, or 20 seconds or less at temperatures of about 70° C., about 60° C., about 50° C., about 40° C., about 30° C., about 20° C., or about 10° C.

[0043] "Comprising," as used herein, means that various components, ingredients, or steps can be used in conjunction to practice the present disclosure. Thus, the term "comprising" encompasses the more restrictive terms "consisting essentially of" and "consisting of." The compositions can comprise, consist essentially of, or consist of any of the necessary and optional elements disclosed herein. The inventions illustratively disclosed herein may suitably be practiced in the absence of any element or step not specifically disclosed herein.

[0044] All percentages, parts and ratios referred to herein are based on the total dry weight of the fibers, nonwoven webs, nonwoven composite articles, flushable wipes or absorbent articles, as the case may be, of the present disclosure, and all measurements are made at about 25° C. unless otherwise specified. All such weights are based on the active level, as they pertain to listed ingredients, and therefore do not include carriers or by-products that may be included in commercially available materials, unless otherwise specified.

[0045] All ranges set forth herein include all possible subsets of ranges and any combination of such subset ranges. By default, unless otherwise stated, ranges include the stated endpoints. When a range of values ​​is presented, it is understood that each intervening value between the upper and lower limits of that range, and any other stated or intervening value in that stated range, is encompassed within the disclosure. The upper and lower limits of these smaller ranges may be independently included in the smaller ranges and are also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. When a stated range includes one or both limits, ranges excluding either or both of the included limits are also contemplated as part of the disclosure.

[0046] For example, for any numerical value described herein as part of a parameter of or range associated with the described subject matter, alternatives forming part of the description are expressly contemplated as functionally equivalent ranges surrounding the particular value (e.g., for a dimension disclosed as "40 mm," an alternative embodiment contemplated is "about 40 mm"). Similarly, values ​​described by "about" expressly include the particular value itself as an alternative embodiment (e.g., for an endpoint described as "about 40," an alternative embodiment contemplated is "40").

[0047] As used herein, unless otherwise specified, the terms "wt.%" and "wt%" are intended to refer to the composition of a specified element in terms of the "dry" (non-aqueous) weight of a fiber, nonwoven web, nonwoven composite article, flushable wipe, or entire absorbent article.

[0048] As used herein, unless otherwise specified, the term "PHR" ("phr") is intended to refer to the composition of a particular element in parts per hundred parts of polymeric resin or parts per hundred parts of fiber-forming material (whether PVOH or other polymeric resin) in a water-soluble fiber, nonwoven web, nonwoven composite article, flushable wipe, or absorbent article.

[0049] Fiber-forming materials

[0050] Generally, the fibers of the present disclosure may comprise a single fiber-forming material or a combination (i.e., blend) of fiber-forming materials. A single fiber may comprise one or more water-soluble fiber-forming materials, one or more water-insoluble fiber-forming materials, or a combination of water-soluble and water-insoluble fiber-forming materials. The fibers of the present disclosure may generally comprise synthetic fiber-forming materials, natural fiber-forming materials, plant-based fiber-forming materials, bio-based fiber-forming materials, biodegradable fiber-forming materials, compostable fiber-forming materials, or combinations thereof. Plant-based fiber-forming materials may be naturally occurring (e.g., cotton) or reconstituted (e.g., bamboo).

[0051] Water-soluble fiber-forming materials

[0052] Generally, the water-soluble fiber-forming material can be a water-soluble polymer. Water-soluble polymers can include, but are not limited to, polyvinyl alcohol, polyacrylate, water-soluble acrylate copolymer, polyvinylpyrrolidone, polyethyleneimine, pullulan, water-soluble natural polymers including, but not limited to, guar gum, acacia gum, xanthan gum, carrageenan, and water-soluble starch, water-soluble polymer derivatives including, but not limited to, modified starch, ethoxylated starch, and hydroxypropylated starch, copolymers of the foregoing, and combinations of any of the foregoing. Still other water-soluble polymers can include polyalkylene oxides, polyacrylamides, polyacrylic acids and their salts, water-soluble celluloses, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polycarboxylic acids and their salts, polyamino acids, polyamides, gelatin, methylcellulose, carboxymethylcellulose and its salts, dextrin, ethylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose, maltodextrin, polymethacrylates, and combinations of any of the foregoing. Such water-soluble polymers, whether PVOH or otherwise, are commercially available from a variety of sources.

[0053] In embodiments, the water soluble fiber forming material comprises polyvinyl alcohol, polyacrylate, polyvinylpyrrolidone, polyethyleneimine, guar gum, acacia gum, xanthan gum, carrageenan, water soluble starch, water soluble cellulose, cellulose ether, cellulose ester, cellulose amide, or a combination thereof. In embodiments, the water soluble fiber forming material comprises polyacrylate, polyvinylpyrrolidone, polyethyleneimine, guar gum, acacia gum, xanthan gum, carrageenan, water soluble starch, water soluble cellulose, cellulose ether, cellulose ester, cellulose amide, or a combination thereof.

[0054] Polyvinyl alcohol is a synthetic polymer typically prepared by alcoholysis, commonly called hydrolysis or saponification, of polyvinyl acetate. Fully hydrolyzed PVOH, in which virtually all acetate groups have been converted to alcohol groups, is a strongly hydrogen-bonded, highly crystalline polymer that is soluble only in hot water above about 140°F (about 60°C). If a sufficient number of acetate groups are allowed to remain after hydrolysis of polyvinyl acetate, i.e., the PVOH polymer is partially hydrolyzed, the polymer is more weakly hydrogen-bonded, less crystalline, and generally soluble in cold water below about 50°F (about 10°C). Therefore, the partially hydrolyzed polymer is a vinyl alcohol-vinyl acetate copolymer, which is a PVOH copolymer, but is generally referred to as PVOH.

[0055] In some embodiments, the polyvinyl alcohol includes modified polyvinyl alcohol, e.g., copolymers. Modified polyvinyl alcohol can include copolymers or higher order polymers (e.g., terpolymers) containing one or more monomers in addition to vinyl acetate / vinyl alcohol groups. Optionally, the modification is neutral, e.g., with ethylene, propylene, N-vinylpyrrolidone, or other uncharged monomer species. Optionally, the modification is cationic, e.g., with positively charged monomer species. Optionally, the modification is anionic, e.g., with negatively charged monomer species. Thus, in some embodiments, the polyvinyl alcohol includes anionically modified polyvinyl alcohol. Anionically modified polyvinyl alcohol can include partially or fully hydrolyzed PVOH copolymers containing anionic monomer units, vinyl alcohol monomer units, and optionally vinyl acetate monomer units (i.e., if not fully hydrolyzed). In some embodiments, the PVOH copolymer can include two or more anionic monomer units. General classes of anionic monomeric units that can be used in PVOH copolymers include vinyl polymerized units corresponding to vinyl sulfonic acid monomers and their esters, vinyl monocarboxylic acid monomers, their esters and anhydrides, dicarboxylic acid monomers having a polymerizable double bond, their esters and anhydrides, and alkali metal salts of any of the foregoing.Examples of suitable anionic monomer units are vinyl acetic acid, maleic acid, monoalkyl maleates, dialkyl maleates, maleic anhydride, fumaric acid, monoalkyl fumarates, dialkyl fumarates, itaconic acid, monoalkyl itaconates, dialkyl itaconates, citraconic acid, monoalkyl citraconates, dialkyl citraconates, citraconic anhydride, mesaconic acid, monoalkyl mesaconates, dialkyl mesaconates, glutaconic acid, monoalkyl glutaconates, dialkyl glutaconates, glutaconic anhydride, alkyl acrylates, (alkyl)acrylates, vinyl sulfonic acid, alkyl sulfonic acid, alkyl ... The PVOH copolymers may comprise polymerized vinyl units corresponding to vinyl anionic monomers, including benzoic acid, ethylene sulfonic acid, 2-acrylamido-1-methylpropanesulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid, 2-methylacrylamido-2-methylpropanesulfonic acid, 2-sulfoethyl acrylate, alkali metal salts of the foregoing (e.g., sodium, potassium, or other alkali metal salts), esters of the foregoing (e.g., methyl, ethyl, or other C1-C4 or C6 alkyl esters), and combinations of the foregoing (e.g., multiple anionic monomers or equivalent forms of the same anionic monomer). In some embodiments, the PVOH copolymers may comprise two or more types of monomer units selected from neutral, anionic, and cationic monomer units.

[0056] The incorporation level of one or more anionic monomer units in the PVOH copolymer is not particularly limited. In embodiments, the one or more anionic monomer units are present in the PVOH copolymer in an amount ranging from about 1 mol.% or 2 mol.% to about 6 mol.% or 10 mol.% (e.g., at least 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, or 4.0 mol.% and / or up to about 3.0, 4.0, 4.5, 5.0, 6.0, 8.0, or 10 mol.%) in various embodiments.

[0057] Polyvinyl alcohol can undergo changes in its solubility characteristics. It is known to those skilled in the art that the acetate groups of co-poly(vinyl acetate vinyl alcohol) polymers (PVOH homopolymers) can be hydrolyzed by either acid or alkaline hydrolysis. As the degree of hydrolysis increases, polymer compositions made with PVOH homopolymers have increased mechanical strength but exhibit reduced solubility at lower temperatures (e.g., requiring hot water temperatures for complete dissolution). Therefore, exposure of PVOH homopolymers to an alkaline environment (e.g., resulting from laundry bleach additives) can convert the polymer from one that dissolves quickly and completely in a given aqueous environment (e.g., cold water medium) to one that dissolves slowly and / or incompletely in the aqueous environment, potentially resulting in undissolved polymer residue at the end of the wash cycle.

[0058] For example, PVOH copolymers with pendant carboxyl groups, such as vinyl alcohol / hydrolyzed methyl acrylate sodium salt polymers, can form lactone rings between adjacent pendant carboxyl and alcohol groups, thus reducing the aqueous solubility of the PVOH copolymer. In the presence of a strong base, the lactone rings can open over a period of several weeks under relatively warm (ambient) and humid conditions (e.g., via a lactone ring-opening reaction, the corresponding pendant carboxyl and alcohol groups are formed, increasing aqueous solubility). Therefore, contrary to the effect observed with PVOH homopolymers, it is believed that such PVOH copolymers may become more soluble during storage due to chemical interactions between the polymer and alkaline compositions inside the pouch. As a result, as they age, packets may become increasingly susceptible to premature dissolution during hot water cycles (nominal 40°C), which in turn may reduce the effectiveness of certain laundry detergents due to the presence of bleach and the resulting drop in pH.

[0059] Certain sulfonic acids and their derivatives with polymerizable vinyl bonds can copolymerize with vinyl acetate to produce cold-water-soluble PVOH polymers that are stable in the presence of strong bases. The base-catalyzed alcoholysis products of these copolymers used in water-soluble fiber formulations are rapidly soluble vinyl alcohol-sulfonate salt copolymers. The sulfonate groups of the PVOH copolymer can revert to sulfonic acid groups in the presence of hydrogen ions, but the sulfonic acid groups still provide the polymer with excellent cold-water solubility. In embodiments, the vinyl alcohol-sulfonate salt copolymers contain no residual acetate groups (i.e., are fully hydrolyzed) and therefore cannot be further hydrolyzed by either acid or alkaline hydrolysis.

[0060] Generally, water solubility increases with increasing modification; therefore, sufficient modification via sulfonate or sulfonic acid groups inhibits hydrogen bonding and crystallinity, enabling dissolution in cold water. In the presence of acidic or basic species, the copolymer is generally unaffected except for the sulfonate or sulfonic acid groups, which maintains excellent cold water solubility even in the presence of acidic or basic species. Examples of suitable sulfonic acid comonomers (and / or their alkali metal salt derivatives) include vinyl sulfonic acid, alkyl sulfonic acid, ethylene sulfonic acid, 2-acrylamido-1-methylpropanesulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid, 2-methacrylamido-2-methylpropanesulfonic acid, and 2-sulfoethyl acrylate, with the sodium salt of 2-acrylamido-2-methylpropanesulfonic acid (AMPS) being the preferred comonomer.

[0061] Water-soluble polymers can be blended, whether polyvinyl alcohol polymers or not. When a polymer blend includes a blend of polyvinyl alcohol polymers, the PVOH polymer blend can include a first PVOH polymer ("first PVOH polymer"), which can include a PVOH homopolymer or a PVOH copolymer containing one or more anionic monomer units (e.g., a PVOH ter-(or higher copolymer) polymer), and a second PVOH polymer ("second PVOH polymer"), which can include a PVOH homopolymer or a PVOH copolymer containing one or more anionic monomer units (e.g., a PVOH ter-(or higher copolymer) polymer). In some embodiments, the PVOH polymer blend includes only a first PVOH polymer and a second PVOH polymer (e.g., a binary blend of two polymers). Alternatively, or in addition, the PVOH polymer blend or fibers or nonwoven fabrics made therefrom can be characterized as being free or substantially free of other polymers (e.g., other water-soluble polymers in general, other PVOH-based polymers in particular, or both). As used herein, "substantially free" means that the first and second PVOH polymers constitute at least 95 wt.%, at least 97 wt.%, or at least 99 wt.% of the total amount of water-soluble polymers in the water-soluble fiber or film. In other embodiments, the water-soluble fiber or nonwoven may contain one or more additional water-soluble polymers. For example, a PVOH polymer blend may contain a third PVOH polymer, a fourth PVOH polymer, a fifth PVOH polymer, etc. (e.g., one or more additional PVOH homopolymers or PVOH copolymers with or without anionic monomer units). For example, the water-soluble fiber or nonwoven may contain at least a third (or fourth, fifth, etc.) water-soluble polymer other than a PVOH polymer (e.g., other than a PVOH homopolymer or PVOH copolymer with or without anionic monomer units).

[0062] The degree of hydrolysis (DH) of the PVOH homopolymers and PVOH copolymers contained in the water-soluble fibers and nonwoven webs of the present disclosure can range from about 75% to about 99.9% (e.g., for cold water-soluble compositions, about 79% to about 92%, about 80% to about 90%, about 88% to 92%, about 86.5% to about 89%, or about 88%, 90%, or 92%; about 90% to about 99%, about 92% to about 99%, about 95% to about 99%, about 98% to about 99%, about 98% to about 99.9%, about 96%, about 98%, about 99%, or greater than 99%). As the degree of hydrolysis decreases, fibers or films made from the polymers have decreased mechanical strength but dissolve more quickly at temperatures below about 20°C. As the degree of hydrolysis increases, fibers or films made from the polymers tend to have increased mechanical strength and decreased thermoformability. The degree of hydrolysis of the PVOH can be selected so that the water solubility of the polymer is temperature-dependent, thereby affecting the solubility of fibers or films made from the polymer and additional components. In one option, the fiber or film is cold water-soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., homopolymers not copolymerized with anionic monomers), cold water-soluble fibers or films that are soluble in water at temperatures below 10°C can contain PVOH with a degree of hydrolysis ranging from about 75% to about 90%, or from about 80% to about 90%, or from about 85% to about 90%. In another option, the fiber or film is hot water-soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., homopolymers not copolymerized with anionic monomers), hot water-soluble fibers or films that are soluble in water at temperatures of at least about 60°C can contain PVOH with a degree of hydrolysis of at least about 98%.

[0063] The degree of hydrolysis of the polymer blends can also be calculated as an arithmetically weighted, average degree of hydrolysis (

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[0064] The viscosity (μ) of PVOH polymers is determined according to British Standard EN ISO 15023-2:2006 It is determined by measuring freshly made solutions using a Brookfield LV viscometer with a UL adapter, as described in Annex E Brookfield Test Method. It is an international standard to describe the viscosity of a 4% aqueous polyvinyl alcohol solution at 20°C. All viscosities (units: centipoise (cp)) specified herein should be understood to refer to the viscosity of a 4% aqueous polyvinyl alcohol solution at 20°C, unless otherwise specified. Similarly, when a polymer is described as having (or not having) a particular viscosity, unless otherwise specified, the particular viscosity is the average viscosity of the polymer, which is intended to have essentially the corresponding molecular weight distribution, i.e., the weighted natural logarithm average viscosity, as described below. The viscosity of a PVOH polymer is determined based on the weight average molecular weight of the PVOH polymer.

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[0065] For reference, in a polymer blend, a first PVOH polymer is designated as having a first 4% solution viscosity (μ) at 20° C., and a second PVOH polymer is designated as having a second 4% solution viscosity (μ) at 20° C. In various embodiments, the first viscosity μ can range from about 4 cP to about 70 cP (e.g., at least about 4, 8, 10, 12, or 16 cP and / or up to about 12, 16, 20, 24, 28, 30, 32, 35, 37, 40, 45, 48, 50, 56, 60, or 70 cP, e.g., from about 4 cP to about 70 cP, from about 4 cP to about 60 cP, from about 4 cP to about 46 cP, from about 4 cP to about 24 cP, from about 10 cP to about 16 cP, or from about 10 cP to about 20 cP, or from about 20 cP to about 30 cP). Alternatively, or in addition, the second viscosity μ2 can be in the range of about 4 cP to about 70 cP (e.g., at least about 4, 8, 10, 12, or 16 cP and / or up to about 12, 16, 20, 24, 28, 30, 32, 35, 37, 40, 45, 48, 50, 56, 60, or 70 cP, e.g., about 12 cP to about 30 cP, about 10 cP to about 16 cP, or about 10 cP to about 20 cP, or about 20 cP to about 30 cP). When the PVOH polymer blend includes three or more PVOH polymers selected from PVOH polymers and PVOH copolymers, the aforementioned viscosity values ​​can apply to each PVOH polymer or PVOH copolymer individually. Thus, the weight average molecular weight of the water-soluble polymers, including the first PVOH copolymer and the second PVOH copolymer, can range, for example, from about 30,000 to about 175,000, or from about 30,000 to about 100,000, or from about 55,000 to about 80,000. When referring to the average viscosity of a PVOH polymer blend, the weighted natural logarithm average viscosity is used.

number

number

number

[0066] Water-insoluble fiber-forming materials

[0067] The fibers of the present disclosure may include water-insoluble fiber-forming materials. Generally, water-insoluble fiber-forming materials include any material that does not dissolve in 300 seconds or less at a temperature of 80°C or less, as determined by MSTM-205. Suitable water-insoluble fiber-forming materials include, but are not limited to, cotton, cellulose, polyester, polyethylene (e.g., high-density polyethylene and low-density polyethylene), polypropylene, polycarbonate, polybutylene terephthalate, polyethylene terephthalate, polyamide, thermoplastic polyurethane, wood pulp, fluff pulp, Manila hemp, viscose, polylactic acid, nylon 6, cellulose, starch, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, Dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, and combinations thereof.

[0068] In embodiments, the water insoluble fiber forming material is selected from the group consisting of cotton, cellulose, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, seamilk, mohair, angora, cashmere, collagen, actin, In some embodiments, the water insoluble fiber-forming material may be selected from the group consisting of nylon, dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polypropylene, polycarbonate, polybutylene terephthalate, polyethylene terephthalate, polyamide, thermoplastic polyurethane, viscose, and combinations thereof. In some embodiments, the water insoluble fiber-forming material may be selected from the group consisting of cotton, cellulose, wool, bamboo fiber, polypropylene, polycarbonate, viscose, and combinations thereof. In some embodiments, the water insoluble fiber-forming material may be selected from the group consisting of cellulose, wool, polypropylene, viscose, and combinations thereof.

[0069] Supplementary ingredients

[0070] The fibers of the present disclosure may contain additives such as, but not limited to, plasticizers, plasticizer compatibilizers, surfactants, lubricants, release agents, fillers, bulking agents, crosslinkers, antiblocking agents, antioxidants, detackifying agents, antifoaming agents, liquid absorbing materials (e.g., superabsorbent polymers), exfoliants, nanoparticles such as layered silicate nanoclays (e.g., sodium montmorillonite), bleaching agents (e.g., sodium metabisulfite, sodium bisulfite, or others), bittering agents (e.g., denatonium benzoate, denatonium stearate, and others), and the like. Other adjuvants and processing agents may be included in amounts suitable for their intended purpose, including aversive agents such as denatonium salts such as octaacetylsucrose, quinine, flavonoids such as quercetin and naringen, and quassinoids such as cassine and brucine, and pungent agents (e.g., capsaicin, piperine, allyl isothiocyanate, and resiniferatoxin), as well as other functional ingredients. Specific such adjuvants and processing agents may be selected from those suitable for use in water-soluble fibers or those suitable for use in water-soluble nonwoven webs.

[0071] In embodiments, the fibers of the present disclosure include a plasticizer. Plasticizers are liquids, solids, or semi-solids that are added to materials (usually resins or elastomers) to make them softer, more flexible (by lowering the glass transition temperature of the polymer), and easier to process. Polymers can be internally plasticized by chemically modifying the polymer or monomer (e.g., grafting a plasticizer onto the polymer backbone). Additionally or alternatively, polymers can be externally plasticized by adding a suitable plasticizer to the fiber-forming material. Additionally or alternatively, plasticizers can be added as a coating to the formed fiber or nonwoven web. Water is recognized as a very efficient plasticizer for PVOH and other polymers, including, but not limited to, water-soluble polymers. However, its volatility limits its use because polymer fibers, nonwoven webs, and films must have at least some resistance (robustness) to fluctuations in ambient conditions, including low and high relative humidity.

[0072] Plasticizers may include, but are not limited to, glycerin, diglycerin, sorbitol, ethylene glycol, diethylene glycol, triethylene glycol, dipropylene glycol, tetraethylene glycol, propylene glycol, polyethylene glycols up to 400 MW, neopentyl glycol, trimethylolpropane, polyether polyols, sorbitol, 2-methyl-1,3-propanediol (MPDiol®), ethanolamine, and mixtures thereof. The total amount of non-aqueous plasticizer provided in the fibers can be in the range of about 1 wt.% to about 45 wt.%, or about 5 wt.% to about 45 wt.%, or about 10 wt.% to about 40 wt.%, or about 20 wt.% to about 30 wt.%, or about 1 wt.% to about 4 wt.%, or about 1.5 wt.% to about 3.5 wt.%, or about 2.0 wt.% to about 3.0 wt.%, for example, about 1 wt.%, about 2.5 wt.%, about 5 wt.%, about 10 wt.%, about 15 wt.%, about 20 wt.%, about 25 wt.%, about 30 wt.%, about 35 wt.%, or about 40 wt.%, based on the total fiber weight.

[0073] In embodiments, the fibers of the present disclosure include a surfactant. Surfactants for use with fibers are well known in the art. Optionally, a surfactant is included to aid in fiber dispersion during processing, such as carding. Suitable surfactants for the fibers of the present disclosure include, but are not limited to, dialkyl sulfosuccinates, lactylated fatty acid esters of glycerin and propylene glycol, lactic acid esters of fatty acids, sodium alkyl sulfates, polysorbate 20, polysorbate 60, polysorbate 65, polysorbate 80, alkyl polyethylene glycol ethers, lecithin, acetylated fatty acid esters of glycerin and propylene glycol, sodium lauryl sulfate, acetylated esters of fatty acids, myristyl dimethylamine oxide, trimethyl tallow alkyl ammonium chloride, quaternary ammonium compounds, alkali metal salts of higher fatty acids containing about 8 to 24 carbon atoms, alkyl sulfates, alkyl polyethoxylate sulfates, alkyl benzene sulfonates, monoethanolamine, lauryl alcohol ethoxylate, propylene glycol, diethylene glycol, salts thereof, and combinations of any of the foregoing.

[0074] Suitable surfactants may include nonionic, cationic, anionic, and zwitterionic classes. Suitable surfactants include, but are not limited to, propylene glycol, diethylene glycol, monoethanolamine, polyoxyethylated polyoxypropylene glycol, alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylenic glycols and alkanolamides (nonionic), polyoxyethylated amines, quaternary ammonium salts and quaternized polyoxyethylated amines (cationic), alkali metal salts of higher fatty acids containing about 8 to 24 carbon atoms, alkyl sulfates, alkyl polyethoxylate sulfates, and alkylbenzene sulfonates (anionic), and amine oxides, N-alkyl betaines, and sulfobetaines (zwitterionic). Other suitable surfactants include dioctyl sodium sulfosuccinate, lactylated fatty acid esters of glycerin and propylene glycol, lactic acid esters of fatty acids, sodium alkyl sulfate, polysorbate 20, polysorbate 60, polysorbate 65, polysorbate 80, lecithin, acetylated fatty acid esters of glycerin and propylene glycol, and acetylated esters of fatty acids, and combinations thereof. The surfactant may be included in the fiber-forming material or may be added. In various embodiments, the amount of surfactant in the fiber ranges from about 0.01 wt.% to about 2.5 wt.%, from about 0.1 wt.% to about 2.5 wt.%, from about 1.0 wt.% to about 2.0 wt.%, from about 0.01 wt.% to about 0.25 wt.%, or from about 0.10 wt.% to about 0.20 wt.%.

[0075] In embodiments, the fibers of the present disclosure are substantially free of adjuncts. As used herein, unless otherwise specified, "substantially free of adjuncts" means that the fibers contain less than about 0.01 wt.%, less than about 0.005 wt.%, or less than about 0.001 wt.% adjuncts, based on the total weight of the fiber.

[0076] activator

[0077] In embodiments, the fibers may include one or more active agents as part of the fiber or on its surface. The active agent, when present in the fiber in an amount of at least about 1 wt %, or in a range of about 1 wt % to about 99 wt %, provides additional functionality to the fiber. In embodiments, the active agent is selected from the group consisting of enzymes, oils, fragrances, colorants, odor absorbers, fragrances, insecticides, fertilizers, oxidizers, stripping agents, liquid absorbent materials, activators, acid catalysts, metal catalysts, ion scavengers, detergents, disinfectants, surfactants, plasticizers, bleaching agents, bleaching ingredients, fabric softeners, and combinations thereof. In embodiments, the active agent is selected from the group consisting of enzymes, oils, fragrances, colorants, odor absorbers, fragrances, insecticides, oxidizers, stripping agents, liquid absorbent materials, detergents, disinfectants, surfactants, plasticizers, bleaching agents, bleaching ingredients, fabric softeners, and combinations thereof. In embodiments, the active agent is selected from the group consisting of enzymes, oils, fragrances, colorants, odor absorbers, fragrances, insecticides, oxidizers, stripping agents, liquid absorbent materials, detergents, disinfectants, surfactants, plasticizers, bleaching agents, bleaching ingredients, fabric softeners, and combinations thereof.

[0078] In certain embodiments, the active agent may comprise an enzyme. Suitable enzymes include those classified into any one of the six traditional Enzyme Commission (EC) classifications: EC1 oxidoreductases (catalyzing oxidation / reduction reactions), EC2 transferases (transferring functional groups, e.g., methyl or phosphate groups), EC3 hydrolases (catalyzing the hydrolysis of various bonds), EC4 lyases (cleaving various bonds by methods other than hydrolysis and oxidation), EC5 isomerases (catalyzing intramolecular isomerization changes), and EC6 ligases (covalently joining two molecules). Examples of such enzymes include EC1 dehydrogenases and oxidases, EC2 transaminases and kinases, EC3 lipases, cellulases, amylases, mannases, and peptidases (also known as proteases or proteolytic enzymes), EC4 decarboxylases, EC5 isomerases and mutases, and EC6 synthetases and synthases. Suitable enzymes from each class are described, for example, in US Pat. No. 9,394,092, the entire disclosure of which is incorporated herein by reference.

[0079] Enzymes for use in cleaning applications may include one or more of proteases, amylases, lipases, dehydrogenases, transaminases, kinases, cellulases, mannases, peptidases, decarboxylases, isomerases, mutases, synthetases, synthases, and oxido-reductase enzymes, including oxido-reductase enzymes that catalyze the formation of bleach.

[0080] It is contemplated that the enzyme for use herein can be derived from any suitable source or combination of sources, for example, from bacterial, fungal, plant or animal sources.In one embodiment, the mixture of two or more enzymes is derived from at least two different sources.For example, the mixture of protease and lipase can be derived from bacterial (protease) and fungal (lipase) sources.

[0081] Optionally, enzymes for use herein, including but not limited to any enzyme class or member described herein, function at alkaline pH conditions, e.g., for use in cleaning applications, e.g., a pH in the range of about 8 to about 11. Optionally, enzymes for use herein, including but not limited to any enzyme class or member described herein, function at temperatures in the range of about 5°C to about 45°C.

[0082] Another class of embodiments includes one or more odor absorbers as active agents. Odor absorbers suitable for use as active agents according to the present disclosure include, but are not limited to, zeolites and complex zinc salts of ricinoleic acid. Odor absorbing active agents may also include fixatives known in the art as substantially odor-neutral fragrances, including, but not limited to, ladanum, extracts of Styrax japonica, and derivatives of abietic acid.

[0083] Another class of embodiments includes one or more fragrances as active agents. As used herein, the term fragrance refers to any applicable material that volatilizes sufficiently to produce a fragrance. Embodiments including a fragrance as an active agent may include fragrances that are pleasant to humans, or alternatively, fragrances that are repelling to humans, animals, and / or insects. Suitable fragrances include, but are not limited to, fruity scents, including, but not limited to, lemon, apple, cherry, grape, pear, pineapple, orange, strawberry, and raspberry; musk; and floral scents, including, but not limited to, lavender-like, rose-like, iris-like, and carnation-like. Optionally, the fragrance is also not a flavoring. Other fragrances include, but are not limited to, herbaceous scents, including, but not limited to, rosemary, thyme, and sage, and woodland scents derived from pine, spruce, and other woodsy scents. Fragrances may also be derived from various oils, including, but not limited to, essential oils, or plant materials, including, but not limited to, peppermint, spearmint, and the like. Suitable fragrance oils can be found in US Pat. No. 6,458,754, which is incorporated herein by reference in its entirety.Suitable fragrance oils include, but are not limited to, 4-(2,2,6-trimethylcyclohex-1-enyl)-2-en-4-one, acetaldehyde phenylethyl propyl acetal, 2,6,10-trimethyl-9-undecenal, hexanoic acid 2-propenyl ester, 1-octen-3-ol, trans-anethole, isobutyl (z)-2-methyl-2-butenoate, anisaldehyde diethyl acetal, 3-methyl-5-propyl-cyclohexen-1-one, 2,4-dimethyl-3-cyclohexene, These include decene-1-carbaldehyde, trans-4-decenal, decanal, 2-pentylcyclopentanone, ethyl anthranilate, eugenol, 3-(3-isopropylphenyl)butanol, methyl 2-octynoate, isoeugenol, cis-3-hexenylmethyl carbonate, linalool, methyl 2-nonylinonate, benzoic acid 2-hydroxymethyl ester, nonal, octanal, 2-nonenenitrile, 4-nonanolide, 9-decen-1-ol, and 10-undecen-1-al. Applicable fragrances can also be found in U.S. Patent Nos. 4,534,981, 5,112,688, 5,145,842, 6,844,302 and Perfumes Cosmetics and Soaps, Second Edition, edited by W.A. Poucher, 1959, all of which are incorporated herein by reference in their entireties. These fragrances include acacia, cassia, chypre, cyclamen, fern, gardenia, hawthorn, heliotrope, honeysuckle, hyacinth, jasmine, lilac, lily, magnolia, mimosa, daffodil, freshly cut hay, orange blossom, orchid, mignonette, sweet pea, clover (trefle), moonflower, vanilla, violet, saffron laurel, and the like.

[0084] The fragrance may include a perfume. The perfume may include a neat perfume, an encapsulated perfume, or a mixture thereof. Preferably, the perfume includes a neat perfume. A portion of the perfume may be encapsulated in a core-shell capsule. In another type of embodiment, the perfume is not encapsulated in a core / shell capsule.

[0085] As used herein, the term "perfume" encompasses perfume raw materials (PRMs) and perfume formulations. The term "perfume raw materials" as used herein refers to compounds having a molecular weight of at least about 100 g / mol and useful, either alone or in conjunction with other perfume raw materials, to impart an odor, fragrance, essence, or scent. As used herein, the terms "perfume ingredient" and "perfume raw material" are interchangeable. The term "formulation" as used herein refers to a mixture of two or more PRMs.

[0086] Typical PRMs include, among others, alcohols, ketones, aldehydes, esters, ethers, nitrites, and alkenes such as terpenes. Listings of common PRMs can be found in various reference works, e.g., "Perfume and Flavor Chemicals," Vols. I and II; Steffen Arctander Allured Pub. Co. (1994) and "Perfumes: Art, Science and Technology," Miller, P. M. and Lamparsky, D., Blackie Academic and Professional (1994). PRMs are those compounds whose solubility is measured at atmospheric pressure (760 mmHg). They are characterized by their boiling point (BP) and their octanol / water partition coefficient (P). Based on these characteristics, PRMs may be classified as Quadrant I, Quadrant II, Quadrant III or Quadrant IV perfumes.

[0087] Suitable insect repellent fragrances include one or more of dichlorvos, pyrethrins, allethrins, naled, and / or fenthion insecticides, as disclosed in U.S. Patent No. 4,664,064, the entire contents of which are incorporated herein by reference. Suitable insect repellents are citronellal (3,7-dimethyl-6-octanal), N,N-diethyl-3-methylbenzamide (DEET), vanillin, and volatile oils extracted from turmeric (Curcuma longa), kaffir lime (Citrus hystrix), Japanese cypress (Cymbopogon winterianus), and Thai basil (Ocimum americanum). Furthermore, suitable insect repellents can be mixtures of insect repellents.

[0088] In an alternative embodiment, the active agent may optionally be an ion scavenger. Suitable ion scavenger agents include, but are not limited to, zeolites. Optionally, zeolites may be added to water-soluble packets containing encapsulated laundry or dishwashing detergent as a water softener.

[0089] Inorganic and organic bleaches are suitable cleaning actives for use herein. Inorganic bleaches include peroxygen salts, including, but not limited to, perborates, percarbonates, perphosphates, persulfates, and persilicates. Inorganic peroxygen salts are typically alkali metal salts. Alkali metal percarbonates, particularly sodium percarbonate, are suitable peroxygen salts for use herein. Organic bleaches may include diacyl and tetraacyl peroxides, particularly organic peroxyacids, including, but not limited to, diperoxydodecanedioic acid, diperoxytetradecanedioic acid, and diperoxyhexadecanedioic acid. Dibenzoyl peroxide is a suitable organic peroxyacid according to the present disclosure. Other organic bleaches include peroxyacids, specific examples of which are alkyl peroxyacids and aryl peroxyacids.

[0090] In one class of embodiments, the activator may include a bleach activator containing an organic peracid precursor that enhances bleaching action during cleaning at temperatures of 60°C and below. Bleach activators suitable for use herein include compounds that, under perhydrolysis conditions, yield aliphatic peroxycarboxylic acids having 1 to 10 carbon atoms, or 2 to 4 carbon atoms, and / or optionally substituted perbenzoic acids. Suitable materials have O-acyl and / or N-acyl groups of the specified number of carbon atoms, and / or optionally substituted benzoyl groups. Suitable substances include, but are not limited to, polyacylated alkylenediamines, particularly tetraacetylethylenediamine (TAED), acylated triazine derivatives, particularly 1,5-diacetyl-2,4-dioxohexahydro-1,3,5-triazine (DADHT), acylated glycolurils, particularly tetraacetylglycoluril (TAGU), N-acylimides, particularly N-nonanoylsuccinimide (NOSI), acylated phenolsulfonates, particularly n-nonanoyl- or isononanoyloxybenzenesulfonate (n- or iso-NOBS), carboxylic acid anhydrides, particularly phthalic anhydride, acylated polyhydric alcohols, particularly triacetin, ethylene glycol diacetate and 2,5-diacetoxy-2,5-dihydrofuran, and also triethylacetylcitrate (TEAC).

[0091] In embodiments including a fabric softener as an active agent, various rinse-off fabric softeners, particularly the fine smectite clays of U.S. Patent No. 4,062,647, which is incorporated herein by reference in its entirety, and other softener clays known in the art, can be used to provide fabric softening benefits along with fabric cleaning, if desired. Clay softeners can be used in combination with amine and cationic softeners, for example, as disclosed in U.S. Patent Nos. 4,375,416 and 4,291,071, which are incorporated herein by reference in their entireties.

[0092] In embodiments, the active agent may include a disinfectant. Disinfectants suitable for use herein may include, but are not limited to, hydrogen peroxide, inorganic peroxides and their precursors, sodium metabisulfite, quaternary ammonium cation-based compounds, chlorine, activated carbon, and hypochlorite.

[0093] In embodiments, the active agent may comprise a surfactant. Surfactants suitable for use herein include, but are not limited to, propylene glycol, diethylene glycol, monoethanolamine, polyoxyethylated polyoxypropylene glycol, alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylenic glycols and alkanolamides (nonionic), polyoxyethylated amines, quaternary ammonium salts and quaternized polyoxyethylated amines (cationic), alkali metal salts of higher fatty acids containing about 8 to 24 carbon atoms, alkyl sulfates, alkylpolyethoxylates, and the like. The surfactants may include esters of fatty acids such as hydroxypropyl esters of glycerin and propylene glycol, hydroxypropyl esters of fatty acids ...

[0094] The active agent may be solid or liquid. A solid active agent may have an average particle size (e.g., Dv50) of at least about 0.01 μm, or, for example, a size range of about 0.01 μm to about 2 mm.

[0095] In embodiments, the fibers of the nonwoven webs, composite articles, flushable wipes, liquid-containing articles, and absorbent articles of the present disclosure comprise water-soluble fibers, water-insoluble fibers, or a combination thereof, and the fibers can have the same or different diameters, lengths, tenacity, shapes, stiffness, elasticity, solubility, melting points, glass transition temperatures, and / or fiber-forming materials.

[0096] In embodiments where the fiber comprises a water-soluble fiber, the water-soluble fiber may comprise any of the water-soluble polymer fiber-forming materials disclosed herein. Generally, the water-soluble fiber may comprise a single water-soluble polymer fiber-forming material or a blend of water-soluble fiber-forming materials. In embodiments, the water-soluble fiber consists of a single water-soluble polymer fiber-forming material. In embodiments, the water-soluble fiber comprises a blend of water-soluble polymers.

[0097] In an embodiment, the plurality of water-soluble fibers comprises a polyvinyl alcohol (PVOH) fiber-forming material. In a refinement of the aforementioned embodiment, the water-soluble fiber-forming material comprises a PVOH homopolymer. In another refinement of the aforementioned embodiment, the water-soluble fiber-forming material comprises a PVOH copolymer. In an embodiment, the water-soluble fiber comprises a blend of polyvinyl alcohol fiber-forming materials. In a refinement of the aforementioned embodiment, the water-soluble fiber comprises one or more PVOH homopolymer fiber-forming materials. In another refinement of the aforementioned embodiment, the water-soluble fiber comprises one or more PVOH copolymer fiber-forming materials. In yet another refinement of the aforementioned embodiment, the water-soluble polymer comprises one or more PVOH homopolymer fiber-forming materials and one or more PVOH copolymer fiber-forming materials.

[0098] In embodiments in which the water-soluble fiber comprises a blend of a polyvinyl alcohol homopolymer and a polyvinyl copolymer, the polyvinyl alcohol homopolymer may comprise from about 15 wt.% to about 70 wt.% of the total weight of the water-soluble polymer blend, for example, at least about 15 wt.%, at least about 20 wt.%, at least about 25 wt.%, at least about 30 wt.%, at least about 40 wt.%, at least about 50 wt.%, or at least about 60 wt.%, and up to about 70 wt.%, up to about 60 wt.%, up to about 50 wt.%, up to about 40 wt.%, or up to about 30 wt.%, based on the total weight of the water-soluble polymer blend, and may be a single homopolymer or a blend of one or more homopolymers (e.g., having differences in viscosity and / or degree of hydrolysis). The water-soluble polyvinyl alcohol copolymer may comprise about 30 wt.% to about 85 wt.% of the total weight of the water-soluble polymer blend, for example, at least about 30 wt.%, at least about 40 wt.%, at least about 50 wt.%, at least about 60 wt.%, at least about 70 wt.%, at least about 75 wt.%, or at least about 80 wt.%, and up to about 85 wt.%, up to about 80 wt.%, up to about 70 wt.%, up to about 60 wt.%, up to about 50 wt.%, or up to about 40 wt.%, based on the total weight of the water-soluble polymer blend. The water-soluble polyvinyl alcohol copolymer may be a single copolymer or a blend of one or more copolymers. The blend may consist of a polyvinyl alcohol homopolymer and a polyvinyl alcohol copolymer. The blend may consist of a polyvinyl alcohol homopolymer and multiple polyvinyl alcohol copolymers. The blend may consist of more than one polyvinyl alcohol homopolymer and more than one polyvinyl alcohol copolymer.

[0099] biodegradable

[0100] Polyvinyl alcohol polymers are generally biodegradable because they decompose under aerobic, anaerobic, soil, and compost conditions (in the presence of water), and in the presence of water and enzymes. Generally, the biodegradation activity of polyvinyl alcohol polymers increases as the degree of hydrolysis of the polyvinyl alcohol polymer increases, up to about 80%. Without intending to be bound by theory, it is believed that increasing the degree of hydrolysis beyond 80% does not appreciably affect biodegradability.

[0101] Without intending to be bound by theory, it is believed that while the degree of polymerization of a polyvinyl alcohol polymer has little or no effect on the biodegradability of fibers or nonwoven webs prepared with the polymer, the polymerization temperature may have an effect on the biodegradability of the film or nonwoven because it can affect the crystallinity and aggregation state of the polymer. In particular, as the crystallinity decreases, the polymer chain hydroxyl groups become less aligned in the polymer structure, and the polymer chains become more disordered, allowing the chains to accumulate as amorphous aggregates, thereby reducing the availability of the ordered polymer structure and decreasing biodegradation activity for soil and / or compost biodegradation mechanisms in which the polymer does not dissolve.

[0102] Furthermore, the stereoregularity of the hydroxyl groups of polyvinyl alcohol polymers has a significant effect on the biodegradation activity level; the more isotactic the hydroxyl groups in the polymer sequence, the higher the degradation activity. Without intending to be bound by theory, it is believed that because the stereoregularity of the hydroxyl groups of polyvinyl alcohol polymers has a significant effect on the biodegradation activity level, substitution with functional groups other than hydroxyl groups (e.g., anionic AMPS functional groups, carboxylate groups, or lactone groups) is expected to reduce the biodegradation activity level compared to polyvinyl alcohol homopolymers with the same hydrolysis degree, unless the functional groups themselves are also biodegradable and the biodegradability of the polymer can be increased by substitution. Furthermore, while the biodegradation activity level of substituted polyvinyl alcohols may be lower than that of the corresponding homopolymers, substituted polyvinyl alcohols are still believed to be biodegradable. Furthermore, without intending to be bound by theory, it is believed that nonwoven webs prepared from polyvinyl alcohol fibers have a higher level of biodegradation activity compared to water-soluble films prepared from similar polyvinyl alcohol polymers due to the increased polymer surface area provided by the nonwoven web compared to the film for soil and / or compost biodegradation.

[0103] Methods for determining biodegradation activity are known in the art. Suitable standards include OECD 301B (ready biodegradability), OECD 302B (intrinsic biodegradability), OECD 311 (anaerobic), and ASTM D5988 (soil).

[0104] Fiber properties

[0105] The plurality of fibers can be prepared by any method known in the art, such as wet-cooled gel spinning, thermoplastic fiber spinning, meltblown, spunbond, electrospinning, rotary spinning, continuous filament manufacturing techniques, tow fiber manufacturing techniques, and combinations thereof.

[0106] In embodiments, the fibers comprise water-soluble fibers prepared by wet chill gel spinning, meltblown, spunbonding, or a combination thereof. In embodiments, the fibers comprise water-soluble fibers prepared by wet chill gel spinning and carded into a nonwoven web. In embodiments, the fibers comprise water-soluble fibers, and the nonwoven web prepared therefrom is formed by a continuous meltblown process. In embodiments, the fibers comprise water-soluble fibers, and the nonwoven web prepared therefrom is formed by a continuous spunbond process. It is standard in the art to refer to fibers and nonwoven webs by the process used to prepare them. Thus, for example, any reference herein to "meltblown fibers" or "carded nonwoven webs" should not be understood as a limitation of the process product to a particular meltblown or carded process, but rather should be understood simply to identify a particular fiber or web. Thus, process terms may be used to distinguish between the fibers and / or nonwoven webs described without limiting the fibers and / or nonwoven webs to their preparation by any particular process.

[0107] The fibers of the present disclosure may be bicomponent fibers. As used herein, unless otherwise specified, "bicomponent fiber" does not refer to a fiber containing a blend of fiber-forming materials, but rather to a fiber containing two or more distinct regions of fiber-forming materials, with the composition of the fiber-forming materials differing from region to region. Examples of bicomponent fibers include, but are not limited to, core / sheath bicomponent fibers, islands-in-the-sea bicomponent fibers, and side-by-side bicomponent fibers. Core / sheath bicomponent fibers generally contain a core having a first composition of fiber-forming materials (e.g., a single fiber-forming material or a first blend of fiber-forming materials) and a sheath having a second composition of fiber-forming materials (e.g., a single fiber-forming material different from the core material, or a second blend of fiber-forming materials different from the first blend of fiber-forming materials in the core). Islands-in-the-sea bicomponent fibers generally contain a first, continuous "sea" region having a first composition of fiber-forming materials and discrete "island" regions dispersed therein having a second composition of fiber-forming materials different from the first composition. Side-by-side bicomponent fibers generally include a first region along the length of the fiber that includes a first composition of fiber-forming material and at least a second region adjacent the first region along the length of the fiber that includes a second composition of fiber-forming material that is different from the first composition. Such bicomponent fibers are well known in the art.

[0108] The fibers of the present disclosure may be hydrophobic and / or hydrophilic. As used herein, unless otherwise specified, "hydrophobic fiber" refers to any fiber whose surface is hydrophobic. A fiber may have a hydrophobic surface if, for example, the fiber contains a hydrophobic fiber-forming material, the fiber is a core / sheath bicomponent fiber containing a hydrophobic fiber-forming material in the sheath, and / or the fiber is surface-treated to contain a hydrophobic surfactant on its surface. Similarly, as used herein, unless otherwise specified, "hydrophilic fiber" refers to any fiber whose surface is hydrophilic. A fiber may have a hydrophilic surface if, for example, the fiber contains a hydrophilic fiber-forming material, the fiber is a core / sheath bicomponent fiber containing a hydrophilic fiber-forming material in the sheath, and / or the fiber is surface-treated to contain a hydrophilic material on its surface. Without intending to be bound by theory, it is believed that the hydrophilic fibers of a nonwoven fabric may promote capillary action / absorption of liquid from the surface of the nonwoven fabric, providing improved liquid acquisition compared to an identical nonwoven fabric that does not contain hydrophilic fibers.

[0109] The fibers of the present disclosure may comprise one or more of the fiber-forming materials disclosed herein. When the fiber comprises one PVOH polymer fiber-forming material, the degree of hydrolysis of the fiber is the same as the degree of hydrolysis of the PVOH polymer. When the fiber comprises two or more PVOH polymer fiber-forming materials, the degree of hydrolysis of the fiber is the arithmetic weight average of the degrees of hydrolysis of the individual PVOH polymers. Without intending to be bound by theory, it is believed that as the degree of hydrolysis of a fiber increases, the hydrophilicity of the fiber increases, resulting in an increase in the fiber's water absorption rate. Therefore, nonwoven webs comprising fibers with a relatively high average degree of hydrolysis may be particularly suitable for applications where water absorption rate is a primary factor, such as wearable articles where rapid absorption and removal of liquids from the consumer's skin is desirable. In embodiments where water absorption rate is a primary factor, the fibers of the present disclosure may have an average degree of hydrolysis of about 95% to about 99.9%.

[0110] The fiber shape is not particularly limited and may have a cross-sectional shape including, but not limited to, round, elliptical (also called ribbon), triangular (also called delta), trilobal, and / or other multilobal shapes ( FIG. 1 ). It is understood that the fiber shape need not be perfectly geometric; for example, a fiber having a round cross-sectional shape need not have a perfect circle as a cross-sectional area, and a fiber having a triangular cross-sectional shape generally has rounded corners. Without intending to be bound by theory, it is believed that hydrophilic fibers in a nonwoven fabric having a shape that provides capillary or channel-type directional passages for liquid (e.g., trilobal fibers) can promote capillary action / wicking of liquid from the surface of the nonwoven fabric, providing improved liquid acquisition compared to the same nonwoven fabric having a fiber shape that does not include capillary or channel-type directional passages.

[0111] The diameter of a fiber is understood to refer to the cross-sectional diameter of the fiber along its longest cross-sectional axis. When a fiber is described as having (or not having) a specific diameter, unless otherwise specified, the specific diameter is intended to be the average diameter of the particular fiber type being referenced; that is, multiple fibers prepared from a polyvinyl alcohol fiber-forming material have an arithmetic average fiber diameter across the multiple fibers. In the case of shapes that are typically not considered to have a "diameter," such as triangular or multi-lobal shapes, the diameter refers to the diameter of a circle surrounding the fiber shape (Figure 1).

[0112] Fibers of the present disclosure typically have diameters in the range of about 10 microns to 300 microns, e.g., at least 10 microns, at least 15 microns, at least 20 microns, at least 25 microns, at least 50 microns, at least 100 microns, or at least 125 microns, and up to about 300 microns, up to about 275 microns, up to about 250 microns, up to about 225 microns, up to about 200 microns, up to about 100 microns, up to about 50 microns, up to about 45 microns, up to about 40 microns, or up to about 35 microns, e.g., from about 10 microns to about 300 microns, from about 50 microns to about 300 microns, from about 100 microns to about 300 microns, from about 10 microns to about 50 microns, from about 10 microns to about 45 microns, or from about 10 microns to about 40 microns. In embodiments, water-soluble fibers used to prepare water-dispersible nonwoven webs of the present disclosure may have diameters of greater than 100 microns to about 300 microns. In embodiments, the fibers comprise cellulose having diameters ranging from about 10 microns to about 50 microns, about 10 microns to about 30 microns, about 10 microns to about 25 microns, about 10 microns to about 20 microns, or about 10 microns to about 15 microns. In embodiments, the fibers comprise a water-soluble fiber-forming material and have diameters ranging from about 50 microns to about 300 microns, about 100 microns to about 300 microns, about 150 microns to about 300 microns, or about 200 microns to about 300 microns. In embodiments, the diameters of the water-soluble fibers used to prepare the water-dispersible nonwoven webs of the present disclosure are substantially uniform. As used herein, fiber diameters are "substantially uniform" when the fiber-to-fiber diameter variation is less than 10%, e.g., 8% or less, 5% or less, 2% or less, or 1% or less. Fibers having substantially uniform diameters can be prepared by wet-cooled gel spinning or thermoplastic fiber spinning, as described herein. Additionally, if a blend of fibers is used, the average diameter of the fibers can be determined using a weighted average of the individual fibers.

[0113] The fibers of the present disclosure used to prepare the nonwoven webs and nonwoven composite articles of the present disclosure generally can be of any length. In embodiments, the fiber lengths can range from about 20 mm to about 100 mm, from about 20 mm to about 90 mm, from about 30 mm to about 80 mm, from about 10 mm to about 60 mm, or from about 30 mm to about 60 mm, such as at least about 30 mm, at least about 35 mm, at least about 40 mm, at least about 45 mm, or at least about 50 mm, and up to about 100 mm, up to about 95 mm, up to about 90 mm, up to about 80 mm, up to about 70 mm, or up to about 60 mm. In embodiments, the length of the water-soluble fibers can be less than about 30 mm, or from about 0.25 mm to less than about 30 mm, for example, at least about 0.25 mm, at least about 0.5 mm, at least about 0.75 mm, at least about 1 mm, at least about 2.5 mm, at least about 5 mm, at least about 7.5 mm, or at least about 10 mm, and up to about 29 mm, at most about 28 mm, at most about 27 mm, at most about 26 mm, at most about 25 mm, at most about 20 mm, or at most about 15 mm. Fibers can be prepared to any length by cutting and / or crimping the extruded polymer mixture. In embodiments, the fibers can be continuous filaments prepared by processes such as spunbonding, meltblown, electrospinning, and rotary spinning, where the continuous filaments are directly prepared and provided in web form. Furthermore, when a blend of fibers is used, the average fiber length can be determined using a weighted average of the individual fibers.

[0114] Fibers of the present disclosure can generally have any length-to-diameter ratio, hi embodiments, the length-to-diameter ratio of a fiber can be greater than about 2, greater than about 3, greater than about 4, greater than about 6, greater than about 10, greater than about 50, greater than about 60, greater than about 100, greater than about 200, greater than about 300, greater than about 400, or greater than about 1000.

[0115] Fibers used to prepare nonwoven webs of the present disclosure can generally have any tenacity. Fiber tenacity correlates with fiber coarseness. Generally, as fiber tenacity decreases, fiber coarseness increases. Fibers used to prepare nonwoven webs of the present disclosure can have a tenacity of from about 1 to about 100 cN / dtex, or from about 1 to about 75 cN / dtex, or from about 1 to about 50 cN / dtex, or from about 1 to about 45 cN / dtex, or from about 1 to about 40 cN / dtex, or from about 1 to about 35 cN / dtex, or from about 1 to about 30 cN / dtex, or from about 1 to about 25 cN / dtex, or from about 1 to about 20 cN / dtex, or from about 1 to about 15 cN / dtex, or from about 1 to about 10 cN / dtex, or from about 1 to about 5 cN / dtex, or from about 3 to about 8 cN / dtex, or may have a tenacity in the range of about 4 to about 8 cN / dtex, or about 6 to about 8 cN / dtex, or about 4 to about 7 cN / dtex, or about 10 to about 20, or about 10 to about 18, or about 10 to about 16, or about 1 cN / dtex, about 2 cN / dtex, about 3 cN / dtex, about 4 cN / dtex, about 5 cN / dtex, about 6 cN / dtex, about 7 cN / dtex, about 8 cN / dtex, about 9 cN / dtex, about 10 cN / dtex, about 11 cN / dtex, about 12 cN / dtex, about 13 cN / dtex, about 14 cN / dtex, or about 15 cN / dtex. In embodiments, the fibers may have a tenacity of about 3 cN / dtex to about 10 cN / dtex. In embodiments, the fibers may have a tenacity of about 7 cN / dtex to about 10 cN / dtex. In embodiments, the fibers may have a tenacity of about 4 cN / dtex to about 8 cN / dtex. In embodiments, the fibers may have a tenacity of about 6 cN / dtex to about 8 cN / dtex.

[0116] In embodiments in which fibers are prepared from a wet-cooled gel spinning process, the resulting fibers can generally have any tenacity as described herein. In refinements of the foregoing embodiments, the fibers can have a tenacity in the range of about 3 to about 15, about 3 to about 13, about 3 cN / dtex to about 10 cN / dtex, about 5 cN / dtex to about 10 cN / dtex, or about 6 cN / dtex to about 10 cN / dtex, about 7 cN / dtex to about 10 cN / dtex, about 4 cN / dtex to about 8 cN / dtex, or about 6 cN / dtex to about 8 cN / dtex.

[0117] The fibers used to prepare the nonwoven webs of the present disclosure can generally have any fineness. Fiber fineness correlates with fiber mass relative to length. The primary physical unit of fiber fineness is 1 tex, which is equal to 1000 m of fiber weighing 1 g. Typically, the unit dtex is used, representing 1 g / 10,000 m of fiber. Fiber fineness can be selected to provide a nonwoven web with suitable hardness / handle, torsional rigidity, light reflection and interaction, dye and / or other active agent / additive absorption, ease of fiber spinning in the manufacturing process, and uniformity of the finished article. Generally, as fiber fineness increases, the resulting nonwoven web exhibits greater uniformity, improved tensile strength, extensibility, and luster. Furthermore, without intending to be bound by theory, it is believed that finer fibers result in slower dissolution times compared to larger fibers based on density. Furthermore, without intending to be bound by theory, when a blend of fibers is used, the average fiber fineness can be determined using a weighted average of the individual fiber components. The fibers may be characterized as very fine (dtex≦1.22), fine (1.22≦dtex≦1.54), medium (1.54≦dtex≦1.93), slightly coarse (1.93≦dtex≦2.32), and coarse (dtex≧2.32). Nonwoven webs of the present disclosure may contain very fine, fine, medium, slightly coarse fibers, or combinations thereof. In embodiments, the fibers have a fineness ranging from about 1 dtex to about 10 dtex, from about 1 dtex to about 7 dtex, from about 1 dtex to about 5 dtex, from about 1 dtex to about 3 dtex, or from about 1.7 dtex to about 2.2 dtex. In embodiments, the fibers have a fineness of about 1.7 dtex. In an embodiment, the fibers have a fineness of about 2.2 dtex.

[0118] The plurality of water-soluble fibers can be prepared by any method known in the art, such as thermoplastic fiber spinning, wet-cooled gel spinning, meltblown, spunbonded, electrospinning, rotary spinning, continuous filament manufacturing techniques, tow fiber manufacturing techniques, and combinations thereof.

[0119] Wet-cooled gel spinning

[0120] In an embodiment, the plurality of fibers comprises fibers prepared according to a wet cryogel spinning process, the wet cryogel spinning process comprising: (a) dissolving a fiber-forming polymer (or polymers) in a solution to form a polymer mixture, the polymer mixture optionally including an adjuvant; (b) extruding the polymer mixture through a spinneret nozzle into a solidification bath to form an extruded polymer mixture; (c) passing the extruded polymer mixture through a solvent exchange bath; (d) optionally wet drawing the extruded polymer mixture; and (e) finishing the extruded polymer mixture to provide fibers. Includes.

[0121] The solvent in which the fiber-forming polymer is dissolved can suitably be any solvent that the polymer is soluble in. In embodiments, the solvent in which the polymer is dissolved comprises a polar aprotic solvent. In embodiments, the solvent in which the polymer is dissolved comprises dimethyl sulfoxide (DMSO).

[0122] The solidification bath generally contains a cooled solvent to gel the extruded polymer mixture. The solidification bath can generally be at any temperature that promotes solidification of the extruded polymer mixture. The solidification bath can contain a mixture of solvents in which the polymer is soluble and solvents in which the polymer is insoluble. The solvent in which the polymer is insoluble is generally the primary solvent, and the solvent in which the polymer is insoluble constitutes more than 50% of the mixture.

[0123] After passing through the solidification bath, the extruded polymer mixture gel may be passed through one or more solvent exchange baths. The solvent exchange baths are provided to exchange the solvent in which the polymer is soluble for a solvent in which the polymer is insoluble, further solidifying the extruded polymer mixture, and to exchange the solvent in which the polymer is soluble for a solvent that evaporates more easily, thereby reducing drying time. The solvent exchange baths may include a series of solvent exchange baths having a gradient of solvents in which the polymer is soluble and solvents in which the polymer is insoluble, a series of solvent exchange baths having only a solvent in which the polymer is insoluble, or a single solvent exchange bath having only a solvent in which the polymer is insoluble.

[0124] The finished fiber is sometimes referred to as staple fiber, short-cut fiber, or pulp. In embodiments, finishing includes drying the extruded polymer mixture. In embodiments, finishing includes cutting or crimping the extruded polymer mixture to form individual fibers. Wet drawing of the extruded polymer mixture results in a substantially uniform diameter for the extruded polymer mixture, and therefore the fibers cut therefrom. Drawing is distinct from extrusion, as is well known in the art. In particular, extrusion refers to the process of creating fibers by passing a resin mixture through a spinneret head, while drawing refers to the process of mechanically drawing the fiber in the machine direction to improve polymer chain orientation and crystallinity for increased fiber strength and toughness.

[0125] In embodiments in which the fibers are prepared from a wet-cooled gel spinning process, the fiber-forming polymer can generally be any fiber-forming polymer or blend thereof, e.g., two or more different polymers, as generally described herein. In a refinement of the foregoing embodiment, the polymer can have a molecular weight of, for example, 10 to 10,000,000, e.g., at least 10, at least 20, at least 50, at least 100, at least 200, at least 300, at least 400, at least 500, at least 750, or at least 1000, and up to 10,000,000, up to 5,000,000, up to 2,500,000, up to 1,000,000, up to 900,000, up to 750,000, up to 500,000, up to 250,000, up to 100,000, up to 90,000, up to 75,000, up to 500,000, up to 250,000, up to 100,000, up to 90,000, up to 75,000, up to 10 ... The degree of polymerization (DP) may be any value ranging from 50,000, up to 25,000, up to 12,000, up to 10,000, up to 5,000, or up to 2,500, for example, from 1,000 to about 50,000, from 1,000 to about 25,000, from 1,000 to about 12,000, from 1,000 to about 5,000, from 1,000 to about 2,500, from about 50 to about 12,000, from about 50 to about 10,000, from about 50 to about 5,000, from about 50 to about 2,500, from about 50 to about 1,000, from about 50 to about 900, from about 100 to about 800, from about 150 to about 700, from about 200 to about 600, or from about 250 to about 500. In an embodiment, the DP is at least 1,000. In embodiments, the fiber-forming polymer comprises a polyvinyl alcohol polymer having a DP ranging from 1000 to about 50,000, 1000 to about 25,000, 1000 to about 12,000, 1000 to about 5,000, 1000 to about 2,500, about 50 to about 12,000, about 50 to about 10,000, about 50 to about 5,000, about 50 to about 2,500, about 50 to about 1000, about 50 to about 900, about 100 to about 800, about 150 to about 700, about 200 to about 600, or about 250 to about 500. In embodiments, the fiber-forming polymer comprises polyvinyl alcohol having a DP ranging from 1000 to about 50,000, 1000 to about 25,000, 1000 to about 12,000, 1000 to about 5,000, or 1000 to about 2,500.

[0126] Thermoplastic fiber spinning

[0127] Thermoplastic fiber spinning is well known in the art. Briefly, thermoplastic fiber spinning is (a) preparing a polymer mixture comprising a fiber-forming polymer, optionally including an adjuvant; (b) extruding the polymer mixture through a spinneret nozzle to form an extruded polymer mixture; (c) optionally drawing the extruded polymer mixture; and (d) finishing the extruded polymer mixture to provide fibers. Includes.

[0128] The finished staple fibers from thermoplastic fiber spinning can be finished by drying, cutting, and / or crimping to form individual fibers. Drawing an extruded polymer mixture involves pulling the fibers through a machine in the machine direction to improve polymer chain orientation and crystallinity, thereby increasing fiber strength and toughness. Preparing a polymer mixture for thermoplastic fiber spinning typically involves (a) preparing a solution of fiber-forming materials and a readily volatile solvent and extruding the solution through a spinneret, where the solvent readily evaporates when the solution comes into contact with a hot air stream, leaving behind a solid fiber; or (b) melting the polymer and solidifying it by extruding the hot polymer through a spinneret and quenching it with cold air. Thermoplastic fiber spinning is distinct from wet-cooled gel spinning in at least that (a) in thermoplastic fiber spinning, the extruded fiber is solidified by evaporation of a solvent or by quenching the hot solid fiber with cold air rather than by the use of a solidifying bath; and (b) in wet-cooled gel spinning, any required drawing is performed while the fiber is in a gel state rather than a solid state.

[0129] The fiber-forming material for preparing fibers from thermoplastic fiber spinning can generally be any fiber-forming polymer or blend thereof, for example, two or more different polymers, provided that the polymer or blend has a suitable solubility in a readily volatile solvent and / or a melting point below and distinct from its decomposition temperature. Furthermore, when a fiber is made using a blend of fiber-forming polymers, the fiber-forming materials must have similar solubility in a readily volatile solvent and / or a similar thermal profile so that the two or more fiber-forming materials melt at similar temperatures. Conversely, the fiber-forming material for preparing fibers from wet-cooled gel spinning is not limited, and fibers can be prepared from a blend of any two or more polymers that are soluble in the same solvent system, and the solvent system does not need to be a single solvent or even a volatile solvent.

[0130] Fiber-forming polymers for preparing thermoplastic spun fibers can have a degree of polymerization (DP) ranging from, for example, 10 to 10,000, e.g., at least 10, at least 20, at least 50, at least 100, at least 200, at least 300, at least 400, at least 500, at least 750, or at least 1000, and up to 10,000, up to 5,000, up to 2,500, up to 1,000, up to 900, up to 750, up to 500, or up to 250. In embodiments, the DP is less than 1,000.

[0131] Meltspun

[0132] Meltspun is well known in the art and is understood to refer to both spunbonding and meltblown processes. Meltspun is a continuous process in which a nonwoven web is prepared directly in-line with fiber formation. As such, the meltspun fibers are not finished and cut to any fixed length (e.g., staple fibers are not prepared by these methods). Furthermore, meltspun does not involve a drawing step, and therefore the only control over the diameter of the resulting meltspun fibers is the size of the hole through which the fiber-forming material is extruded, and the polymer chains are typically not oriented in any particular direction.

[0133] In brief, meltspun: (a) preparing a polymer mixture comprising a fiber-forming polymer, optionally including an adjuvant; (b) extruding the polymer mixture through a die assembly to form an extruded polymer mixture; (c) quenching the extruded polymer mixture; (d) depositing the quenched extruded polymer mixture onto a belt to form a nonwoven web; and (e) bonding the nonwoven web Includes.

[0134] In the spunbond process, the extruded polymer mixture is pumped as a molten polymer into a die assembly and quenched with cold air once it has passed through the die assembly. In the meltblown process, the extruded polymer mixture is pumped into a die assembly through which hot air is blown and is quenched upon exiting the die assembly and contacting ambient temperature air. In both processes, the fibers are continuously dropped onto a belt or drum, usually aided by the application of a vacuum below the belt or drum.

[0135] The diameter of the spunbond fibers is generally about 0.1 to about 50 microns, e.g., at least about 0.1 micron, at least about 1 micron, at least about 2 microns, at least about 5 microns, at least about 10 microns, at least about 15 microns, or at least about 20 microns, and up to about 50 microns, up to about 40 microns, up to about 30 microns, up to about 25 microns, up to about 20 microns, up to about 15 microns, up to about 10 microns, from about 0.1 micron to about 50 microns, from about 0.1 micron to about 40 microns, from about 0.1 micron to about 30 microns, 0 micron, about 0.1 micron to about 25 microns, about 0.1 micron to about 20 microns, about 0.1 micron to about 15 microns, about 0.1 micron to about 10 microns, about 0.1 micron to about 9 microns, about 0.1 micron to about 8 microns, about 0.1 micron to about 7 microns, about 0.1 micron to about 6 microns, about 0.1 micron to about 6 microns, about 5 microns to about 35 microns, about 5 microns to about 30 microns, about 7.5 microns to about 25 microns, about 10 microns to about 25 microns, or about 15 microns to about 25 microns. Meltblown processes can provide microfibers having an average diameter in the range of about 1 to 10 microns; however, it is known in the art that meltblown processes have very high fiber-to-fiber diameter variations, e.g., 100 to 300% variation. Additionally, it is well known in the art that spunbond fibers may have larger average fiber diameters, e.g., typically about 15 to about 25 microns, but with improved fiber-to-fiber uniformity, e.g., about a 10% variation.

[0136] The fiber-forming materials for heat extrusion processes (e.g., melt-spun, thermoplastic fiber spinning) are more limited than those for wet-cooled gel spinning. Generally, the degree of polymerization for heat extrusion processes is limited to a range of about 200 to about 500. When the degree of polymerization decreases below 200, the viscosity of the fiber-forming material becomes too low, and individual fibers prepared by pumping the material through a die assembly do not maintain sufficient separation after exiting the die assembly. Similarly, when the degree of polymerization increases above 500, the viscosity becomes too high to effectively pump the material through sufficiently small holes in the die assembly to achieve high process speeds, resulting in a loss of process efficiency and fiber and / or nonwoven uniformity. Furthermore, homopolymers generally lack the necessary thermal stability, so processes requiring heating of the fiber-forming material are not suitable for polyvinyl alcohol homopolymers. Furthermore, melt-processable polymers are known to have a viscosity of 5 cP or less. Thus, wet chill gel spinning can advantageously provide fibers derived from polymers, including polyvinyl alcohol homopolymers and copolymers, having viscosities greater than 5 cP that otherwise cannot be processed into fibers.

[0137] The wet chill gel spinning process advantageously offers one or more advantages, such as providing fibers containing a blend of water-soluble polymers, controlling the fiber diameter, providing relatively large diameter fibers, controlling the fiber length, controlling the fiber tenacity, providing high tenacity fibers, providing fibers from polymers with a high degree of polymerization, and / or providing fibers that can be used to provide self-supporting nonwoven webs. Continuous processes such as spunbonding, meltblown, electrospinning, and rotary spinning generally do not allow blending of water-soluble polymers (e.g., due to the difficulty of matching the melt index of various polymers), forming large diameter fibers (e.g., greater than 50 microns), controlling the fiber length, providing high tenacity fibers, or using polymers with a high degree of polymerization. Furthermore, the wet chill gel spinning process advantageously is not limited to only melt-processable polymers, and therefore can utilize fibers made from fiber-forming materials with very high molecular weights, high melting points, low melt flow indexes, or combinations thereof, providing fibers with stronger physical properties and different chemical functionality compared to fibers prepared by heated extrusion processes.

[0138] nonwoven web

[0139] The nonwoven webs of the present disclosure are generally sheet-like structures having two outer surfaces, and the nonwoven web comprises a plurality of fibers. As used herein, unless otherwise specified, the "outer surfaces" of a nonwoven web refer to the surfaces of the sheet-like structure designated by 100 and 101 in FIG. 2. A nonwoven web generally refers to an arrangement of fibers bonded together, and the fibers are neither woven nor knitted. Generally, the plurality of fibers can be arranged in any orientation. In embodiments, the plurality of fibers are arranged randomly (i.e., have no orientation). In embodiments, the plurality of fibers are arranged in a unidirectional orientation. In embodiments, the plurality of fibers are arranged in a bidirectional orientation. In some embodiments, the plurality of fibers are multidirectional, having different arrangements in different regions of the nonwoven web. In embodiments, the nonwoven web can comprise a single type of water-soluble fiber. In embodiments, the nonwoven web can comprise a single type of water-insoluble fiber. In embodiments, the nonwoven web can comprise a single type of water-soluble fiber and one or more different types of water-insoluble fiber. In embodiments, the nonwoven web may comprise one or more different types of water-soluble fibers and one or more different types of water-insoluble fibers. In embodiments, the nonwoven web may consist of water-soluble fibers or consist essentially of water-soluble fibers. In embodiments, the nonwoven web may consist of water-insoluble fibers or consist essentially of water-insoluble fibers. In some embodiments, the nonwoven web may comprise a single type of fiber-forming material (i.e., all fibers have the same composition of fiber-forming material), but may contain fibers prepared by one or more fiber-forming processes, such as wet-cooled gel spinning, thermoplastic fiber spinning, meltblown, spunbonding, or a combination thereof. In some embodiments, the nonwoven web may comprise a single type of fiber-forming material, and the fibers are made from a single fiber-forming process. In some embodiments, the nonwoven web may comprise two or more fiber-forming materials (e.g., a blend of fibers having fiber-forming materials of different compositions, fibers comprising a blend of fiber-forming materials, or both), and the fibers may be prepared by one or more fiber-forming methods, such as wet-chill gel spinning, thermoplastic fiber spinning, meltblowing, spunbonding, or a combination thereof.In some embodiments, the nonwoven web may include two or more fiber-forming materials, and the fibers are made from a single fiber-forming process. In embodiments, the fibers of the nonwoven web may have substantially the same diameter or different diameters.

[0140] In embodiments where the nonwoven web of the present disclosure comprises a blend of water-soluble fibers comprising a first water-soluble fiber and a second water-soluble fiber, the first and second water-soluble fibers may have characteristics such as diameter, length, tenacity, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T g In embodiments where the nonwoven web of the present disclosure comprises a blend of water-insoluble fibers comprising first water-insoluble fibers and second water-insoluble fibers, the first and second water-insoluble fibers may have differences in diameter, length, tenacity, shape, stiffness, elasticity, solubility, melting point, glass transition temperature, fiber-forming material, color, or a combination thereof.

[0141] Generally, nonwoven webs can be characterized by the average degree of hydrolysis of the polyvinyl alcohol fiber-forming material used to make the fibers of the nonwoven. When a nonwoven web is composed of a single fiber type, the degree of hydrolysis of the nonwoven web is the same as the degree of hydrolysis of the single fiber type. In embodiments, nonwoven webs of the present disclosure can include a blend of fibers, with each fiber having a different degree of hydrolysis. In such cases, the degree of hydrolysis of the nonwoven web is the arithmetic weight average of the degrees of hydrolysis of the individual fiber types. In embodiments in which nonwoven webs are layered to prepare nonwoven articles, the nonwoven article has a degree of hydrolysis that is the arithmetic weight average of the degrees of hydrolysis of the individual web layers. In embodiments in which a nonwoven web or article is used to absorb liquids (e.g., wearables that remove liquids from a user's skin), the web or article can have an average degree of hydrolysis in the range of about 95-99.9%, about 96-99%, or about 97-98%. In embodiments where the nonwoven web or article is used for its liquid absorption capacity (e.g., wipes for cleaning up spills), the web or article may have an average degree of hydrolysis in the range of about 93-97%, about 94-96%, or about 95% and may be air-through bonded rather than calender bonded. As shown in the examples below, when nonwoven webs of similar composition were air-through bonded, their liquid absorption capacity was significantly increased compared to calender bonded nonwoven webs. The air-through bonded nonwoven webs contained thermoplastic fibrous materials at levels of 5 wt.% or less (based on the total weight of the fibers) to promote bonding. Without intending to be bound by theory, it is believed that the higher the level of bonding in a nonwoven web, the lower its liquid absorption capacity. Therefore, it is further believed that bonding conditions can be selected to increase the liquid absorption capacity of nonwoven webs prepared from specific fiber types. Without intending to be bound by theory, it is believed that air-through bonding results in a more absorbent nonwoven web compared to calendar bonding, and that as the residence time of the calendar bonded nonwoven web increases, the absorbent capacity decreases.

[0142] Method for Making a Nonwoven Web

[0143] The nonwoven webs of the present disclosure can be prepared from the fibers using any method known in the art. As known in the art, when the fibers are spunbond or meltblown, the fibers are continuously laid to form the nonwoven web, and the fibers are subsequently bonded.

[0144] Staple fibers can be carded or airlaid and bonded to obtain a nonwoven web. Carding and airlaid methods are well known in the art. Furthermore, as is known in the art, carded webs are typically stronger in the machine direction than in the cross direction due to fiber alignment during carding, and carding methods typically use two doffer cylinders to provide a double-ply carded web having a first ply with a first strength in the cross direction and a second ply with a second strength in the cross direction that imparts additional cross-directional strength to the overall carded nonwoven web. As used herein, unless otherwise specified, the term "carded nonwoven web" encompasses single-ply carded nonwoven webs and multi-ply (e.g., two-ply, three-ply, etc.) carded nonwoven webs. Thus, when such a double-ply carded nonwoven web is used as a layer in a composite article of the present disclosure, it is understood that the double-ply carded nonwoven web is considered a single layer. As known in the art, airlaid is similar to carded except that the fibers are blown from a cylinder onto a belt or drum with the use of a vacuum, resulting in air turbulence, which means that airlaid nonwovens generally have no directionality in the alignment of the fibers. Thus, airlaid nonwovens generally have equal strength in the machine and cross directions.

[0145] Methods for bonding nonwoven webs are well known in the art. Generally, bonding can include thermal, mechanical, and / or chemical bonding. Thermal bonding can include, but is not limited to, calendaring, embossing, air-through, and ultrasonic bonding. Mechanical bonding can include, but is not limited to, hydroentanglement (spunlace), needle punching, and stitch bonding. Chemical bonding can include, but is not limited to, solvent bonding and resin bonding.

[0146] Thermal bonding is generally achieved by applying heat and pressure, typically maintaining the pore size, shape, and alignment produced by the carding / meltspun process. The conditions for thermal bonding can be readily determined by those skilled in the art. Generally, if too little heat and / or pressure is applied, the fibers will not bond sufficiently to form a self-supporting web; if too much heat and / or pressure is applied, the fibers will begin to fuse together. Fiber chemistry dictates upper and lower limits for heat and / or pressure for thermal bonding. Without intending to be bound by theory, it is believed that polyvinyl alcohol-based fibers decompose at temperatures above 235°C. Calender bonding, also known in the art as thermal point bonding, uses an engraved calender and smooth opposing rolls to apply heat and pressure locally to form a film-like reinforcing structure throughout the nonwoven. Calendering can be used with nonwoven webs formed by any of the methods disclosed herein. Typically, calendered meltspun nonwoven webs have a typical bond area of ​​about 10-25% of the nonwoven surface, while calendered carded nonwoven webs have a typical bond area of ​​about 20% or more. The bond point configuration can be hexagonal, rectangular, etc., and the individual points in the bond pattern can be shaped like diamonds and ellipses. It is generally recognized in the art that ellipsoidal bonds result in smoother bond areas and increased strength. Embossing methods for thermally bonding fibers are known. Embossing can be single-sided or double-sided embossing. Typically, embossing of water-soluble fibers involves a single embossing roll consisting of a regular circular array and single-sided embossing using a steel roll with a flat surface. As embossing increases (e.g., surface features are imparted to the web), the surface area of ​​the web increases. Without intending to be bound by theory, it is expected that as the surface area of ​​the web increases, the solubility of the web increases. Thus, the solubility characteristics of the nonwoven web can be advantageously adjusted by modifying the surface area through embossing.

[0147] Through-air bonding generally requires a high thermoplastic content in the nonwoven web and two materials with different melting points. In through-air bonding, the unbonded nonwoven web is circulated around a drum, with hot air flowing from the outside of the drum toward the center of the drum. Through-air bonding is suitable for low densities and higher basis weights (e.g., greater than 20 to about 2000 g / m). 2 ) Nonwoven fabrics bonded by air bonding are typically very soft.

[0148] Hydroentanglement is also known in the art as spunlace or jetlace, and bonding is achieved by contacting the nonwoven fabric with an array of high-pressure water jets that physically entangle the fibers of the nonwoven fabric. Nonwoven fabrics bonded by hydroentanglement are generally soft and drapeable, can have high elongation in the cross direction, can have high strength in the machine direction, do not contain chemical binders, and do not have embossing as a result of thermal bonding.

[0149] Chemical bonding generally includes solvent bonding and resin bonding. In particular, chemical bonding typically uses a binder solution in a solvent and a resin (e.g., latex or waste polymers left over from fiber preparation). The nonwoven fabric can be coated with the binder solution and heat and pressure applied to cure the binder and bond the nonwoven fabric. The binder solution can be applied by immersing the nonwoven fabric in a bath of binder solution, spraying the binder solution onto the nonwoven fabric, extruding the binder solution onto a web (foam bond), and / or applying the binder solution as a print or gravure.

[0150] Chemical bonding can result in smaller, less regular pores than carded / melt-spun pores. Without intending to be bound by theory, it is believed that if the resin solution used for chemical bonding is sufficiently concentrated and / or sufficient pressure is applied, a nonporous water-dispersible nonwoven web can be formed. The solvent used for chemical bonding induces partial solubilization of the fibers present in the web, welding and bonding the fibers together. Therefore, in general, the solvent for chemical bonding can be any solvent capable of at least partially solubilizing one or more fiber-forming materials of the fibers of the nonwoven. In embodiments, the solvent is selected from the group consisting of water, ethanol, methanol, DMSO, glycerin, and combinations thereof. In embodiments, the solvent is selected from the group consisting of water, glycerin, and combinations thereof. In embodiments, the binder solution comprises a solvent selected from the group consisting of water, ethanol, methanol, DMSO, glycerin, and combinations thereof, and further comprises a resin selected from the group consisting of polyvinyl alcohol, latex, and polyvinylpyrrolidone. The binder provided in the solution aids in the welding process, providing a more mechanically robust web. The temperature of the polymer solution is not particularly limited, and it may be provided at room temperature (about 23°C).

[0151] In some embodiments, a second layer of fibers can be used to bond the nonwoven web. In embodiments, at least one nonwoven layer of a composite article of the present disclosure is bonded using a second layer of nonwoven web / fibers. In embodiments, at least two nonwoven layers of a composite article of the present disclosure are bonded using an additional layer of nonwoven web / fibers. In embodiments, at least one nonwoven layer of a composite article of the present disclosure is bonded using thermal, mechanical, or chemical bonding, either alone or in addition to bonding using an additional layer of nonwoven web / fibers.

[0152] Basis weight / porosity

[0153] Nonwoven webs can be characterized by their basis weight. The basis weight of a nonwoven is the mass per unit area of ​​the nonwoven. As is known in the art, the basis weight can be modified by changing the manufacturing conditions. A nonwoven web may have the same basis weight before and after bonding. Alternatively, the bonding method may change the basis weight of the nonwoven web. For example, if bonding occurs through the application of heat and pressure, the thickness of the nonwoven (and therefore the area of ​​the nonwoven) may decrease, thereby increasing the basis weight. Therefore, as used herein, unless otherwise specified, the basis weight of a nonwoven refers to the basis weight of the nonwoven after bonding.

[0154] Nonwoven webs of the present disclosure generally have a density of about 0.1 g / m 2 ~about 700g / m 2 , about 0.5g / m 2 ~about 600g / m 2 , about 1g / m 2 ~about 500g / m 2 , about 1g / m 2 ~about 400g / m 2 , about 1g / m 2 ~about 300g / m 2 , about 1g / m 2 ~about 200g / m 2 , about 1g / m 2 ~about 100g / m 2 , about 30g / m 2 ~about 100g / m 2 , about 20g / m 2 ~about 100g / m 2 , about 20g / m 2 ~about 80g / m 2 , or approximately 25 g / m 2 ~about 70g / m 2 The sheet may have any basis weight in the range of 1000 to 15000.

[0155] In an embodiment, the nonwoven web may be carded and may have a density of about 5 g / m 2 ~about 15g / m 2 , about 7g / m 2 ~Approx. 13g / m 2 , approximately 9 g / m 2 ~Approx. 11g / m 2 , or approximately 10 g / m 2In an embodiment, the nonwoven web may be carded and have a basis weight of 30 g / m 2 or larger, e.g., 30 g / m 2 ~about 70g / m 2 , about 30g / m 2 ~about 60g / m 2 , about 30g / m 2 ~about 50g / m 2 , about 30g / m 2 ~about 40g / m 2 , or approximately 30 g / m 2 ~Approx. 35g / m 2 In embodiments, the nonwoven web may be meltspun and have a basis weight in the range of about 1 g / m 2 ~about 20g / m 2 , about 2g / m 2 ~about 15g / m 2 , about 3g / m 2 ~about 10g / m 2 , about 5g / m 2 ~about 15g / m 2 , about 7g / m 2 ~Approx. 13g / m 2 , approximately 9 g / m 2 ~Approx. 11g / m 2 range, or approximately 10 g / m 2 In embodiments, the nonwoven web may be meltspun and has a basis weight of about 0.1 g / m 2 ~about 10g / m 2 , about 0.1g / m 2 ~about 8g / m 2 , about 0.2g / m 2 ~about 6g / m 2 , about 0.3g / m 2 ~approx. 4g / m 2 , approximately 0.4 g / m 2 ~about 2g / m 2 , or about 0.5 g / m 2 ~about 1g / m 2 The sheet may have a basis weight of

[0156] The basis weight is related to the fiber volume density and porosity of the nonwoven fabric. Nonwoven webs as prepared and before bonding generally have a fiber density of about 30% or less by volume, i.e., for a given volume of nonwoven fabric, 30% or less of the volume is composed of fibers, and the remaining volume is air. Therefore, nonwoven webs are generally highly porous. The fiber volume density and porosity of nonwoven fabrics are inversely related to the characteristics of the nonwoven fabric; for example, a nonwoven fabric with a fiber volume density of about 30% by volume will have a porosity of about 70% by volume. It is well understood in the art that as the fiber volume density increases, the porosity decreases. The fiber volume density can be increased by increasing the basis weight of the nonwoven fabric, for example, by bonding through the application of heat and pressure, potentially reducing the thickness (and therefore the volume) of the nonwoven fabric. Thus, as used herein, unless otherwise specified, the fiber volume density and porosity of a nonwoven fabric refer to the fiber volume density and porosity of the nonwoven fabric after bonding.

[0157] The nonwoven webs of the present disclosure may generally have a porosity of from about 50% to about 95%, e.g., at least about 50%, at least about 60%, at least about 70%, at least about 75%, or at least about 80%, and up to about 95%, up to about 90%, up to about 85%, up to about 80%, up to about 75%, or up to about 70%, or from about 50% to about 95%, from about 50% to about 80%, from about 50% to about 70%, from about 60% to about 75%, from about 60% to about 80%, from about 60% to about 90%, from about 75% to about 85%, from about 75% to about 90%, or from about 75% to about 95%.

[0158] Pore ​​size can be determined using high magnification ordered surface analysis techniques including, but not limited to, Brunauer-Emmett-Teller theory (BET), small angle X-ray scattering (SAXS) and molecular adsorption.

[0159] The nonwoven web of the present disclosure may generally have any thickness. Suitable thicknesses include, but are not limited to, about 5 to about 10,000 μm (1 cm), about 5 to about 5,000 μm, about 5 to about 1,000 μm, about 5 to about 500 μm, about 200 to about 500 μm, about 5 to about 200 μm, about 20 to about 100 μm, about 40 to about 90 μm, about 50 to 80 μm, or about 60 to 65 μm, for example, 50 μm, 65 μm, 76 μm, or 88 μm. The nonwoven web of the present disclosure may be characterized by high or low loft. Loft generally refers to the ratio of thickness to basis weight. High loft nonwoven webs can be characterized by a high ratio of thickness to basis weight. As used herein, "high loft" refers to a nonwoven web of the present disclosure having a basis weight as defined herein and a thickness greater than 200 μm. The thickness of a nonwoven web can be determined in accordance with ASTM D5729-97, ASTM D5736, and ISO 9073-2:1995, and can include, for example, subjecting the nonwoven web to a 2N load and measuring the thickness. High loft materials can be used according to methods known in the art, such as through-air bonding or cross-wrapping, in which an unbonded web is folded over itself using a cross-wrapper to create loft and basis weight. Without intending to be bound by theory, it is believed that the solubility of a nonwoven web containing water-soluble fibers is independent of the thickness of the web, as opposed to a water-soluble film, in which the solubility of the film may depend on the film's thickness. In this regard, it is believed that the basis weight is the parameter that limits water access to the fibers, and thereby the dissolution of the fibers in a water-soluble nonwoven web, because individual fibers provide a greater surface area than water-soluble films, regardless of film thickness.

[0160] The water solubility of the nonwoven web of the present disclosure is generally a function of the type of fiber used to prepare the web and the basis weight of the nonwoven web. Without intending to be bound by theory, it is believed that the solubility profile of the nonwoven web follows the same solubility profile as the fiber used to prepare the nonwoven web, and the solubility profile of the fiber generally follows the same solubility profile as the fiber-forming polymer. For example, in the case of a nonwoven web containing PVOH fibers, the degree of hydrolysis of the PVOH polymer can be selected so that the water solubility of the nonwoven web also affects it. Generally, at a given temperature, as the degree of hydrolysis of the PVOH polymer increases from partial hydrolysis (88% DH) to complete hydrolysis (≧98% DH), the water solubility of the polymer generally decreases. Therefore, in one option, the nonwoven web can be cold water-soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., not copolymerized with anionic monomers), cold water-soluble webs that are soluble in water at temperatures below 10°C can comprise fibers of PVOH having a degree of hydrolysis ranging from about 75% to about 90%, or from about 80% to about 90%, or from about 85% to about 90%. Alternatively, the nonwoven web can be hot water-soluble. For co-poly(vinyl acetate vinyl alcohol) polymers that do not contain any other monomers (e.g., not copolymerized with anionic monomers), hot water-soluble webs that are soluble in water at temperatures of at least about 60°C can comprise fibers of PVOH having a degree of hydrolysis of at least about 98%.

[0161] Modification of PVOH generally increases the solubility of the PVOH polymer. Therefore, at a given temperature, the solubility of a nonwoven web prepared from a PVOH copolymer is expected to be higher than that of a nonwoven web prepared from a PVOH homopolymer having the same degree of hydrolysis as the PVOH copolymer. Following these trends, water-soluble nonwoven webs with specific solubility characteristics can be engineered by blending polymers within the fibers and / or fibers within the nonwoven web.

[0162] The inclusion of water-insoluble fibers in a nonwoven web can also be used to design a nonwoven web with a particular solubility and / or delayed disintegration (e.g., when the nonwoven web is included in a flushable wipe). Without intending to be bound by theory, it is believed that as the weight percentage of water-insoluble fibers included in the nonwoven web (based on the total weight of the nonwoven web) increases, the solubility of the nonwoven web generally decreases, increasing the stability of the wet flushable wipe, preventing disintegration during use and maintaining the flushability of the wipe. Upon contact with water at or above the dissolution temperature of the water-soluble fibers, a nonwoven web comprising water-soluble and water-insoluble fibers begins to disperse as the water-soluble fibers dissolve, thereby disintegrating the web structure and / or increasing the porosity of the nonwoven web. Similarly, delayed disintegration and / or dissolution of the nonwoven webs of the present disclosure can be achieved by using a blend of water-soluble fibers with different dissolution properties and / or different dissolution temperatures. In embodiments in which the nonwoven web comprises water-soluble and water-insoluble fibers, the ratio of soluble to non-soluble fibers is not particularly limited. The water-soluble fibers may comprise from about 1% to about 99%, about 20% to about 80%, about 40% to about 90%, about 50% to about 90%, or about 60% to about 90% by weight of the total fiber weight, and the water-insoluble fibers may comprise from about 1% to about 99%, about 20% to about 80%, about 10% to about 60%, about 10% to about 50%, or about 10% to about 40% by weight of the total fiber weight.

[0163] Furthermore, for water-soluble nonwoven webs, as the basis weight of the web increases, the dissolution rate of the web decreases, but the fiber composition remains constant, as more material dissolves. For example, at a given temperature, a nonwoven web prepared from fibers containing PVOH polymers, e.g., 40 g / m 2 A water-soluble nonwoven web having a basis weight of, for example, 30 g / m 2 Therefore, basis weight can also be used to modify the dissolution characteristics of a nonwoven web. Nonwoven webs generally have a basis weight of about 1 g / m 2~about 700g / m 2 , about 1g / m 2 ~about 600g / m 2 , about 1g / m 2 ~about 500g / m 2 , about 1g / m 2 ~about 400g / m 2 , about 1g / m 2 ~about 300g / m 2 , about 1g / m 2 ~about 200g / m 2 , about 1g / m 2 ~about 100g / m 2 , about 30g / m 2 ~about 100g / m 2 , about 20g / m 2 ~about 100g / m 2 , about 20g / m 2 ~about 80g / m 2 , or approximately 25 g / m 2 ~about 70g / m 2 The sheet may have any basis weight in the range of 1000 to 15000.

[0164] Without intending to be bound by theory, it is believed that the solubility (in terms of time to complete dissolution) of a water-soluble nonwoven web would be expected to exceed that of a water-soluble film of the same size (L x W) and / or mass prepared from the same PVOH polymer. This is due to the larger surface area found in the nonwoven compared to the film, resulting in faster dissolution.

[0165] Mechanical properties

[0166] As is well understood in the art, the term machine direction (MD) refers to the direction in which a nonwoven web travels as it is produced, for example, on a commercially available nonwoven fabric-making machine. Similarly, the term cross direction (CD) refers to the direction in the plane of the web that is perpendicular to the machine direction. With respect to nonwoven composite articles, wipes, absorbent articles, or other articles that comprise the nonwoven composite articles of the present disclosure, these terms refer to the corresponding direction of the article with respect to the nonwoven web used to make the article.

[0167] The tenacity of a nonwoven web can be the same as or different from the tenacity of the fibers used to prepare the web. Without intending to be bound by theory, it is believed that the tenacity of a nonwoven web is related to the strength of the nonwoven web, with higher tenacity corresponding to stronger nonwoven webs. Generally, the tenacity of a nonwoven web can be modified by using fibers with different tenacities. The tenacity of a nonwoven web can also be affected by processing. Generally, the nonwoven webs of the present disclosure can have relatively high tenacity, i.e., the nonwoven web is a self-supporting web that can be used as a sole material to prepare articles and / or pouches. In embodiments, the nonwoven web is a self-supporting web. Conversely, nonwoven webs prepared by meltblown, electrospinning, and / or rotary spinning methods typically have low tenacity and may not be self-supporting or may not be usable as a sole web to form articles or pouches. Therefore, in some embodiments, the nonwoven web is not self-supporting and is used in combination with a second nonwoven web.

[0168] In embodiments, nonwoven webs of the present disclosure may have a machine direction tenacity to cross direction tenacity (MD:CD) ratio ranging from about 0.5 to about 1.5, from about 0.75 to about 1.5, from about 0.80 to about 1.25, from about 0.90 to about 1.1, or from about 0.95 to about 1.05, or about 1. In embodiments, nonwoven webs of the present disclosure have a tenacity ratio MD:CD of from about 0.8 to about 1.25. In embodiments, nonwoven webs of the present disclosure have a tenacity ratio MD:CD of from about 0.9 to about 1.1. In embodiments, nonwoven webs of the present disclosure have a tenacity of about 1. Without intending to be bound by theory, it is believed that as the toughness ratio MD:CD approaches 1, the durability of the nonwoven increases, imparting better resistance to degradation to the nonwoven when stress is applied to the nonwoven during use, for example, by pulling / tugging of the nonwoven caused by scrubbing with a flushable wipe comprising a nonwoven web of the present disclosure or movement during donning of a wearable absorbent article.

[0169] Generally, the nonwoven web of the present disclosure has a rough surface compared to a water-soluble film, which reduces the contact between the surface and the nonwoven web compared to the contact between the surface and the water-soluble film. Advantageously, this surface roughness allows the nonwoven web to have a lower dynamic coefficient of friction and a lower ratio of the resulting static coefficient of friction to the dynamic coefficient of friction compared to a comparable film, resulting in improved consumer feel (i.e., a softer, cloth-like feel rather than a rubbery feel) and / or improved aesthetics (i.e., less glossy than a water-soluble film). Therefore, the fibers must be sufficiently rough to provide surface roughness to the resulting nonwoven web without being so rough that it creates drag.

[0170] Supplementary ingredients

[0171] The nonwoven web of the present disclosure may contain auxiliary agents and / or treatment agents. When the auxiliary agents and treatment agents are included in the nonwoven web, they may be dispersed throughout the web, for example, between the fibers, or may be applied to one or more surfaces of the nonwoven web. The auxiliary agents may be added to the nonwoven web during the melt-spun process using the "co-forming" method developed by Kimberly Clark, as is well known in the art. The adjuvants and processing agents may include, but are not limited to, plasticizers, plasticizer compatibilizers, surfactants, lubricants, release agents, fillers, extenders, crosslinkers, antiblocking agents, antioxidants, detackifying agents, antifoaming agents, nanoparticles such as layered silicate-type nanoclays (e.g., sodium montmorillonite), bleaching agents (e.g., sodium metabisulfite, sodium bisulfite, or others), aversive agents such as bittering agents (e.g., denatonium salts such as denatonium benzoate, denatonium sugar, and denatonium chloride; octaacetylsucrose; quinine; flavonoids such as quercetin and naringenin; and quassinoids such as cassine and brucine) and pungent agents (e.g., capsaicin, piperine, allyl isocyanate, and resiniferatoxin), and other functional ingredients in amounts suitable for their intended purpose. Certain such adjuvants and treatments may be selected from those suitable for use in water-soluble fibers or those suitable for use in water-soluble films.

[0172] In embodiments, the nonwoven web comprises a plasticizer. If included in / on the nonwoven web, the plasticizer can be, for example, any plasticizer or combination thereof described herein for use with the fibers of the present disclosure. The total amount of non-aqueous plasticizer included can be in the range of about 1 wt.% to about 45 wt.%, or about 5 wt.% to about 45 wt.%, or about 10 wt.% to about 40 wt.%, or about 20 wt.% to about 30 wt.%, or about 1 wt.% to about 4 wt.%, or about 1.5 wt.% to about 3.5 wt.%, or about 2.0 wt.% to about 3.0 wt.%, for example, about 1 wt.%, about 2.5 wt.%, about 5 wt.%, about 10 wt.%, about 15 wt.%, about 20 wt.%, about 25 wt.%, about 30 wt.%, about 35 wt.%, or about 40 wt.%, based on the total weight of the nonwoven web.

[0173] In embodiments, the nonwoven web includes a surfactant. If included in / on the nonwoven web, the surfactant can be, for example, any surfactant or combination thereof described herein for use with the fibers of the present disclosure. In various embodiments, the surfactant can be provided in a range of about 0.01 wt.% to about 2.5 wt.%, about 0.1 wt.% to about 2.5 wt.%, about 1.0 wt.% to about 2.0 wt.%, about 0.01 wt.% to 0.25 wt.%, or about 0.10 wt.% to 0.20 wt.%, based on the total weight of the nonwoven web.

[0174] In embodiments, the nonwoven webs of the present disclosure are substantially free of adjuvants. As used herein, unless otherwise specified, "substantially free of adjuvants" means that the nonwoven web contains less than about 0.01 wt.%, less than about 0.005 wt.%, or less than about 0.001 wt.% adjuvants, based on the total weight of the nonwoven web.

[0175] In embodiments, the water-dispersible nonwoven web may be colored, pigmented, and / or dyed to provide improved aesthetic effects compared to water-soluble films. Suitable colorants may include indicator dyes, such as pH indicators (e.g., thymol blue, bromothymol, thymolphthalein, and thymolphthalein), moisture / water indicators (e.g., hydrochromic inks or leuco dyes), or thermochromic inks that change color as the temperature increases and / or decreases. Suitable colorants include, but are not limited to, triphenylmethane dyes, azo dyes, anthraquinone dyes, perylene dyes, indigoid dyes, Food, Drug, and Cosmetic (FD&C) colors, organic pigments, inorganic pigments, or combinations thereof. Examples of colorants include, but are not limited to, FD&C Red #40, Red #3, FD&C Black #3, Black #2, mica-based pearlescent pigments, FD&C Yellow #6, Green #3, Blue #1, Blue #2, titanium dioxide (food grade), brilliant black, and combinations thereof.

[0176] When included in the water soluble fibers, the colorant may be provided in an amount of 0.01% to 25% by weight of the water soluble polymer mixture, for example, 0.02%, 0.05%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, and 24% by weight of the water soluble polymer mixture.

[0177] activator

[0178] In embodiments, the nonwoven web of the present disclosure may include an active agent. The active agent may generally be any active agent described herein for use with the fibers of the present disclosure. The active agent may be added to the nonwoven web during carding of staple fibers, laying of continuous fibers, and / or before bonding. Active agents added to the fibers during carding or laying may be dispersed throughout the nonwoven web. Active agents may be added to the nonwoven web during melt-spun processes, as is well known in the art, using the "co-forming" method developed by Kimberly Clark. Active agents added to the nonwoven web after carding or laying, and before or after bonding, may be selectively added to one or both surfaces of the nonwoven web. Additionally, active agents may be added to the surface of wipes, absorbent articles, or other articles prepared from the nonwoven web.

[0179] The active agent provides additional functionality to the nonwoven web when present in an amount of at least about 1 wt %, or in a range of about 1 wt % to about 99 wt %, in the nonwoven web. In embodiments, the active agent is selected from the group consisting of enzymes, oils, fragrances, colorants, odor absorbers, fragrances, insecticides, fertilizers, oxidizers, stripping agents, liquid absorbent materials, activators, acid catalysts, metal catalysts, ion scavengers, detergents, disinfectants, surfactants, plasticizers, bleaching agents, bleaching ingredients, fabric softeners, and combinations thereof, as described herein. In embodiments, the active agent is selected from the group consisting of enzymes, oils, fragrances, colorants, odor absorbers, fragrances, insecticides, oxidizers, stripping agents, liquid absorbent materials, detergents, disinfectants, surfactants, plasticizers, bleaching agents, bleaching ingredients, fabric softeners, and combinations thereof. In embodiments, the active agent is selected from the group consisting of enzymes, oils, odor absorbers, fragrances, stripping agents, liquid absorbent materials, detergents, disinfectants, and combinations thereof, as described herein.

[0180] The active agent may be solid or liquid. Solid active agents may have an average particle size (e.g., Dv50) of at least about 0.01 μm, or, for example, in the range of about 0.01 μm to about 2 mm. Liquid active agents may be applied directly to the nonwoven web, mixed with a carrier powder, or microencapsulated. In embodiments including a carrier powder, the average particle size of the carrier powder may be at least about 0.01 μm, or, for example, in the range of about 0.01 μm to about 2 mm.

[0181] In one class of embodiments, the active agent is encapsulated to allow for controlled release of the active agent. Suitable microcapsules may comprise or be made from one or more of melamine formaldehyde, polyurethane, urea formaldehyde, chitosan, polymethyl methacrylate, polystyrene, polysulfone, polytetrahydrofuran, gelatin, gum arabic, starch, polyvinylpyrrolidone, carboxymethylcellulose, hydroxyethylcellulose, methylcellulose, arabinogalactan, polyvinyl alcohol, polyacrylic acid, ethylcellulose, polyethylene, polymethacrylate, polyamide, poly(ethylene vinyl acetate), cellulose nitrate, silicone, poly(lactide-co-glycolide), paraffin, carnauba, spermaceti, beeswax, stearic acid, stearyl alcohol, glyceryl stearate, shellac, cellulose acetate phthalate, zein, and combinations thereof. In one embodiment, the microcapsules are characterized by an average particle size (e.g., Dv50) of at least about 0.1 micron, or, for example, in the range of about 0.1 micron to about 200 microns. In alternative embodiments, the microcapsules may form agglomerates of individual particles, for example, the individual particles having an average particle size of at least about 0.1 micron, or in the range of about 0.1 micron to about 200 microns.

[0182] In embodiments in which the activator is applied to one or more surfaces of a nonwoven web or article, the activator can be applied by any suitable method. In one embodiment, one or more stationary powder spray guns are used to direct a stream of activator powder toward the web or article from one or more directions, while the web or article is transported through a coating zone by a belt conveyor. In an alternative embodiment, the article is transported through a suspension of activator powder in air. In yet another alternative embodiment, the article is tumble-mixed with the activator powder in a tubular device. In another embodiment, which can be combined with any other embodiment, electrostatic forces are used to enhance the attraction between the activator powder and the article. This type of method is typically based on negatively charging the powder particles and directing these charged particles toward a grounded article. In other alternative embodiments, the activator powder is applied to the article by a secondary transfer tool, including, but not limited to, a rotating brush in contact with the powder, or a powdering glove that can transfer the powder from a container to the article. In yet another embodiment, the activator powder is applied by dissolving or suspending the powder in a non-aqueous solvent or carrier, which is then atomized and sprayed onto the nonwoven fabric or article. In one type of embodiment, the solvent or carrier then evaporates, leaving behind the activator powder. In one class of embodiments, the activator powder is applied to the nonwoven fabric or article in a precise dosage. This class of embodiments utilizes closed-system dry lubricant application equipment, such as the PekuTECH PM 700 D powder applicator. In this method, the activator powder is fed into the application equipment's feed trough in batches or continuously as needed. The nonwoven web or article is transferred from the exit belt of a standard rotary drum pouch machine onto the conveyor belt of the powder applicator, and a controlled dosage of the activator is applied to the nonwoven web or article.

[0183] The liquid active agent can be applied to the nonwoven web or article by, for example, spin coating, spraying a solution such as an aerosolized solution, roll coating, flow coating, curtain coating, extrusion, knife coating, and combinations thereof.

[0184] composite article

[0185] A composite article of the present disclosure may include at least two layers of nonwoven webs. The composite article may have a first layer of a first nonwoven web comprising a first plurality of fibers having a first diameter; a second layer of a second nonwoven web comprising a second plurality of fibers having a second diameter; and a first interface comprising at least a portion of the first nonwoven web and at least a portion of the second nonwoven web, where the first and second nonwoven webs are fused together, the second diameter being smaller than the first diameter, and the first plurality of fibers, the second plurality of fibers, or both, comprising a water-soluble polyvinyl alcohol fiber-forming material. Any nonwoven layer of the composite article may include a water-soluble film laminated thereto. The water-soluble film may be prepared from any of the polymers described herein as water-soluble fiber-forming materials.

[0186] The composite articles of the present disclosure may provide one or more advantages including, but not limited to, increased mechanical strength compared to the same nonwoven web of the single layer composite article alone, improved liquid acquisition functionality (e.g., a liquid acquisition layer in a diaper or a wipe to absorb spills) compared to the same nonwoven web of the single layer composite article alone, and / or improved liquid retention and / or active composition (e.g., an active lotion in a wet wipe) compared to the same nonwoven web of the single layer composite article alone.

[0187] The first interface, comprising at least a portion of the first nonwoven web and at least a portion of the second nonwoven web, is a composite region where the first and second nonwoven webs overlap, resulting in a mixture of the first and second plurality of fibers, as shown in Figure 3. As shown in Figure 3, the portion of first nonwoven web 201 forming first interface 200 is typically the outer surface of the first nonwoven web. In embodiments, the first interface comprises 50% or less of the thickness of the first nonwoven web, 40% or less, 30% or less, 25% or less, 20% or less, 10% or less, 5% or less, 2.5% or less, or 1% or less of the thickness of the first nonwoven web. In embodiments, the first interface comprises at least 0.1%, at least 0.5%, at least 1%, or at least 5% of the thickness of the first nonwoven web. In embodiments, the first interface constitutes about 0.1% to about 25% of the thickness of the first nonwoven web. Generally, as shown in FIG. 3, the portion of the second nonwoven web 202 forming the interface is the outer surface of the second nonwoven web. In embodiments, the interface constitutes 75% or less, 70% or less, 60% or less, 50% or less, 40% or less, 30% or less, 25% or less, 20% or less, or 15% or less of the thickness of the second nonwoven web. In embodiments, the first interface constitutes at least 1%, at least 5%, at least 10%, at least 20%, at least 25%, at least 30%, or at least 40% of the thickness of the second nonwoven web. In embodiments, the first interface constitutes about 1% to about 75% of the thickness of the second nonwoven web.

[0188] As used herein, unless otherwise specified, two layers of nonwoven webs are "fused" if at least a portion of the fibers from each web are bonded to the fibers from the other web. As described herein, fiber bonding includes fiber entanglement. Two layers of nonwoven webs can be fused using any suitable method. In embodiments, a portion of the first nonwoven web and a portion of the second nonwoven web are heat-fused, solvent-fused, or both. In embodiments, a portion of the first nonwoven web and a portion of the second nonwoven web are heat-fused. Heat-fusion can include the use of heat and / or pressure. In embodiments, one or both of two separate nonwoven webs can be heated until the fibers soften, and then the webs are compressed together, and as the fibers cool, at least a portion of the fibers from each web bond to at least a portion of the fibers from the other web. In embodiments, one or both of the first and second nonwoven webs may be meltspun and applied in an in-line process, such that heated, soft fibers are applied directly to the preformed nonwoven web after it passes through the die assembly and fuse to the fibers of the preformed nonwoven, forming a fused interface. In embodiments, a portion of the first nonwoven web and a portion of the second nonwoven web are solvent fused. Solvent fusing may involve applying a binder solution to one or both of the nonwoven webs, followed by contacting the nonwoven webs so that, upon drying, at least a portion of the fibers from each web bond to at least a portion of the fibers from the other web. Solvent fusing may be performed as a separate process involving two separate preformed webs, or it may be an in-line process in which a binder solution is applied to a preformed nonwoven web and a second nonwoven web is formed on the preformed nonwoven web in a continuous process. The binder solution for solvent fusing the nonwoven webs may be any of the binder solutions described herein for bonding. As used herein, unless otherwise specified, "preformed nonwoven web" includes formed but unbonded nonwoven webs, and formed and bonded nonwoven webs.As used herein, unless otherwise specified, "separate nonwoven webs" encompasses nonwoven webs formed by carding or air laying staple fibers or by a continuous process, and the nonwoven webs may be bonded or unbonded. In embodiments, fusing of two nonwoven webs can also be used to bond one or both of the nonwoven webs.

[0189] In embodiments, the first interface is solvent fused, and the solvent is selected from the group consisting of water, ethanol, methanol, DMSO, glycerin, and combinations thereof. In embodiments, the first interface is solvent fused, and the solvent is selected from the group consisting of water, glycerin, and combinations thereof. In embodiments, the first interface is solvent fused using a binder solution comprising polyvinyl alcohol and water, glycerin, or a combination thereof. In embodiments, the first interface is solvent fused using a binder solution comprising polyvinyl alcohol, latex, or a combination thereof, and water, glycerin, or a combination thereof.

[0190] As used herein, unless otherwise specified, a particular type of fiber has a diameter "smaller than" the diameter of another particular type of fiber if the average fiber diameter of that particular type of fiber is less than the average fiber diameter of that other particular type of fiber. For example, a particular type of fiber may have a diameter size distribution that overlaps with another type of fiber and still have a smaller diameter as long as the average fiber diameter for that particular type of fiber is smaller than the average fiber diameter of the other type of fiber. In embodiments, the smaller fiber type has an average fiber diameter that is smaller than the minimum diameter of the diameter size distribution of the larger fiber type. A diameter difference exists if the difference can be visualized using projection microscope imaging, as outlined in ISO 137:2015. In embodiments, for example, when multiple meltspun layers are used, the diameter difference between the smaller and larger fiber types can be submicron. In embodiments, the difference in diameter between the smaller and larger fiber types can be about 1 micron to about 300 microns, about 5 microns to about 300 microns, about 5 microns to about 250 microns, about 5 microns to about 200 microns, about 10 microns to about 150 microns, about 10 microns to about 100 microns, about 10 microns to about 90 microns, about 15 microns to about 80 microns, about 15 microns to about 70 microns, about 20 microns to about 60 microns, about 20 microns to about 50 microns, or about 25 microns to about 45 microns. In embodiments, the difference in diameter between the smaller and larger fiber types can be about 5 microns to about 75 microns. In embodiments, the difference in diameter between the smaller and larger fiber types can be about 20 microns to about 80 microns.Without intending to be bound by theory, it is believed that providing a composite of two nonwoven webs, in which the nonwoven webs are fused together and the second nonwoven web has a smaller fiber diameter than the first nonwoven web, may advantageously improve the adsorption / absorption rate and fluid capacity of the composite article, with fluid preferentially migrating directly from larger diameter fibers to smaller diameter fibers; the surface-to-volume ratio of the nonwoven composite article may be increased compared to a single diameter material, resulting in increased loading capacity and / or improved dispersion and / or improved overall dissolution of the nonwoven composite article compared to a nonwoven fabric having a single diameter material. The average diameter of the fibers of the individual web layers may be any of the diameters provided herein. In embodiments, the first plurality of fibers of the first layer of the first nonwoven web may have a diameter of about 10 microns to about 300 microns, about 50 microns to about 300 microns, or greater than about 100 microns to about 300 microns. In embodiments, the first plurality of fibers may have an average diameter of greater than about 100 microns to about 300 microns. In embodiments in which a nonwoven layer of a nonwoven composite comprises a blend of fiber types having different diameters, if the distribution of fiber diameters is unimodal, then the average fiber diameter refers to the average fiber diameter of the blend. A blend of fiber types may have a bimodal or higher order distribution of fiber diameters for the nonwoven layer. If a blend of fibers has a bimodal or higher order diameter distribution, then a fiber has a smaller diameter than the fibers of the blend if it has an average fiber diameter less than the average of the distribution of the smallest diameter fibers in the blend, and a fiber has a larger diameter than the fibers of the blend if it has an average fiber diameter greater than the average of the distribution of larger diameter fibers in the blend.

[0191] In some embodiments, the composite article further includes a third layer of a third nonwoven web comprising a third plurality of fibers. In embodiments in which the nonwoven composite article includes a third layer of a third nonwoven web, a second layer may be disposed between the first and third layers, and at least a second portion of the second nonwoven web and at least a portion of the third nonwoven web may be fused to form a second interface. The second interface, comprising at least a second portion of the second nonwoven web and at least a portion of the third nonwoven web, is a region of the composite where the second and third nonwoven webs overlap and the second plurality of fibers and the third plurality of fibers are interwoven. In some embodiments, depending on the thickness of the second layer of the second nonwoven web, the first plurality of fibers and the third plurality of fibers may be interwoven and / or fused together such that there is no clear delineation between the first and second interfaces. Typically, the portion of the second nonwoven web that forms the second interface is the outer surface of the second nonwoven web opposite the outer surface of the second nonwoven web fused to the first nonwoven web. In embodiments, the second interface comprises 75% or less, 70% or less, 60% or less, 50% or less, 40% or less, 30% or less, 25% or less, 20% or less, or 15% or less of the thickness of the second nonwoven web. In embodiments, the second interface comprises at least 1%, at least 5%, at least 10%, at least 20%, at least 25%, at least 30%, or at least 40% of the thickness of the second nonwoven web. In embodiments, the second interface comprises from about 1% to about 75% of the thickness of the second nonwoven web. In embodiments, the portion of the third nonwoven web that forms the second interface is the outer surface of the third nonwoven web. In embodiments, the second interface comprises 50% or less of the thickness of the third nonwoven web, 40% or less, 30% or less, 25% or less, 20% or less, 10% or less, 5% or less, 2.5% or less, or 1% or less of the thickness of the first nonwoven web, hi embodiments, the second interface comprises at least 0.1%, at least 0.5%, at least 1%, or at least 5% of the thickness of the third nonwoven web.In an embodiment, the second interface comprises about 0.1% to about 25% of the thickness of the third nonwoven fabric.

[0192] In an embodiment, the second portion of the second nonwoven web and a portion of the third nonwoven web are heat-fused, solvent-fused, or both. In an embodiment, the second portion of the second nonwoven web and a portion of the third nonwoven web are heat-fused. In an embodiment, the second portion of the second nonwoven web and a portion of the third nonwoven web are solvent-fused.

[0193] In embodiments, the second interface is solvent fused, and the solvent is selected from the group consisting of water, ethanol, methanol, DMSO, glycerin, and combinations thereof. In embodiments, the second interface is solvent fused, and the solvent is selected from the group consisting of water, glycerin, and combinations thereof. In embodiments, the second interface is solvent fused using a binder solution comprising polyvinyl alcohol and water, glycerin, or a combination thereof. In embodiments, the second interface is solvent fused using a binder solution comprising polyvinyl alcohol, latex, or a combination thereof, and water, glycerin, or a combination thereof.

[0194] In an embodiment, the first layer of the first nonwoven web and the second layer of the second nonwoven web have different porosities. As used herein, unless otherwise specified, two nonwoven webs have "different porosities" if the difference in porosity of the nonwoven webs is at least about 1%. In an embodiment, the difference in porosity between two layers of the nonwoven web of a composite article can be from about 1% to about 20%. For example, one layer of the nonwoven web of the composite article can have a porosity of about 80% and the second layer of the nonwoven web of the composite article can have a porosity of about 85%, with a porosity difference of 5%. In an embodiment, the porosity of the second nonwoven web is less than the porosity of the first nonwoven web. In an embodiment, the porosity of the second nonwoven web is the same as the porosity of the first nonwoven web. As used herein, unless otherwise specified, two nonwoven webs have the "same porosity" if the difference in porosity values ​​between the two nonwoven webs is less than 1%.

[0195] In embodiments in which the composite article includes a third layer of a third nonwoven web, the third nonwoven web may have the same or different porosity as the first nonwoven web. In embodiments, the third nonwoven web may have the same porosity as the first nonwoven web. In embodiments, the third nonwoven web may have a different porosity than the first nonwoven web. In embodiments, the third nonwoven web may have a lesser porosity than the first nonwoven web. In embodiments, the third nonwoven web may have the same porosity as the second nonwoven web. In embodiments, the third nonwoven web may have a different porosity than the second nonwoven web. In embodiments, the third nonwoven web may have a lesser porosity than the second nonwoven web. In embodiments, the second nonwoven web may have a lesser porosity than the first nonwoven web, and the third nonwoven web may have a lesser porosity than the second nonwoven web. In embodiments, the nonwoven composite article may have a porosity gradient between layers of the nonwoven web, with one outer surface of the composite structure having the greatest porosity and the other outer surface of the composite structure having the least porosity. In embodiments, the composite structure may have a porosity gradient between layers of the nonwoven web, with the outer surface of the composite structure having the greatest porosity and an intermediate layer of the composite structure having the least porosity. In embodiments, the composite structure may include a fourth or greater layer of nonwoven web, with the intermediate layer including the second and third layers of nonwoven web (in the case of a four-layer composite structure) or the third layer of nonwoven web (in the case of a five-layer composite structure).

[0196] Without intending to be bound by theory, it is believed that when the porosity of a composite structure includes a gradient, the composite structure advantageously has enhanced liquid absorption from the more porous outer surface to the less porous outer surface or to the less porous intermediate layer.

[0197] The fibers of any given nonwoven layer of the composite article can be any of the fibers disclosed herein and can be the same or different. In embodiments, the composition of the fiber-forming material of the first, second, and third pluralities of fibers can be the same or different, and can have similar properties, such as diameter, length, tenacity, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T g ), fiber-forming material, color, or any combination thereof. The following table illustrates contemplated composite articles in which the nonwoven layers may include fibers having three different fiber compositions, where each of the letters "A," "B," and "C" refers to a particular fiber composition, and "-" means that the contemplated composite article does not include a third layer of nonwoven web. Each of fiber compositions A, B, and C may be (a) a single fiber type with a single fiber-forming material, (b) a single fiber type with a blend of fiber-forming materials, (c) a blend of fiber types where each fiber type includes a single fiber-forming material, (d) a blend of fiber types where each fiber type includes a blend of fiber-forming materials, or (e) a blend of fiber types where each fiber type includes a single fiber-forming material or a blend of fiber-forming materials. [Table 1]

[0198] In embodiments, the first plurality of fibers comprises a water-soluble polyvinyl alcohol fiber-forming material. In embodiments, the second plurality of fibers comprises a water-soluble polyvinyl alcohol fiber-forming material. In embodiments, the first plurality of fibers and the second plurality of fibers comprise a water-soluble polyvinyl alcohol fiber-forming material. In embodiments including a third layer of the nonwoven web having a third plurality of fibers, the third plurality of fibers may comprise a water-soluble polyvinyl alcohol fiber-forming material. In embodiments, the polyvinyl alcohol fiber-forming material may be present in one or more fiber types of the plurality of fibers. The water-soluble polyvinyl alcohol fiber-forming material of any of the first, second, or third plurality of fibers may be any water-soluble polyvinyl alcohol fiber-forming material disclosed herein. In embodiments in which two or more of the first plurality of fibers, the second plurality of fibers, and / or the third plurality of fibers comprise a polyvinyl alcohol fiber-forming material, the polyvinyl alcohol may be the same or different in each plurality, and may be the sole fiber-forming material or part of a blend of fiber-forming materials in each plurality, and when each plurality comprises different polyvinyl alcohol fiber-forming materials, the diameter, length, tenacity, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T g ), fiber-forming material, color, or a combination thereof. In embodiments, the water-soluble polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. In embodiments, the polyvinyl alcohol comprises a copolymer, and the copolymer may be anionically modified polyvinyl alcohol. In embodiments, the polyvinyl alcohol comprises an anionically modified polyvinyl alcohol, and the anionically modified polyvinyl alcohol comprises an (alkyl)acrylate-modified polyvinyl alcohol, a maleate-modified polyvinyl alcohol, a sulfonate-modified polyvinyl alcohol, or a combination thereof.

[0199] In embodiments, the fibers of the first, second, and / or third plurality of fibers may comprise a water-soluble fiber-forming material other than polyvinyl alcohol fiber-forming material. In embodiments, the fibers of the first, second, and / or third plurality of fibers may comprise a blend of water-soluble fiber-forming materials including a polyvinyl alcohol fiber-forming material and a water-soluble fiber-forming material other than polyvinyl alcohol fiber-forming material. In embodiments, the water-soluble fiber-forming material other than polyvinyl alcohol fiber-forming material may comprise polyacrylate, polyvinylpyrrolidone, polyethyleneimine, guar gum, acacia gum, xanthan gum, carrageenan, water-soluble starch, water-soluble cellulose, cellulose ether, cellulose ester, cellulose amide, or a combination thereof. In embodiments, the first plurality of fibers comprises a water-soluble fiber-forming material selected from the group consisting of polyacrylate, polyvinylpyrrolidone, polyethyleneimine, guar gum, acacia gum, xanthan gum, carrageenan, water-soluble starch, water-soluble cellulose, cellulose ether, cellulose ester, cellulose amide, and a combination thereof. In embodiments, the second plurality of fibers comprises a water soluble fiber-forming material selected from the group consisting of polyacrylates, polyvinylpyrrolidone, polyethyleneimine, guar gum, acacia gum, xanthan gum, carrageenan, water soluble starch, water soluble cellulose, cellulose ethers, cellulose esters, cellulose amides, and combinations thereof. In embodiments, the third plurality of fibers comprises a water soluble fiber-forming material selected from the group consisting of polyacrylates, polyvinylpyrrolidone, polyethyleneimine, guar gum, acacia gum, xanthan gum, carrageenan, water soluble starch, water soluble cellulose, cellulose ethers, cellulose esters, cellulose amides, and combinations thereof.

[0200] In embodiments, the fibers of the first plurality of fibers, the second plurality of fibers, and / or the third plurality of fibers may comprise a water-insoluble fiber-forming material disclosed herein. In embodiments, the water-insoluble fiber-forming material may include cellulose, cotton, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, Dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polypropylene, polycarbonate, polybutylene terephthalate, polyethylene terephthalate, polyamide, thermoplastic polyurethane, elastomeric polypropylene, viscose, or a combination thereof. In embodiments, the water-insoluble fiber-forming material comprises cellulose. In embodiments, the water insoluble fiber forming material comprises cellulose, cotton, hemp, jute, flax, ramie, sisal, bagasse, Basho fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polypropylene, polycarbonate, polybutylene terephthalate, polyethylene terephthalate, polyamide, thermoplastic polyurethane, elastomeric polypropylene, viscose, or a combination thereof.

[0201] The following embodiments are contemplated for the first, second, and third pluralities of fibers, as well as any additional pluralities of fibers provided in the composite material, for example, if the composite article includes additional nonwoven layers (i.e., a fourth layer, a fifth layer, etc.). [Table 2]

[0202] In an embodiment, the first plurality of fibers comprises a single type of fiber. In a refinement of the foregoing embodiment, the single type of fiber comprises a single fiber-forming material selected from a water-soluble polyvinyl alcohol fiber-forming material, a water-soluble fiber-forming material other than polyvinyl alcohol, and a water-insoluble fiber-forming material. In a further refinement, the single type of fiber comprises a blend of fiber-forming materials comprising two or more of a water-soluble polyvinyl alcohol fiber-forming material, a water-soluble fiber-forming material other than polyvinyl alcohol, a water-insoluble fiber-forming material, and combinations thereof. In an embodiment, the first plurality of fibers comprises a blend of fibers. In an embodiment, the first plurality of fibers comprises a single fiber type comprising a fiber-forming material selected from the group consisting of a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, and combinations thereof.

[0203] In an embodiment, the second plurality of fibers comprises a single type of fiber. In a refinement of the foregoing embodiment, the single type of fiber comprises a single fiber-forming material selected from a water-soluble polyvinyl alcohol fiber-forming material, a water-soluble fiber-forming material other than polyvinyl alcohol, and a water-insoluble fiber-forming material. In a further refinement, the single type of fiber comprises a blend of fiber-forming materials comprising two or more of a water-soluble polyvinyl alcohol fiber-forming material, a water-soluble fiber-forming material other than polyvinyl alcohol, a water-insoluble fiber-forming material, and combinations thereof. In an embodiment, the second plurality of fibers comprises a blend of fibers. In an embodiment, the second plurality of fibers comprises a single fiber type comprising a water-soluble fiber-forming material. In a refinement of the foregoing embodiment, the water-soluble fiber-forming material comprises a water-soluble polyvinyl alcohol fiber-forming material, a water-soluble fiber-forming material other than polyvinyl alcohol, or a combination thereof. In an embodiment, the second plurality of fibers comprises a single fiber type, and the single fiber type comprises a water-insoluble fiber-forming material. In an embodiment, the second plurality of fibers comprises a blend of fiber types, and at least one of the blend of fiber types comprises a water-soluble fiber-forming material.

[0204] In an embodiment, the third plurality of fibers comprises a single type of fiber. In a refinement of the foregoing embodiment, the single type of fiber comprises a single fiber-forming material selected from a water-soluble polyvinyl alcohol fiber-forming material, a water-soluble fiber-forming material other than polyvinyl alcohol, and a water-insoluble fiber-forming material. In a further refinement, the single type of fiber comprises a blend of fiber-forming materials comprising two or more of a water-soluble polyvinyl alcohol fiber-forming material, a water-soluble fiber-forming material other than polyvinyl alcohol, a water-insoluble fiber-forming material, and combinations thereof. In an embodiment, the third plurality of fibers comprises a blend of fibers. In an embodiment, the first plurality of fibers comprises a single fiber type comprising a fiber-forming material selected from the group consisting of polyvinyl alcohol homopolymer, polyvinyl alcohol copolymer, and combinations thereof. In an embodiment, the third plurality of fibers comprises a blend of fiber types. In an embodiment, the third plurality of fibers is the same as the first plurality of fibers.

[0205] In an embodiment, the first plurality of fibers, the second plurality of fibers, the third plurality of fibers, or a combination thereof, comprises a natural fiber-forming material, a plant-based fiber-forming material, a bio-based fiber-forming material, a biodegradable fiber-forming material, a compostable fiber-forming material, or a combination thereof.

[0206] In an embodiment, the first nonwoven web has a toughness ratio (MD:CD) of about 0.5 to about 1.5. In an embodiment, the first nonwoven web has a MD:CD of about 0.8 to about 1.25. In an embodiment, the first nonwoven web has a MD:CD of about 0.9 to about 1.1. In an embodiment, the second nonwoven web has a toughness ratio (MD:CD) of about 0.5 to about 1.5. In an embodiment, the second nonwoven web has a MD:CD of about 0.8 to about 1.25. In an embodiment, the second nonwoven web has a MD:CD of about 0.9 to about 1.1. In an embodiment, the third nonwoven web has a toughness ratio (MD:CD) of about 0.5 to about 1.5. In an embodiment, the third nonwoven web has a MD:CD of about 0.8 to about 1.25. In embodiments, the third nonwoven web has a MD:CD of about 0.9 to about 1.1. In embodiments, the nonwoven composite article has a toughness ratio (MD:CD) ranging from about 0.5 to about 1.5, from about 0.8 to about 1.25, from about 0.9 to about 1.1, or from about 0.95 to about 1.05. In embodiments, the nonwoven composite article has a MD:CD of about 0.8 to about 1.5. In embodiments, the nonwoven composite article has a MD:CD of about 0.9 to 1.1. The MD:CD of a nonwoven composite article is related to the MD:CD ratio of each individual layer of nonwoven web present in the composite article. Without intending to be bound by theory, it is believed that the MD:CD of a composite article cannot be determined by considering the MD and CD of each layer of nonwoven web individually, but rather the MD and CD of a nonwoven composite article must be measured. Without intending to be bound by theory, it is believed that as the toughness ratio MD:CD of a nonwoven composite article approaches 1, the durability of the composite article increases and provides the nonwoven with greater resistance to degradation when stress is applied to the nonwoven during use. Furthermore, without intending to be bound by theory, it is believed that a composite article comprising at least one layer of a meltspun nonwoven web will have an MD:CD ratio closer to 1:1 than an identical composite article except that it comprises all carded layers.

[0207] In embodiments, the first plurality of fibers, the second plurality of fibers, the third plurality of fibers, or combinations thereof comprise bicomponent fibers. In embodiments, the first plurality of fibers comprise bicomponent fibers. In embodiments, the second plurality of fibers comprise bicomponent fibers. In embodiments, the third plurality of fibers comprise bicomponent fibers. In embodiments, the first and second plurality of fibers comprise bicomponent fibers. In embodiments, the first and third plurality of fibers comprise bicomponent fibers. In embodiments, the second and third plurality of fibers comprise bicomponent fibers. In embodiments, the first, second, and third plurality of fibers comprise bicomponent fibers. In embodiments where the first, second, and / or third plurality of fibers comprise bicomponent fibers, the bicomponent fiber may comprise a core of fiber-forming material surrounded by a sheath of fiber-forming material, the sheath fiber-forming material having a higher solubility in water than the core fiber-forming material for a given water temperature.

[0208] In an embodiment, the first plurality of fibers, the second plurality of fibers, the third plurality of fibers, or a combination thereof, comprise a plasticizer, a surfactant, or a combination thereof. In an embodiment, the nonwoven composite article of the present disclosure comprises an active agent, an absorbent material, or a combination thereof. In a refinement of the foregoing embodiment, the first plurality of fibers, the second plurality of fibers, the third plurality of fibers, or a combination thereof, comprise an active agent, an absorbent material, or a combination thereof. In an embodiment, the nonwoven composite article of the present disclosure comprises an active agent comprising an enzyme, oil, fragrance, colorant, odor absorber, fragrance, insecticide, fertilizer, oxidizer, activator, acid catalyst, metal catalyst, ion scavenger, detergent, disinfectant, surfactant, bleach, bleaching ingredient, fabric softener, or a combination thereof. In an embodiment, the nonwoven composite article of the present disclosure comprises an active agent comprising an enzyme, oil, colorant, odor absorber, fragrance, insecticide, oxidizer, ion scavenger, detergent, disinfectant, surfactant, bleach, bleaching ingredient, fabric softener, or a combination thereof. In embodiments, the nonwoven composite articles of the present disclosure comprise active agents including oils, colorants, odor absorbers, fragrances, ion scavengers, disinfectants, or combinations thereof. In embodiments where the nonwoven composite article comprises a perfume, the perfume may be encapsulated.

[0209] The layers of the nonwoven web of the composite article can generally be prepared using any of the methods described herein. In some embodiments, the first layer of the first nonwoven web can be a carded layer. In embodiments, the second layer of the second nonwoven web can be a meltspun layer. In embodiments, the first layer comprises a carded layer and the second layer comprises a meltspun layer. In embodiments, the first layer can be a carded layer and the second layer can be a meltblown layer. In embodiments, the first layer can be a carded layer and the second layer can be an airlaid layer. In embodiments, the first layer can be a carded layer comprising fibers comprising a polyvinyl alcohol fiber-forming material, and the second layer can be a meltblown layer comprising fibers comprising a low molecular weight polyvinyl alcohol homopolymer having a viscosity of about 5 cP or less. In embodiments, the first layer can be a carded layer comprising fibers comprising a polyvinyl alcohol fiber-forming material, and the second layer can be an airlaid layer comprising cellulose fibers. In embodiments, the third layer may be a carded layer or a meltspun layer. In embodiments, the third layer may be a carded layer. In embodiments, the third layer may be a meltblown layer. In embodiments, the first layer may be a carded layer, the second layer may be a meltspun layer, and the third layer may be a carded layer. In embodiments, the first layer may be a carded layer, the second layer may be an airlaid layer, and the third layer may be a meltspun layer.

[0210] The basis weight of the nonwoven fabric composite article of the present disclosure is not particularly limited, and may be about 5 g / m 2 ~Approx. 150g / m 2 , about 5g / m 2 ~Approx. 125g / m 2 , about 5g / m 2 ~about 100g / m 2 , about 5g / m 2 ~about 70g / m 2 , about 5g / m 2 ~about 50g / m 2 , about 5g / m 2 ~about 30g / m 2 In embodiments, the nonwoven composite article of the present disclosure may have a fiber density in the range of about 5 g / m 2 ~about 50g / m2 In embodiments, the nonwoven composite article of the present disclosure may have a basis weight of about 50 g / m 2 ~Approx. 150g / m 2 In an embodiment, the first layer of nonwoven web may have a basis weight of about 30 g / m 2 ~about 70g / m 2 and the nonwoven composite article may have a basis weight of about 60 g / m 2 ~Approx. 150g / m 2 In an embodiment, the first layer of nonwoven web may have a basis weight of about 5 g / m 2 ~about 15g / m 2 In an embodiment, the first layer of nonwoven web may have a basis weight of about 5 g / m 2 ~about 15g / m 2 and the nonwoven composite article may have a basis weight of about 15 g / m 2 ~about 50g / m 2 In an embodiment, the third layer of nonwoven web may have a basis weight in the range of about 5 g / m 2 ~about 15g / m 2 In an embodiment, the first layer of nonwoven web may have a basis weight of about 5 g / m 2 ~about 15g / m 2 and the third layer of nonwoven web may have a basis weight of about 5 g / m 2 ~about 15g / m 2In embodiments, the second layer of nonwoven web may be present in the composite article at about 2.5 wt.% to about 10 wt.%, based on the total weight of the composite article. In embodiments, the second layer of nonwoven web may be present in the composite article at about 2.5 wt.% to about 10 wt.%, based on the total weight of the composite article, and the first layer of nonwoven web may be present in the composite article at about 90 wt.% to about 97.5 wt.%, based on the total weight of the composite article. In embodiments, the second layer of nonwoven web may be present in the composite article at about 2.5 wt.% to about 10 wt.%, based on the total weight of the composite article, and the first layer of nonwoven web and the third layer of nonwoven web together may be present in the composite article at about 90 wt.% to about 97.5 wt.%, based on the total weight of the composite article. In an embodiment, the third layer of nonwoven web may be included in the composite article at about 2.5 wt.% to about 10 wt.%, based on the total weight of the composite article, and the first layer of nonwoven web and the second layer of nonwoven web together include about 45 wt.% to about 48 wt.%, based on the total weight of the composite article.

[0211] In embodiments, the fiber diameter of the first plurality of fibers may be substantially uniform. In embodiments, the fiber diameter of the second plurality of fibers may be substantially uniform. In embodiments, the fiber diameter of the third plurality of fibers may be substantially uniform. In embodiments, the fiber diameter of the first plurality of fibers and the third plurality of fibers may be substantially uniform. In embodiments, the fiber diameter of each of the first plurality of fibers, the second plurality of fibers, and the third plurality of fibers may be substantially uniform.

[0212] Generally, the first, second, and / or third plurality of fibers may have a tenacity of about 3 cN / dtex to about 10 cN / dtex, optionally about 3 cN / dtex to about 5 cN / dtex, about 4 cN / dtex to about 7 cN / dtex, about 7 cN / dtex to about 10 cN / dtex, about 4 cN / dtex to about 8 cN / dtex, about 5 cN / dtex to about 8 cN / dtex, or about 6 cN / dtex to about 8 cN / dtex. In embodiments, the first, second, and / or third plurality of fibers may have a tenacity of 4 cN / dtex to about 8 cN / dtex. In embodiments, the first, second, and / or third plurality of fibers may have a tenacity of about 6 cN / dtex to about 8 cN / dtex. In embodiments, the first, second, and / or third plurality of fibers may have a tenacity of about 3 cN / dtex to about 5 cN / dtex. In embodiments, the first plurality of fibers may have a tenacity in the range of about 4 cN / dtex to about 8 cN / dtex. In embodiments where the plurality of fibers comprises a blend of fiber types, the tenacity of the fiber blend is an arithmetic weighted average of the tenacities of each fiber type.

[0213] In embodiments, the nonwoven composite article may have improved modulus, tensile strength, elongation, toughness, or a combination thereof, in the machine direction, cross direction, or both, compared to an identical article including only the first layer. In embodiments, the nonwoven composite article may have improved modulus, tensile strength, elongation, toughness, or a combination thereof, in the machine direction, compared to an identical article including only the first layer. In embodiments, the nonwoven composite article may have improved modulus, tensile strength, elongation, toughness, or a combination thereof, in the cross direction, compared to an identical article including only the first layer. In embodiments, the nonwoven composite article may have improved modulus, tensile strength, elongation, toughness, or a combination thereof, in the machine direction and cross direction, compared to an identical article including only the first layer.

[0214] Method for preparing a composite article

[0215] Generally, the composite article can be made using any method known in the art suitable for combining two or more layers of nonwoven webs such that at least a portion of the first layer and a portion of the second layer are fused together, thereby forming an interface.

[0216] In an embodiment, a method of forming a nonwoven composite article of the present disclosure includes: (a) depositing a second layer comprising a second nonwoven web onto a first layer comprising the first nonwoven web under conditions sufficient to fuse at least a portion of the first nonwoven web to at least a portion of the second nonwoven web, thereby forming a first interface; and (b) optionally depositing a third layer comprising a third nonwoven web onto the second layer comprising the second nonwoven web under conditions sufficient to fuse at least a second portion of the second nonwoven web to at least a portion of the third nonwoven web, thereby forming a second interface; may include:

[0217] In embodiments, steps (a) and (b) may be repeated to include additional nonwoven layers in the composite structure, for example, a fourth nonwoven layer, a fifth nonwoven layer, etc.

[0218] Generally, conditions sufficient to fuse at least a portion of a first nonwoven web to at least a portion of a second nonwoven web and / or fuse at least a second portion of a second nonwoven web to at least a portion of a third nonwoven web may include heat fusing and / or solvent fusing as described herein.

[0219] In an embodiment, the heat fusing includes contacting a portion of a first nonwoven web with a portion of a second nonwoven web, contacting a second portion of the second nonwoven web with a portion of a third nonwoven web, or both, where one of the first or second nonwoven web, or one of the second or third nonwoven web, is in a heated state and the portion or portions of the nonwoven webs to be fused are in a softened state. In an embodiment, the heat fusing includes contacting a portion of the first nonwoven web with a portion of the second nonwoven web while the second nonwoven web is in a heated state. In an embodiment, contacting a portion of the first nonwoven web with a portion of the second nonwoven web while the second nonwoven web is in a heated state forms fibers of the second nonwoven web and includes depositing the fibers of the second nonwoven web onto the first nonwoven web in an in-line process such that the fibers of the second nonwoven web are deposited after extrusion through a die assembly and before cooling and / or quenching. In an embodiment, the heat fusing comprises contacting a second portion of the second nonwoven web with a portion of a third nonwoven web while the second nonwoven web is in a heated state. In an embodiment, contacting a second portion of the second nonwoven web with a portion of the third nonwoven web while the second nonwoven web is in a heated state comprises depositing the fibers of the second nonwoven web onto the first nonwoven web in an in-line process such that the fibers of the second nonwoven web are deposited after extrusion through a die assembly and before cooling and / or quenching, and subsequently depositing the third nonwoven web onto the still-heated second layer of nonwoven webs before cooling and / or quenching the second nonwoven web.

[0220] In embodiments, solvent coalescing involves applying a solvent to a portion of the first nonwoven web, a portion of the second nonwoven web, or both, before depositing the second nonwoven web on the first nonwoven web, thereby forming a first interface. In embodiments, solvent coalescing involves applying a solvent to a second portion of the second nonwoven web, a portion of the third nonwoven web, or both, before depositing the third nonwoven web on the second nonwoven web, thereby forming a second interface. In embodiments, solvent coalescing involves applying a solvent to a portion of the first nonwoven web before depositing the second nonwoven web. In embodiments, solvent coalescing involves applying a solvent to a second portion of the second nonwoven web before depositing the third nonwoven web. The solvent for solvent coalescing can be any solvent or binder solution disclosed herein for solvent coalescing and chemical bonding. In embodiments, a portion of the first nonwoven web, a portion of the second nonwoven web, a second portion of the second nonwoven web, a portion of the third nonwoven web, or a combination of the foregoing, is at least partially soluble in a solvent. In embodiments, the solvent comprises water, glycerin, or a combination thereof. In embodiments, solvent fusing further comprises applying pressure after deposition of the second and / or third nonwoven web layers.

[0221] In embodiments of the aforementioned methods, the first layer may comprise a carded nonwoven web. In embodiments of the aforementioned methods, the third layer may comprise a carded nonwoven web or a meltspun nonwoven web. In embodiments of the aforementioned methods, the second layer may comprise a meltspun nonwoven web or an airlaid nonwoven web. In embodiments, the first layer may comprise a carded nonwoven web, the second layer may comprise a meltspun nonwoven web, and the third layer may comprise a carded nonwoven web. In embodiments, the first layer may comprise a carded nonwoven web, the second layer may comprise a meltblown nonwoven web, and the third layer may comprise a carded nonwoven web. In embodiments, the second layer may comprise an airlaid nonwoven web. In embodiments, the first layer may comprise a carded nonwoven web, the second layer may comprise an airlaid nonwoven web, and the third layer may comprise a meltspun nonwoven web. In an embodiment, the first layer may comprise a carded nonwoven web, the second layer may comprise an airlaid nonwoven web, and the third layer may comprise a meltblown nonwoven web. In an embodiment, the nonwoven composite article may comprise five layers of nonwoven webs, where the first layer may comprise a carded nonwoven web, the second layer may comprise an airlaid nonwoven web, the third layer may comprise a meltspun nonwoven web, the fourth layer may comprise an airlaid nonwoven web, and the fifth layer may comprise a carded nonwoven web. In an embodiment, the nonwoven composite article may comprise five layers of nonwoven webs, where the first layer may comprise a carded nonwoven web, the second layer may comprise an airlaid nonwoven web, the third layer may comprise a meltblown nonwoven web, the fourth layer may comprise an airlaid nonwoven web, and the fifth layer may comprise a carded nonwoven web. In embodiments, the second nonwoven web may include a cellulosic fiber-forming material.

[0222] Flushable wipes

[0223] Flushable wipes of the present disclosure generally comprise a nonwoven composite article according to the present disclosure.

[0224] As used herein, the term "flushable" refers to a nonwoven web, composite article, or other article comprising a nonwoven web or composite article that is dispersible in an aqueous environment, e.g., a sewer system, such that disposal of the web or article does not result in such items remaining in the plumbing of a water supply and drainage system or accumulating over time to cause blockages in such plumbing. Flushable articles have the advantage that they are more treatable in reuse processes or can simply be flushed down a municipal sewerage treatment system for purification, for example, and that after use, the web or article does not need to be landfilled, incinerated, or otherwise disposed of.

[0225] The flushable wipes may comprise a plurality of fibers, and the plurality of fibers may include water-soluble fibers and water-insoluble fibers. The water-soluble fibers of the flushable nonwoven web may comprise any of the water-soluble polymers disclosed herein. In an embodiment, the water-soluble fibers comprise polyvinyl alcohol polymers. In a refinement of the foregoing embodiment, the water-soluble fibers comprise PVOH homopolymers. In another refinement of the foregoing embodiment, the water-soluble fibers comprise PVOH copolymers. In an embodiment, the water-soluble fibers comprise a blend of polyvinyl alcohol polymers. In a refinement of the foregoing embodiment, the water-soluble fibers comprise one or more PVOH homopolymers. In another refinement of the foregoing embodiment, the water-soluble fibers comprise one or more PVOH copolymers. In yet another refinement of the foregoing embodiment, the water-soluble polymers comprise one or more PVOH homopolymers and one or more PVOH copolymers.

[0226] In embodiments, the water-soluble fiber comprises a blend of water-soluble polymers. In a refinement of the foregoing embodiment, the blend of water-soluble polymers may comprise a polyvinyl alcohol polymer or a blend of polyvinyl alcohol polymers comprising a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof. In a further refinement, the water-soluble fiber may comprise a blend of water-soluble polymers comprising a polyvinyl alcohol homopolymer and a polyvinyl alcohol copolymer.

[0227] In embodiments, the water-soluble fibers include bicomponent fibers. In the aforementioned refinement, the bicomponent fibers include core / sheath fibers. Without intending to be bound by theory, it is believed that bicomponent fibers can provide flushable wipe stability during storage and use due to the composition of the sheath, and an easily dissolvable, degradable, or compostable post-use article for disposal based on the composition of the core.

[0228] In embodiments, the flushable nonwoven web may comprise a plurality of water-soluble fibers, including first water-soluble fibers and second water-soluble fibers, the first and second water-soluble fibers having a diameter, length, tenacity, shape, stiffness, elasticity, solubility, melting point, glass transition temperature (T g ), water-soluble polymer, color, or a combination thereof.

[0229] As previously noted, water-insoluble fibers generally include fibers made of any material that does not dissolve in 300 seconds or less at temperatures of 80° C. or less, as determined by MSTM-205. Suitable water-insoluble fiber materials include, but are not limited to, cotton, polyester, polyethylene (e.g., high-density polyethylene and low-density polyethylene), polypropylene, wood pulp, fluff pulp, abaca, viscose, polylactic acid, nylon 6, insoluble cellulose, insoluble starch, hemp, jute, flax, ramie, sisal, bagasse, banana fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, Dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, and combinations thereof.

[0230] The amount of water soluble fibers in the flushable nonwoven web can be in the range of at least about 20, 25, 30, 40, 50, or 60 wt. % and / or up to about 90, 85, 80, 75, 70, 60, 50, or 40 wt. % based on the total weight of the flushable nonwoven web, for example, about 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90 wt. % based on the total weight of the flushable nonwoven web.

[0231] The amount of water-insoluble fibers in the flushable nonwoven web can be in the range of at least about 5, 10, 15, 20, 40, 50, or 60 wt. % and / or up to about 75, 70, 60, 50, 40, 30, or 25 wt. % based on the total weight of the flushable nonwoven web, for example, about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, or 75 wt. % based on the total weight of the flushable nonwoven web.

[0232] The ratio of water-insoluble fibers to water-soluble fibers in the flushable nonwoven web can be in the range of about 1:18 to about 4:1, about 1:10 to about 3:1, about 1:5 to about 2:1, or about 1:2 to about 2:1, for example, about 1:18, 1:16, 1:14, 1:12, 1:10, 1:5, 1:3, 1:2, 1:1, 2:1, 3:1, or 4:1.

[0233] Without intending to be bound by theory, for nonwoven webs containing only polyvinyl alcohol fibers, the flushing property increases as the mechanical stability decreases. Therefore, the inventors have found that by incorporating water-insoluble fibers into the nonwoven web, the flushing property can still be increased without compromising the mechanical stability of the web.

[0234] For water-washable nonwoven webs containing polyvinyl alcohol, flushing increases as water solubility increases, but water solubility and mechanical stability have an inverse relationship. Therefore, the selection of a particular polyvinyl alcohol, as well as any additional water-soluble and / or water-insoluble fibers, can be important to maintain the mechanical integrity of the web while also providing suitable flushing characteristics. For example, parameters such as the DH and percent modification of the polyvinyl alcohol homopolymer or copolymer can affect the flushing and mechanical properties of the fiber.

[0235] The flushable wipes of the present disclosure may contain a cleaning lotion. The flushable wipes of the present disclosure generally contain fibers with a sufficiently high surface energy to allow the fibers to be easily wetted with a cleaning lotion during the wetting step of the wipe manufacturing process. Thus, in embodiments, at least a portion of at least one outer layer of the nonwoven composite article of the flushable wipe contains hydrophilic fibers. In embodiments, at least a portion of each outer layer of the nonwoven composite article used to prepare the flushable wipe contains hydrophilic fibers.

[0236] Non-limiting examples of uses for wipes include surface cleaning, skin cleansing, automotive applications, baby care, feminine care, hair cleaning and makeup, skin conditioners, ointments, sunscreens, insect repellents, chemical removal or application, industrial and institutional cleaning of varnishes.

[0237] Lotion composition

[0238] Flushable wipes of the present disclosure may include a lotion composition that moistens the substrate to promote cleaning. In embodiments where the flushable wipe is a personal care wipe, the lotion composition may also include ingredients to, for example, soothe, soften, or care for the skin, improve the feel of the lotion, improve residue removal from the skin, provide a pleasant fragrance, and / or prevent bacterial growth.

[0239] The lotion composition may have a pH of about 5.5 or thereabouts, which is close to physiological skin pH. A low-pH lotion composition may have a pH of about 3.8 or thereabouts, which may be useful when the wipe is used to remove alkaline residues, such as residues from bowel waste, helping to restore a healthy acidic skin pH of approximately 5 and / or inactivating fecal enzymes, thereby rendering irritants from bowel waste non-irritating. A low-pH lotion may also inhibit microbial growth. In embodiments where the lotion composition has a pH of about 4 or less, the fibers of the first plurality of fibers, the second plurality of fibers, and / or the third plurality of fibers may comprise a polyvinyl alcohol copolymer. The copolymer may be provided as the sole fiber-forming material in a fiber blend or as a component of a fiber-forming material in a fiber comprising a blend of fiber-forming materials. In a refinement of the foregoing embodiment, the fiber may comprise a blend of a polyvinyl alcohol copolymer and a homopolymer. The polyvinyl alcohol copolymer and homopolymer may be provided in a ratio of about 1:1 to about 4:1. In a further refinement of the foregoing embodiment, the polyvinyl alcohol copolymer-containing fiber may be blended with a water-insoluble fiber.

[0240] The lotion composition may include a superwetter, a rheology modifier, an emollient, and / or an emulsifier. The superwetter may be present in an amount of about 0.01% to 0.2% by weight of the superwetter, based on the total weight of the lotion composition. The superwetter may be selected from the group consisting of trisiloxane, polyether dimethicone (wherein the polyether functional group is PEG, PPG, or a mixture thereof), and mixtures of the foregoing.

[0241] The rheology modifier may be present in an amount of about 0.01% to 0.5% by weight of the rheology modifier, based on the total weight of the lotion composition. The rheology modifier may be selected from the group consisting of xanthan gum, modified xanthan gum, and combinations thereof.

[0242] The emollient, if present, may be a viscosity emollient. Suitable emollients include, but are not limited to, PEG-10 sunflower oil glycerides, sunflower oil, palm oil, olive oil, emu oil, babassu oil, evening primrose oil, palm kernel oil, cod liver oil, cottonseed oil, jojoba oil, meadowfoam seed oil, sweet almond oil, canola oil, soybean oil, avocado oil, safflower oil, coconut oil, sesame oil, rice bran oil, grape seed oil, mineral oil, isopropyl stearate, isostearyl isononanoate, diethylhexyl fumarate, diisopropyl methylcellulose, methylcellulose copolymer ... These include stearyl malate, triisocetyl citrate, stearyl stearate, methyl palmitate, methylheptyl isostearate, petrolatum, lanolin oil and wax, long chain alcohols such as cetyl alcohol, stearyl alcohol, behenyl alcohol, isostearyl alcohol and 2-hexyl-decanol, myristyl alcohol, dimethicone fluids of various molecular weights and mixtures thereof, PPG-15 stearyl ether (also known as arlatone E), shea butter, olive butter, sunflower butter, coconut butter, jojoba butter, cocoa butter, squalane and squalene, isoparaffin, polyethylene glycols of various molecular weights, polypropylene glycols of various molecular weights or mixtures thereof.

[0243] The emulsifier, if present, may be solid at room temperature. Suitable emulsifiers include, but are not limited to, laureth-23, ceteth-2, ceteth-10, ceteth-20, ceteth-21, ceteareth-20, steareth-2, steareth-10, steareth-20, oleth-2, oleth-10, oleth-20, steareth-100, steareth-21, PEG-40 sorbitan peroleate, PEG-8 stearate, PEG-40 stearate, PEG-50 stearate, PEG-100 stearate, sorbitan laurate, sorbitan palmitate, sorbitan stearate, and sorbitan tristearate. , sorbitan oleate, sorbitan trioleate, polysorbate 20, polysorbate 21, polysorbate 40, polysorbate 60, polysorbate 61, polysorbate 65, polysorbate 80, polysorbate 81, polysorbate 85, PEG-40 hydrogenated castor oil, citric acid esters, microcrystalline wax, paraffin wax, beeswax, carnauba wax, ozokerite wax, cetyl alcohol, stearyl alcohol, cetearyl alcohol, myristyl alcohol, behenyl alcohol and mixtures thereof.

[0244] In embodiments, the cleansing lotion comprises an aqueous emulsion comprising an emollient and an emulsifier.

[0245] The cleaning lotion may further comprise a humectant, including but not limited to, glycerin, propylene glycol, and phospholipids; a fragrance, such as the essential oils and perfumes described herein; a preservative; an enzyme; a colorant; an oil absorbent; an insecticide; a fertilizer; an activator; an acid catalyst; a metal catalyst; an ion scavenger; a detergent; a disinfectant; a surfactant; a bleaching agent; a bleaching component; and a fabric softener. In an embodiment, the cleaning lotion comprises a fragrance, a preservative, an enzyme, a colorant, an oil absorbent, an insecticide, an ion scavenger, a detergent, a disinfectant, or a combination thereof.

[0246] The preservative prevents the growth of microorganisms in the liquid lotion, flushable wipe, and / or the substrate on which the wipe is used. The preservative may be hydrophobic or hydrophilic. Suitable preservatives include, but are not limited to, parabens such as methylparaben, propylparaben, alkyl glycinates, iodine derivatives, and combinations thereof.

[0247] The lotion loading can be 150% to 480%. As used herein, "loading" refers to combining a nonwoven composite article with a lotion composition, regardless of the method used to combine the nonwoven composite article with the lotion composition, i.e., dipping, spraying, kiss-rolling, etc.; i.e., the lotion composition is loaded onto or into the nonwoven composite article. "Lotion loading" refers to the amount of lotion loaded onto or into the nonwoven composite article, expressed as a percentage of the weight of the lotion relative to the weight of the dry (unloaded) nonwoven composite article. It may be desirable for flushable wipes to be loaded with lotion to an extent that some lotion can be easily transferred to the substrate (e.g., skin or another surface to be cleaned) during use. Transfer can facilitate cleaning, provide a pleasant sensation to the user (such as a smooth skin feel or a cooling sensation upon evaporation), and / or allow for the transfer of compounds that provide a beneficial function to the substrate.

[0248] Flushable wipes can be nonwoven composite articles having a high density of interstitial spaces between the fibers comprising the wipe. To maintain sufficient lotion available on the surface of the wipe for transfer to a substrate, the majority of the interstitial spaces in the wipe can be filled with lotion. For example, the lotion in the interstitial spaces may not be readily available for transfer to a substrate, so that the wipe can be loaded with a sufficient amount of excess lotion to provide a sufficient wet feel, thereby informing the user that lotion is available for transfer to a substrate. Advantageously, nonwoven composite articles used in flushable wipes can have a porosity gradient as described herein, which can facilitate the loading of lotion into the wipe.

[0249] Flushable wipes can be made by wetting a nonwoven composite article with at least 1 gram of liquid cleaning lotion per gram of dry fibrous composite. Suitable methods for delivering the cleaning lotion to a substrate include, but are not limited to, immersion, spraying, embedding, extrusion coating, and dip coating. After wetting, the wet composite article can be folded, stacked, cut to length, and wrapped as desired. Flushable wipes are generally large enough to be conveniently handled, yet small enough to be easily disposed of in sewer systems. The wet composite article can be cut or folded to such dimensions during the manufacturing process, or it can be larger and have a means, such as a perforation line, that allows the user to separate individual wipes from the web to the desired size.

[0250] Generally, the nonwoven composite articles of the present disclosure can be used in flushable wipes. In embodiments, the flushable wipes of the present disclosure comprise the nonwoven composite article of the present disclosure and a cleaning lotion. In embodiments, the flushable wipes of the present disclosure consist of the nonwoven composite article of the present disclosure and a cleaning lotion.

[0251] absorbent articles

[0252] The nonwoven webs and nonwoven composite articles of the present disclosure can be used as liquid acquisition layers in absorbent articles. Absorbent articles can include bibs, chest pads, care mats, cleaning pads (e.g., floor cleaning pads), diapers, pant diapers, incontinence liners, pads and other articles (e.g., adult incontinence diapers, adult incontinence pads, adult incontinence pants, potty training liners, potty training pads, potty training pants, and pet training pads, e.g., puppy pads), interlabial devices, menstrual pads, pant liners, sanitary napkins, tampons, spill absorption mats, spill absorption pads, spill absorption rolls, wound dressings, and the like. In one aspect, any of the foregoing articles can be disposable. The term "disposable" refers to an article designed or intended to be discarded after a single use. That is, disposable articles are not intended to be washed or otherwise restored or reused, and in embodiments, may not be capable of being washed, restored, or reused.

[0253] As used herein, the term "absorbent article" includes articles that absorb and contain body exudates. The term "absorbent article" is intended to include diapers, incontinence articles, sanitary napkins, and the like. The term "incontinence article" is intended to include pads, undergarments (pads held in place by some type of support system such as a belt, etc.), absorbent article inserts, absorbent article volume boosters, briefs, bed pads, and the like, whether worn by adults or other incontinent individuals. At least some such absorbent articles are intended to absorb body fluids such as menstrual flow or blood, vaginal secretions, urine, sweat, breast milk, and bowel waste.

[0254] As used herein, "diaper" refers to a device intended to be placed against the wearer's skin to absorb and contain various exudates discharged from the body. Diapers are generally worn by infants and incontinent individuals around the wearer's waist and legs, around the lower torso. Examples of diapers include infant or adult diapers and pant-like diapers, such as training pants. "Training pants," as used herein, refer to disposable undergarments with a waist opening and leg openings designed for infant or adult wearers. Pants can be placed in position on a wearer by inserting the wearer's legs into the leg openings and moving the pant into position around the wearer's lower torso. Pants may be preformed by any suitable technique, including, but not limited to, connecting parts of the article together using refastenable and / or non-refastenable bonds (e.g., stitching, welding, adhesives, sealants, zippers, etc.). Pants may be preformed at any location along the circumference of the article (e.g., side fastening, front waist fastening).

[0255] The absorbent article of the present disclosure typically comprises a liquid-permeable topsheet, a liquid-impermeable backsheet connected to the topsheet, and a liquid acquisition layer and an absorbent core between the topsheet and the backsheet. In embodiments in which the absorbent article is a wearable article (e.g., an incontinence article, a sanitary napkin, etc.), the article may have a wearer-facing side and an outer side. Generally, the liquid-permeable topsheet is on the wearer-facing side of the absorbent article, and the liquid-impermeable backsheet is on the outer side. The absorbent core is generally a sheet-like structure and, when provided as a wearable, has a wearer-facing side and an outer side.

[0256] Generally, the liquid-permeable topsheet can be any liquid-permeable topsheet known in the art. In the case of wearable articles, the topsheet can be fully or partially elasticized, or can be foreshortened to provide a void between the topsheet and the absorbent core. Generally, the liquid-impermeable backsheet can be any liquid-impermeable backsheet known in the art. The backsheet prevents exudates absorbed by the absorbent core and contained within the article from contacting any substrates with which the absorbent article may come into contact. The backsheet is liquid-impermeable and can include a laminate of a nonwoven fabric and a thin plastic film, such as a thermoplastic film. Suitable backsheet films include those manufactured by Tredegar Industries Inc. of Terre Haute, Ind., and sold under the trade names X15306, X10962, and X10964. Other suitable backsheet materials can include breathable materials that allow vapor to escape from the absorbent article while preventing liquid from passing through the backsheet. Exemplary breathable materials may include materials such as woven webs, nonwoven webs, and composite materials such as those manufactured by Mitsui Toatsu Col. of Japan under the designation ESPOIR NO. and EXXON Chemical Co. of Bay City, Tex. under the designation EXXAIRE.

[0257] The absorbent core is disposed between the topsheet and the backsheet. The absorbent core may generally comprise any absorbent material capable of absorbing and retaining liquids, such as urine and other body exudates. The absorbent core may comprise a wide variety of liquid-absorbing materials commonly used in disposable diapers and other absorbent articles, such as superabsorbent polymers, comminuted wood pulp (airfelt), creped cellulose wadding; absorbent foam, absorbent sponge, absorbent gelling material, or any other known absorbent material or combination of materials. The absorbent core may comprise a small amount (less than about 10%) of a non-liquid-absorbent material, such as adhesives, waxes, oils, etc.

[0258] Generally, the liquid acquisition layer comprises a nonwoven web of the present disclosure comprising a plurality of fibers comprising a water-soluble polyvinyl alcohol fiber-forming material. The plurality of fibers may comprise a single fiber type or a blend of fiber types, and the fibers may comprise a single polyvinyl alcohol fiber-forming material or a blend of fiber-forming materials including a polyvinyl alcohol fiber-forming material.

[0259] In embodiments, the liquid acquisition layer may be disposed between the absorbent core and the topsheet. In wearable embodiments, the liquid acquisition layer may be disposed on the wearer-facing side of the absorbent core. In embodiments, the liquid acquisition layer may be disposed between the absorbent core and the backsheet. In wearable embodiments, the liquid acquisition layer may be disposed on the outer surface of the absorbent core. In embodiments, the liquid acquisition layer encases the absorbent core. The liquid acquisition layer may be a single sheet encasing the absorbent core, or may be provided as two connected individual layers. Without intending to be bound by theory, it is believed that including a liquid acquisition layer between the absorbent core and the backsheet or on the outer surface of the absorbent core advantageously prevents leakage of liquid from the absorbent article by providing additional liquid acquisition material that captures any runoff of liquid from the topsheet side and / or wearer-facing side.

[0260] In general, the liquid acquisition layer may be in direct contact with the absorbent core, may include a space between the absorbent core and the liquid acquisition layer, or may include an intervening layer between the absorbent core and the liquid acquisition layer. In embodiments, the liquid acquisition layer is in contact with the absorbent core. In embodiments, the absorbent article includes an intervening layer disposed between the acquisition layer and the absorbent core. In embodiments, the liquid acquisition layer is in contact with the absorbent core on the topsheet / wearer side, and an intervening layer is disposed between the acquisition layer and the absorbent core on the backsheet / outer side. In embodiments, the liquid acquisition layer is in contact with the absorbent core on the backsheet / outer side, and an intervening layer is disposed between the acquisition layer and the absorbent core on the topsheet / wearer side. The intervening layer may be, for example, a second liquid-permeable layer or liquid acquisition layer included to aid and promote the spreading of liquid from the point of deposition to cover the entire area of ​​the absorbent core.

[0261] In an embodiment, the absorbent article comprises an absorbent core and a liquid acquisition layer, wherein the liquid acquisition layer comprises a nonwoven web comprising a plurality of fibers comprising a water-soluble polyvinyl alcohol fiber-forming material, and the liquid acquisition layer comprises a nonwoven composite article comprising a first layer of nonwoven web comprising a first plurality of fibers, a second layer of nonwoven web comprising a second plurality of fibers, and optionally a third layer of nonwoven web, wherein the layer of nonwoven web, the second layer of nonwoven web and / or the third layer of nonwoven web may be a nonwoven web comprising a water-soluble polyvinyl alcohol fiber-forming material. In an embodiment, a wearable absorbent article includes an absorbent core having a wearer-facing surface and an outer surface, and a liquid acquisition layer, the liquid acquisition layer including a nonwoven web including a plurality of fibers including a water-soluble polyvinyl alcohol fiber-forming material, the liquid acquisition layer including a first layer of nonwoven web including a first plurality of fibers, a second layer of nonwoven web including a second plurality of fibers, and optionally a third layer of nonwoven web, wherein the layer of nonwoven web, the second layer of nonwoven web, and / or the third layer of nonwoven web can be a nonwoven web including a water-soluble polyvinyl alcohol fiber-forming material.

[0262] In an embodiment, the absorbent article includes a liquid acquisition layer that is a nonwoven composite article of the present disclosure.In an embodiment, the wearable absorbent article includes a liquid acquisition layer that is a nonwoven composite article of the present disclosure.

[0263] In embodiments, the liquid acquisition layer may be a single layer of a nonwoven web as disclosed herein, wherein a layer of the nonwoven web comprises a water-soluble polyvinyl alcohol fiber-forming material. In embodiments, a nonwoven composite article of the present disclosure may be used for the liquid acquisition layer. In embodiments, the liquid acquisition layer comprises a nonwoven composite article of the present disclosure. In embodiments, the liquid acquisition layer consists of a nonwoven composite article of the present disclosure.

[0264] Liquid-containing nonwoven articles

[0265] The nonwoven webs of the present disclosure can be used in liquid-containing nonwoven articles. The liquid-containing nonwoven articles can be single-unit-dose articles for precise dispensing of liquids containing active agents. The liquids containing active agents can include, but are not limited to, liquid household compositions such as laundry detergents, cleaning compositions, fabric softeners, or dishwashing detergents; liquid personal care compositions such as shampoos, body washes, or shaving creams; or non-household, non-personal care compositions such as liquid agricultural products such as fertilizers and pesticides. The liquids can generally include non-aqueous liquids that do not dissolve the nonwoven articles. Suitable liquids include, but are not limited to, 1,2-propanediol, ethanol, glycerin, propylene glycol, dipropylene glycol, methylpropanediol, and mixtures thereof. Other lower alcohols, low molecular weight polyols, and C1-C4 alkanolamines, such as monoethanolamine and triethanolamine, can also be used. As used herein, a "low molecular weight polyol" is a molecule having more than two hydroxyl groups and a molecular weight ranging from 50 g / mol to 1000 g / mol, 50 g / mol to 800 g / mol, or 50 g / mol to 600 g / mol. The liquid may be present at a level ranging from about 0.1% to about 98%, from about 1% to about 75%, or from about 5% to about 50%, for example, about 10%, about 25%, about 45%, about 40%, about 45%, about 48%, or about 50%, based on the total weight of the liquid and active agent. Typically, the liquid contains less than 50% water, less than 25% water, less than 20% water, less than 10% water, less than 5% water, or from about 0.001% to about 20%, or from about 0.001% to about 10% water.

[0266] The active agents in the liquid may include, but are not limited to, one or more of the following groups: enzymes, oils, fragrances, colorants, odor absorbers, fragrances, insecticides, fertilizers, oxidizers, activators, acid catalysts, metal catalysts, ion scavengers, detergents, disinfectants, surfactants, bleaches, bleaching ingredients, and fabric softeners. In embodiments, the active agents include one or more enzymes and one or more surfactants.

[0267] Advantageously, the nonwoven web of the present disclosure can absorb and / or adsorb the liquid composition into the fiber network and onto the fiber surfaces to provide sufficient active material for a unit dose. The nonwoven web with the absorbed / adsorbed liquid composition can be wrapped or otherwise enclosed in a second nonwoven web to provide a barrier between the active material and the consumer's hands. Thus, the liquid-containing nonwoven article of the present disclosure can be advantageously handled by consumers without contaminating their hands or other surfaces. In contrast to single-unit-dose pouches made of films used in liquid laundry detergents, the liquid-containing nonwoven article of the present disclosure can dissolve faster and more completely than a film due to the increased surface area provided by the fibers of the nonwoven web.

[0268] Generally, the liquid-containing nonwoven web includes a core nonwoven web including a first plurality of fibers containing a first polyvinyl alcohol fiber-forming material, the core nonwoven web containing a liquid including an active agent, and an outer nonwoven web including a second plurality of fibers containing a second polyvinyl alcohol fiber-forming material, the core nonwoven web being encapsulated by the outer nonwoven web. In embodiments, the outer nonwoven web encases the first nonwoven web. As shown in FIG. 4A, the nonwoven web can have a machine direction 301 and a cross direction 302. The nonwoven web can encase the core nonwoven web 302, for example, by folding the nonwoven web about an axis, such as along the machine direction (FIG. 4B). In embodiments, the outer nonwoven web can have the form of a sleeve or envelope, and the core nonwoven web can be disposed in the sleeve or envelope. A sleeve or envelope can be prepared from a single nonwoven web, for example, by folding the web in half and sealing the long edges to provide a sleeve structure with two openings through which the core nonwoven web can be inserted, or by folding the web in half and sealing two of the three edges to form an envelope or pocket structure with one opening through which the core nonwoven web can be inserted. Alternatively, a sleeve or envelope can be prepared from two nonwoven webs that are laminated and sealed along two opposing edges (to form a sleeve) or along three edges (to form a pocket or envelope). In embodiments, the core nonwoven web and the outer nonwoven webs have the same length in at least one dimension. For example, in embodiments in which the outer nonwoven web envelops the core nonwoven web and in embodiments in which the outer nonwoven web is provided as a sleeve, the core nonwoven web can have the same length as the outer nonwoven web. Conversely, in embodiments in which the outer nonwoven web is provided as an envelope or pocket, the core nonwoven web is necessarily shorter than the envelope or pocket because three sides of the envelope or pocket are sealed prior to the introduction of the core nonwoven web.

[0269] Typically, the core nonwoven web contains a liquid, and the liquid includes an active material. Prior to exposure of the core nonwoven web to the liquid, the core nonwoven web may have a dry basis weight ranging from about 15 gsm to about 200 gsm, about 20 gsm to about 175 gsm, about 25 gsm to about 150 gsm, or about 30 gsm to about 120 gsm. The core nonwoven web may be saturated with the liquid. In embodiments, the weight of the core nonwoven web containing the liquid is 2 to 10 times the weight of the core nonwoven web prior to the addition of the liquid. In embodiments, the core nonwoven web contains about 5 to about 30 g of liquid, about 5 to about 25 g of liquid, about 8 to about 20 g of liquid, about 8 to about 19 g of liquid, about 10 to about 19 g of liquid, or about 12 to about 18 g of liquid. In embodiments, the liquid-laden core nonwoven web has a liquid weight of about 30 gsm to about 2000 gsm, about 40 gsm to about 1750 gsm, about 50 gsm to about 1500 gsm, about 60 gsm to about 1200 gsm, about 100 gsm to about 1000 gsm, about 200 gsm to about 800 gsm, or about 300 gsm to about 600 gsm, i.e., the amount of liquid per square meter of core nonwoven web is about 30 g to about 2000 g, about 40 g to about 1750 g, about 50 g to about 1500 g, about 60 g to about 1200 g, about 100 g to about 1000 g, about 200 g to about 800 g, or about 300 g to about 600 g.

[0270] Generally, the core nonwoven web may comprise a single-ply nonwoven web, or may comprise multiple nonwoven webs optionally laminated or bonded together (e.g., discrete layers or stacked layers by folding). In embodiments, the core nonwoven web, whether a single-ply or multi-layer nonwoven web, may be folded upon itself to provide a thicker core for the liquid-containing nonwoven article. The number of times the core nonwoven web may be folded is not particularly limited and depends on the desired thickness of the liquid-containing nonwoven article. In embodiments, the liquid-containing nonwoven article may have a total thickness (including both the outer and core nonwoven webs) of about 2 to about 50 mm, about 3 to about 45 mm, about 4 to about 40 mm, about 5 to about 35 mm, about 5 to about 30 mm, or about 5 to about 25 mm.

[0271] Generally, the outer nonwoven web may comprise a single ply of nonwoven web, or may comprise multiple nonwoven webs optionally laminated or bonded together (e.g., discrete layers or folded layers). In embodiments, the outer nonwoven web may have a basis weight of about 15 gsm to about 400 gsm, about 20 gsm to about 300 gsm, about 25 gsm to about 250 gsm, about 30 gsm to about 210 gsm, or about 30 gsm to about 140 gsm. In embodiments, the outer nonwoven web may have a thickness of about 0.5 mm to about 6.0 mm, about 0.75 mm to about 4.5 mm, or about 1.0 mm to about 3.0 mm. Advantageously, the basis weight and thickness of the outer nonwoven web may be selected to provide a barrier between the active agent and the environment, preventing contamination of secondary packaging, surfaces, or the consumer's hands with the active agent. The outer nonwoven web also advantageously provides a surface that can be burned, printed, or embossed. In embodiments, indicia such as logos or instructions for use can be printed on the outer nonwoven web so that the indicia are visible to the consumer. In embodiments, the outer nonwoven web can be embossed with a pattern. The outer nonwoven web can be printed, embossed, or otherwise marked before and / or after the formation of the liquid-containing nonwoven article.

[0272] Generally, at least a portion of the core nonwoven web may be in contact with at least a portion of the outer nonwoven web. In embodiments, the portion of the core nonwoven web in contact with a portion of the outer nonwoven web may be an edge or periphery of the core nonwoven, and the portion of the outer nonwoven web in contact with a portion of the core nonwoven web may be an edge or periphery. In embodiments, the portion of the core nonwoven web in contact with a portion of the outer nonwoven web may be sealed or otherwise bonded to the outer nonwoven web. In embodiments, the core nonwoven web and the outer nonwoven web may be sealed at at least one edge, at least two edges, or at least three edges. In embodiments, the portion of the core nonwoven web in contact with a portion of the outer nonwoven web may be a portion of the surface of the core nonwoven web, and the portion of the outer nonwoven web in contact with the core nonwoven web may be a portion of the surface of the outer nonwoven web. In embodiments, the core nonwoven web may fit snugly within the outer nonwoven web so that the core nonwoven web substantially fills the interior volume defined by the outer nonwoven web. As used herein, unless otherwise specified, a core nonwoven web "substantially fills" means that the core nonwoven web occupies at least 70% of the interior volume formed by the outer nonwoven webs. In embodiments, the core nonwoven web occupies at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 98% of the interior volume formed by the outer nonwoven webs.

[0273] In general, the shape and dimensions of the liquid-containing nonwoven article are not particularly limited. In embodiments, the size and shape of the liquid-containing nonwoven article are selected so that the liquid-containing article fits within the palm of a consumer's hand. In embodiments, the maximum length in any dimension is about 7 inches (17.78 cm), about 6 inches (15.24 cm), about 5 inches (12.70 cm), or about 4 inches (10.16 cm). In embodiments, the maximum length in any dimension is at least about 0.5 inches (1.27 cm), at least about 1 inch (2.54 cm), at least about 1.5 inches (3.81 cm), or at least about 2 inches (5.08 cm). In embodiments, the maximum length in any dimension is from about 2 inches (5.08 cm) to about 4 inches (10.16 cm). In embodiments, the liquid-containing nonwoven article has a shape selected from the group consisting of a quadrilateral, a triangle, a circle, a star, a heart, an octagon, a pentagon, a hexagon, a heptagon, an oval, a crescent, a semicircle, a cross, a trefoil, a quatrefoil, a teardrop, a five-pointed star, a six-pointed star, an eight-pointed star, a crown, a snowflake, a shield, a cloud, an arrow, and combinations of the foregoing.

[0274] In general, liquid-containing nonwoven articles can include fibers comprising any of the fiber-forming materials disclosed herein. In embodiments, the core nonwoven web includes fibers comprising a first polyvinyl alcohol fiber-forming material selected from polyvinyl alcohol homopolymers, polyvinyl alcohol copolymers, and combinations of the foregoing. In embodiments, the first polyvinyl alcohol includes a polyvinyl alcohol copolymer including an anionically modified polyvinyl alcohol. In embodiments, the anionically modified polyvinyl alcohol includes (alkyl)acrylate-modified polyvinyl alcohol, maleate-modified polyvinyl alcohol, sulfonate-modified polyvinyl alcohol, or a combination thereof. In embodiments, the first polyvinyl alcohol includes a polyvinyl alcohol homopolymer.

[0275] In an embodiment, the outer nonwoven web comprises fibers comprising a second polyvinyl alcohol fiber-forming material selected from polyvinyl alcohol homopolymer, polyvinyl alcohol copolymer, and combinations of the foregoing. In an embodiment, the second polyvinyl alcohol comprises a polyvinyl alcohol copolymer comprising an anionically modified polyvinyl alcohol. In an embodiment, the anionically modified polyvinyl alcohol comprises an (alkyl)acrylate-modified polyvinyl alcohol, a maleate-modified polyvinyl alcohol, a sulfonate-modified polyvinyl alcohol, or a combination thereof. In an embodiment, the second polyvinyl alcohol comprises a polyvinyl alcohol homopolymer.

[0276] In an embodiment, the core nonwoven web comprises a first plurality of fibers comprising a first polyvinyl alcohol fiber-forming material, the first plurality of fibers further comprising one or more fiber-forming materials selected from the group consisting of polyacrylates, polyvinylpyrrolidone, polyethyleneimine, guar gum, acacia gum, xanthan gum, carrageenan, water-soluble starch, water-soluble cellulose, cellulose ethers, cellulose esters, and cellulose amides. In an embodiment, the outer nonwoven web comprises a second plurality of fibers comprising a second polyvinyl alcohol fiber-forming material, the second plurality of fibers further comprising one or more fiber-forming materials selected from the group consisting of polyacrylates, polyvinylpyrrolidone, polyethyleneimine, guar gum, acacia gum, xanthan gum, carrageenan, water-soluble starch, water-soluble cellulose, cellulose ethers, cellulose esters, and cellulose amides.

[0277] Generally, the first polyvinyl alcohol of the core nonwoven web and the second polyvinyl alcohol of the outer nonwoven webs can be the same or different. In embodiments in which the first and second polyvinyl alcohols are different, the first and second polyvinyl alcohol fiber-forming materials can have differences in viscosity, degree of hydrolysis, degree of copolymerization, type of copolymer modification, or a combination thereof.

[0278] Generally, the core nonwoven web before the addition of liquid can be the same or different from the outer nonwoven web. Advantageously, the liquid-containing nonwoven article can provide a consumer product containing a liquid composition that has a cloth-like hand and is comfortable to handle, as opposed to currently available pouches made of water-soluble polymer films that have an unpleasant rubbery or plastic-like feel when handled by consumers. The liquid-containing nonwoven article can have a softness rating of 1 to 5, as determined using the softness rating method disclosed herein.

[0279] Liquid-containing nonwoven articles can be prepared by contacting a core nonwoven web with a liquid containing an active agent, covering the core nonwoven web with outer nonwoven webs, and sealing the outer nonwoven webs to encapsulate the core nonwoven web.

[0280] In embodiments, the method of preparing a liquid-containing nonwoven article further comprises folding the core nonwoven web over itself 2 to 50 times, 3 to 45 times, 4 to 40 times, 5 to 35 times, or 6 to 30 times. As shown in Figures 6 and 7, folding the core nonwoven web over itself results in a thicker nonwoven core. The folding method is not particularly limited and can be an accordion type (Figure 6) or successive folds in the same direction (Figure 7). After folding, the layers can be bonded together, if desired, using any bonding method known in the art.

[0281] Generally, the step of contacting the core nonwoven web with a liquid containing an active agent can be any method known in the art for applying a liquid composition to a substrate. Contacting methods include, but are not limited to, one or more of gravure coating, dip coating, slot die coating, wire coating, flood coating, spray coating, and immersing the core nonwoven web in a liquid bath containing an active agent. In an embodiment, folding occurs after the contacting, and the contacting includes one or more of gravure coating, dip coating, slot die coating, wire coating, flood coating, and spray coating. In an embodiment, folding occurs before the contacting, and the contacting includes immersing the core nonwoven web in a liquid bath containing an active agent.

[0282] In embodiments, the method further includes preparing an outer nonwoven web by plying, stacking, folding, or laminating multiple layers of nonwoven webs. One or more nonwoven webs may be layered and optionally bonded and / or laminated together.

[0283] Generally, the step of covering the core nonwoven web with the outer nonwoven webs can include any method in which the outer nonwoven webs form an interior space and the core nonwoven web is disposed in the interior space. In embodiments, the step of covering the core nonwoven web with the outer nonwoven webs includes wrapping the core nonwoven web with the outer nonwoven webs, inserting the core nonwoven web into an envelope containing the outer nonwoven webs, or inserting the core nonwoven web into a sleeve containing the outer nonwoven webs. In embodiments, the covering step includes horizontal flow wrapping. The outer nonwoven webs can then be sealed together along the machine direction to create a tube around the core nonwoven web containing the liquid containing the active agent.

[0284] As shown in FIG. 4, the outer nonwoven web may have a machine direction (301) and a cross direction (302), and the core nonwoven web (302) may be wrapped by wrapping the outer nonwoven web around the core nonwoven web. As shown in FIG. 5, the sealing step may include sealing the outer nonwoven web along two or more points in the machine direction (303). The sealing step may further include sealing the outer nonwoven web along at least one of the cross-directional edges (304). The sealing step may include any sealing method known in the art, such as heat sealing, solvent welding, and adhesive sealing. Typically, only the area where the seal will be formed is treated with heat or solvent. The heat or solvent may be applied by any method. When solvent or wet sealing or welding is used, it may be preferable to also apply heat. A preferred wet or solvent sealing / welding method involves selectively applying a solvent, for example, by spraying or printing it onto the areas to be sealed and then applying pressure to those areas to form a seal. For example, a sealing roll and belt (which also supplies heat, if necessary) can be used. The solvent for solvent sealing / welding can include any suitable solvent, for example, a polar solvent, including water and / or glycerin. Without intending to be bound by theory, it is believed that solution sealing results in a decrease in the crystallinity of the nonwoven fibers, which in turn can contribute to less residue being left behind upon dissolution of the liquid-containing nonwoven article.

[0285] Liquid-containing nonwoven articles can be prepared as an in-line process. As shown in FIG. 5B, the method for preparing a liquid-containing nonwoven article can further include cutting (305) the nonwoven article transversely along the machine direction seal (303) to provide unit amounts having flanges (307). A die-cutting system can be used to separate the individual doses (FIG. 5B (306)). A cut is made between the inter-unit amount seals to create a flange around each unit amount. In embodiments, the flange can be at least 1 mm and no more than 10 mm, e.g., from about 1.5 mm to about 9 mm, from about 2 mm to about 7.5 mm, or from about 2.5 mm to about 5 mm. The individual unit amounts can then be collected, weighed, and divided for placement into secondary packaging. Dissolution and Disintegration Test (MSTM 205)

[0286] Nonwoven webs, water-soluble films, or composite structures can be characterized or tested for dissolution time and disintegration time according to MonoSol Test Method 205 (MSTM 205), a method known in the art. See, for example, U.S. Patent No. 7,022,656. The description provided below refers to nonwoven webs, but is equally applicable to water-soluble films or composite structures. Equipment and materials: 600mL beaker Magnetic stirrer (Labline model number 1250 or equivalent) Magnetic stirring bar (5cm) Thermometer (0~100℃±1℃) Mold, stainless steel (3.8cm x 3.2cm) Timer (0-300 seconds, second accuracy) Polaroid 35mm slide mount (or equivalent) MonoSol 35mm Slide Mount Holder (or equivalent) Distilled water

[0287] For each nonwoven web to be tested, three test specimens, each measuring 3.8 cm x 3.2 cm, are cut from the nonwoven web sample. The specimens should be cut from areas of the web evenly spaced along the cross direction of the web. Each test specimen is then analyzed using the following procedure.

[0288] Each specimen is mounted on a separate 35 mm slide mound.

[0289] Fill a beaker with 500 mL of distilled water. Measure the water temperature with a thermometer and, if necessary, heat or cool the water to maintain the temperature at the temperature at which dissolution will be determined, e.g., 20°C (approximately 68°F).

[0290] Mark the height of the water column. Place a magnetic stirrer on the base of the holder. Place the beaker on the magnetic stirrer, add a magnetic stir bar to the beaker, start the stirrer, and adjust the stirring speed until a vortex approximately one-fifth the height of the water column is created. Mark the depth of the vortex.

[0291] Secure the 35mm slide mount to the alligator clamp of the 35mm slide mount holder so that the long end of the slide mount is parallel to the water surface. The depth adjustment of the holder should be set so that when dropped, the end of the clamp is 0.6 cm below the water surface. One of the short ends of the slide mount should be against the side of the beaker, and the other end should be placed directly against the center of the stir bar, so that the nonwoven web surface is perpendicular to the water flow.

[0292] In one motion, the secured slide and clamp are dropped into the water and a timer is started. Disintegration occurs when the nonwoven web separates. Once all visible nonwoven web has released from the slide mount, the slide is removed from the water while continuing to monitor the solution for undissolved nonwoven web fragments. Dissolution occurs when all nonwoven web fragments are no longer visible and the solution is clear.

[0293] Results should include the following: complete sample identification, individual and average disintegration and dissolution times, and the water temperature at which the sample was tested. Method for determining single fiber solubility

[0294] The solubility of a single fiber can be characterized by its water decomposition temperature. The fiber decomposition temperature can be determined as follows: A loading of 2 mg / dtex is loaded onto a fiber with a fixed length of 100 mm. The water temperature is started at 1.5°C and then increased in 1.5°C increments every 2 minutes until the fiber decomposes. The temperature at which the fiber decomposes is recorded as the water decomposition temperature.

[0295] The solubility of a single fiber can also be characterized by the temperature of complete dissolution. The temperature of complete dissolution can be determined as follows: 0.2 g of fiber with a fixed length of 2 mm is added to 100 mL of water. The water temperature is started at 1.5°C and then increased in 1.5°C increments every 2 minutes until the fiber is completely dissolved. The sample is stirred at each temperature. The temperature at which the fiber completely dissolves is recorded as the temperature of complete dissolution. Diameter Test Method

[0296] The diameter of individual fibers or fibers within a nonwoven web is determined using a scanning electron microscope (SEM) or optical microscope and image analysis software. A magnification of 200x to 10,000x is selected to ensure that the fibers are appropriately magnified for measurement. When using an SEM, the sample is sputtered with gold or palladium compounds to avoid charging and vibration of the fibers in the electron beam. A manual procedure for determining fiber diameter is used from an image (on a monitor screen) captured by the SEM or optical microscope. Using the mouse and cursor tools, the end of a randomly selected fiber is located and then measured across its width (i.e., perpendicular to the fiber direction at that point) to the other end of the fiber. A scaled and calibrated image analysis tool provides an actual scaled reading in microns. For fibers within a nonwoven web, several fibers are randomly selected across a sample of the nonwoven web using an SEM or optical microscope. At least two sections of the nonwoven web material are cut and tested in this manner. A total of at least 100 such measurements are made and all data is then recorded for statistical analysis, which is used to calculate the average (geometric mean), standard deviation, and median fiber diameter of the fibers. Tensile strength, modulus and elongation tests

[0297] Nonwoven webs, water-soluble films, or composite structures characterized or tested for tensile strength according to the Tensile Strength (TS) Test, modulus (or tensile stress) according to the Modulus of Elasticity (MOD) Test, and elongation according to the Elongation Test are analyzed as follows. The description provided below refers to nonwoven webs, but is equally applicable to water-soluble films or composite structures. The procedure involves determining tensile strength according to ASTM D 882 ("Standard Test Method for Tensile Properties of Thin Plastic Sheets") or equivalent and determining modulus at 10% elongation. An INSTRON tensile testing machine (Model 5544 Tensile Tester or equivalent) is used for collecting nonwoven web data. A minimum of three test specimens, each cut with a reliable cutting tool to ensure dimensional stability and repeatability, are tested in the machine direction (MD) (if applicable) for each measurement. Testing is performed in a standard laboratory atmosphere of 23±2.0°C and 35±5% relative humidity. A 1" wide (2.54 cm) sample of the nonwoven web is prepared for determination of tensile strength or modulus. The sample is then transferred to an Instron tensile tester to proceed with the test while minimizing exposure to a 35% relative humidity environment. The tensile tester is prepared according to the manufacturer's instructions, equipped with a 500 N load cell, and calibrated. Precision grips and faces are installed (Instron grips with rubber-coated 25 mm wide, model number 2702-032 faces, or equivalent). The sample is fitted into the tensile tester and analyzed to determine the 100% modulus (i.e., the stress required to achieve 100% film elongation), tensile strength (i.e., the stress required to break the film), and % elongation (sample length at break compared to the initial sample length). Generally, the higher the % elongation of the sample, the better the processability characteristics of the nonwoven web (e.g., increased formability into packets or pouches). Determining basis weight

[0298] Basis weight is determined in accordance with ASTM D3776 / D3776M-09a(2017). Briefly, a minimum of 130 cm 2 or specimens with an area of ​​at least 130 cm taken from different positions on the sample. 2Cut several smaller die-cut specimens with a total area of ​​1 / 2 inch (0.001 g). Weigh the specimens on a top-loading analytical balance with a resolution of ±0.001 g to determine the mass. Protect the balance from air currents and other disturbances using a draft shield. Fabric specimens may be weighed together. Calculate mass in ounces per square yard, ounces per linear yard, pounds per linear yard, or grams per square meter to three significant figures. Determination of water vapor transmission rate

[0299] Moisture vapor transmission rate (MVTR) is determined in accordance with MSTM-136. MVTR defines how much water transfers through a nonwoven web, film, or composite sample per day. The description provided below refers to a nonwoven web, but is equally applicable to a water-soluble film or composite structure. Equipment and materials: Permatran-W Model 3 / 34 (or equivalent) High-pressure gas cylinder of nitrogen (99.7% or higher) Regulator-Tee (Part Number 027-343) Main Line Supply Regulator HPLC-grade water (or equivalent) 10cc syringe with Luerlok tip (part number 800-020) Powder-free gloves High Vacuum Grease (Part Number 930-022) (2) Test cell Cutting mold cutting board Razor blade with handle Cut-resistant gloves

[0300] Permatran W-Model 3 / 34 Preparation: Ensure the nitrogen pressure level is above 300 psi, the carrier gas regulator-tee pressure reading is 29 psi (not to exceed 32 psi), and the main line supply regulator pressure is set to 35 psi. Open the instrument panel door and utilize the humidifier to check the water level. If the water level is low, fill a syringe with HPLC-grade water and insert the luer attached to the syringe into the reservoir's "fill port." Open the "fill valve" by turning it counterclockwise two to three times, then push the plunger into the syringe to allow the water to enter the reservoir. Close the "fill valve" and remove the syringe. Note: Do not allow the water level to exceed the line marked adjacent to the reservoir.

[0301] 2. Sample Preparation and Testing: For each nonwoven web to be tested, take the sample web and lay it flat on a cutting board. Place a template on top of the web and use a handled razor blade to cut out the sample. Ensure cut-resistant gloves are worn when cutting the sample. Set the sample aside. Grease the sealing surface of the top section of the test cell with high vacuum grease. Place the nonwoven web sample on top of the top section of the test cell. Note: Orientation may be important. For homogeneous materials, orientation is not important. For multi-layer laminate materials, place the multi-layer film or laminate with the barrier coating or laminate facing up towards the top of the cell. For example, a single-sided wax-coated PVOH web should be placed wax-side up, with the wax facing the carrier gas (nitrogen). Place the top section of the test cell on top of the bottom section of the test cell. Ensure the test cells are clamped together with a good seal. Press the cell load / unload button to open the cell tray. Grasp the front and back ends of the test cell and lower straight down. Close the cell tray completely by gently pushing straight down towards the panel. Press the cell load / unload button to clamp the cell. Note: You should hear a click. Repeat for the second sample.

[0302] After the sample is loaded and the instrument is ready, the test parameters must be set. Note: There are two types of test parameters: cell parameters and instrument parameters. Cell parameters are specific to each cell, while instrument parameters are common to all cells. Touch the "Test button" on the screen. Select "Tab A" under "Auto Test". Touch the "Cell Tab". Enter the following by touching each bubble: ID, Area (cm'2), Thickness (mil). Note: The area of ​​the mold is 50cm 2 Repeat for "Tab B". Touch the "Instrument Tab". Enter the following by touching each bubble: Cell temperature (°C) and test gas RH (%). Note: Ensure 100% RH is set to OFF. Cell temperature can be set from a minimum of 10°C to a maximum of 40°C. Test gas RH can be set from a minimum of 5% to 90%. If 100% RH is required, a different method is required. Repeat for "Tab B". Once the test parameters are set, select "Start Selected" or "Start All" depending on the number of samples. Note: A green indicator light for each cell on the front panel indicates the start of the test. Surface resistivity measurement

[0303] The surface resistivity of nonwoven webs and films can be measured according to ASTM D257. Softness Grade

[0304] The hand of the nonwoven web, liquid-containing nonwoven article, or nonwoven composite article of the present disclosure relates to the softness of the sample and can be evaluated using the relevant test method. Using clean hands, the tester conducting the softness evaluation touched the sample in any individually selected manner or method to determine the softness rating of the nonwoven web and article of the present disclosure compared to a control material, including a nonwoven web made of fibers composed of polyvinyl alcohol homopolymer with an 88% degree of hydrolysis and having a 2.2 dtex / 51 mm intersect, having a softness rating of 1 (softest), and a control material made of 75% polyvinyl alcohol homopolymer, having an 88% degree of hydrolysis, having a 2.2 / 51 mm intersect, and 25% PET fibers with a 22 dtex / 38 mm intersect, having a softness rating of 5 (roughest / coarsest). The hand panel was conducted in a blinded study to prevent the raters from changing their opinions based on the name of the sample. The samples could be rated from 1 to 5. Horizontal water absorption test

[0305] The nonwoven fabric was tested for horizontal water absorption as disclosed herein. Testing was completed in a fume hood with the fan turned off. The liquid being tested was exposed to the atmosphere for a suitable time to allow the liquid to equilibrate to room conditions. Nonwoven strips were cut so that the machine direction was parallel to the direction of liquid movement. A glass Petri dish was used as a liquid reservoir and filled to the highest possible level with the liquid being tested for water absorption. A Petri dish lid was placed adjacent to the Petri dish to support the nonwoven web. Binder clips were placed on the Petri dish lid to support the end of the nonwoven strip so that it did not touch the glass. The sample configuration is shown in Figure 8. The liquid was videotaped as it migrated through the nonwoven web, using a ruler as a field of view. The distance traveled by the liquid at different time points was recorded in mm. The distance over time was plotted to obtain the water absorption rate. Horizontal water absorption occurs in three phases: wetting lag, Washburn phase (linear flow of the solution through the substrate), and decay phase. Data used for Washburn slope, water absorption rate and absorption percentage were from 30 seconds to well within the Washburn period during the test.

number

number

[0306] The nonwoven fabrics were tested for absorbency and rate as disclosed herein. For liquid absorption capacity (LAC%), the test specimens were immersed (one at a time) in test liquid to a depth of 200 mm for 60 seconds. The test specimens were then drained vertically for 120 seconds. The LAC% was then calculated using the following formula:

number

[0307] Absorption rate (volume rate of water absorption per unit area),

number

number

[0308] Porosity can be determined by immersing a weighed dry nonwoven sample in a disk of known volume of water.

number

number

[0309] The example nonwoven webs were prepared from one or more fibers selected from the group consisting of Fiber D, Fiber E, Fiber F, and Fiber G described below.

[0310] Fiber D is a commercially available PVOH staple fiber product containing a PVOH homopolymer with a degree of hydrolysis (DH) of 88% and a fineness of 1.7 to 2.2 dtex. Fiber D is dissolved in water at 20°C under the following conditions: 10 g of fiber is placed in a 500 cc container with distilled water in an amount 30 times the weight of the fiber specimen. The water is stirred slightly, and the specimen is observed to be completely dissolved after a few minutes, typically within 15 minutes.

[0311] Fiber E is a commercially available PVOH staple fiber product containing a PVOH homopolymer with a degree of hydrolysis (DH) of 96% and a fineness of 1.4 to 2.2. Fiber E is dissolved in water at 40°C under the following conditions: 10 g of fiber is placed in a 500 cc container with distilled water in an amount 30 times the weight of the fiber sample. The water is stirred slightly, and the sample is observed to be completely dissolved within a few minutes, typically within 15 minutes.

[0312] Fiber F is a commercially available PVOH staple fiber product containing a PVOH homopolymer with a degree of hydrolysis (DH) of 98% and a fineness of 1.4 to 2.2. Fiber F is dissolved in water at 70°C under the following conditions: 10 g of fiber is placed in a 500 cc container with distilled water in an amount 30 times the weight of the fiber specimen. The water is stirred slightly, and the specimen is observed to be completely dissolved within a few minutes, typically within 15 minutes.

[0313] Fiber G is a commercially available PVOH staple fiber product containing PVOH homopolymer with a degree of hydrolysis (DH) of 99+% and a fineness of 1.7 dtex. Fiber G is dissolved in water at a temperature of 95°C under the following conditions: 10 g of fiber is placed in a 500 cc container, followed by distilled water in an amount 30 times the weight of the fiber specimen. The water is stirred slightly, and the specimen is observed to be completely dissolved after a few minutes, typically within 15 minutes.

[0314] Example 1

[0315] Various nonwoven webs were prepared using fibers containing a single PVOH fiber-forming material. The fibers were composed of PVOH homopolymers with different degrees of hydrolysis. Specifically, Fibers D, E, F, and G, each with a DH of 88%, 96%, 98%, and 99%, were used alone or in a 50 / 50 (by weight) blend to provide nonwoven webs with average DHs of 88% (D fiber), 92% (D / E fiber), 93% (D / F fiber), 93.5% (D / G fiber), 96% (E fiber), 97% (E / F fiber), 97.5% (E / G fiber), 98% (F fiber), 98.5% (F / G fiber), and 99+% (G fiber). The fibers were calendered to form the nonwoven web. The nonwoven web with an average DH of 88% was calendered at 40 psi, a speed of 2 FPM (feet per minute), and a temperature of 140°C. The remaining nonwoven web was optionally calendered at 40 psi and a temperature of 140°C to 190°C, depending on the DH of the fibers, at a speed of 1-2 FPM to achieve the same degree of bonding as the nonwoven having an average DH of 88%. The degree of bonding was considered to be the same for two nonwoven webs if the tensile strength of the webs was the same (±5%), as measured according to the Tensile Strength Test disclosed herein. The resulting nonwoven webs were tested for horizontal water absorption and absorbency capacity and rate according to the methods presented herein.

[0316] The liquids tested on the various nonwoven webs were DI water, hexane, synthetic blood, and synthetic urine. Synthetic blood was a 94% water mixture of hemoglobin, amino acids, proteins, and other non-hazardous components. Synthetic urine was a 97% water mixture of urea, magnesium sulfate heptahydrate, calcium chloride dehydrate, and sodium chloride.

[0317] As shown in Figure 9, for water and synthetic urine, the Washburn slope, water absorption rate, and water absorption rate increased as the average DH of the nonwoven web increased. For synthetic blood, the Washburn slope and water absorption rate increased and the water absorption rate remained constant as the average DH increased. For hexane, the Washburn slope, water absorption rate, and water absorption rate each decreased as the DH of the nonwoven web increased.

[0318] As shown in Figure 10, for liquid absorbency, high DH fibers, when provided in a blend, had a greater effect on absorbency than low DH fibers, rather demonstrating the effect of mixture order on absorbency. A nonwoven web containing only cotton pill material was also tested for comparison.

[0319] Example 2

[0320] Various multilayer nonwoven webs were prepared using nonwoven webs containing fibers containing a single PVOH fiber-forming material. The fibers were composed of PVOH homopolymers with different degrees of hydrolysis. Specifically, Fiber D, Fiber E, Fiber F, and Fiber G, with DHs of 88%, 96%, 98%, and 99+%, respectively, were used alone or in blends. The fibers for the first layer were carded, and the fibers for the second layer were layered on top of the fibers for the first layer. The two layers were simultaneously calendered into a nonwoven web and a multilayer nonwoven article. The nonwoven web with an average DH of 88% was calendered at 40 psi, 2 FPM, and 140°C. The remaining nonwoven webs were calendered as needed at 40 psi and 140°C-190°C at 1-2 FPM, depending on the DH of the fibers, to achieve the same degree of bonding as the nonwoven with an average DH of 88%. Two nonwoven webs were considered to have the same degree of bonding if the tensile strengths of the webs were the same (±5%), as measured according to the Tensile Strength Test disclosed herein. Articles having average DH of 92% (50 / 50 D / E fibrous nonwoven), 93% (50 / 50 D / F fibrous nonwoven), 93.5% (50 / 50 D / G fibrous nonwoven), 94% (25 / 75 D / E fibrous nonwoven), 95.2% (10 / 90 D / E fibrous nonwoven), 96% (E fibrous nonwoven), 97% (50 / 50 E / F fibrous nonwoven), and 97.5% (50 / 50 E / G fibrous nonwoven) were prepared from combining two nonwoven webs of the same composition and basis weight.

[0321] All multi-layer articles were tested for horizontal water absorption and absorbent capacity and rate according to the methods presented herein.

[0322] The liquids tested on the various nonwoven webs were DI water, hexane, synthetic blood, and synthetic urine. Synthetic blood was a 94% water mixture of hemoglobin, amino acids, proteins, and other non-hazardous components. Synthetic urine was a 97% water mixture of urea, magnesium sulfate heptahydrate, calcium chloride dihydrate, and sodium chloride.

[0323] As shown in Figure 11, for all liquids except hexane, the Washburn slope, water uptake rate, and absorption rate increased as the average DH of the multilayer article increased. For hexane, the Washburn slope, water uptake rate, and absorption rate increased slightly and remained relatively stable as the DH of the multilayer article increased.

[0324] As shown in Figure 12, for liquid absorbency, the high DH layer, when provided in the blend, had a greater effect on absorbency than the low DH fiber, rather demonstrating the effect of mixture order on absorbency. A nonwoven web containing only cotton pill material was also tested for comparison.

[0325] Example 3

[0326] Various multilayer nonwoven webs were prepared using nonwoven webs with fibers containing a single PVOH fiber-forming material. The fibers were composed of PVOH homopolymers with different degrees of hydrolysis. Specifically, Fiber D, Fiber E, Fiber F, and Fiber G, with DH of 88%, 96%, 98%, and 99+%, respectively, were used alone. The fibers of the first layer were carded, and the fibers of the second layer were layered on top of the fibers of the first layer. The two layers were simultaneously calendered into a nonwoven web and a multilayer nonwoven article. The nonwoven webs were calendered at 40 psi, 2 FPM, and 150°C. Several single-layer articles were also prepared using air-through bonding. Air-through bonding was performed at 180°C and a speed of 6:50. The air-through bonded nonwoven webs contained PVOH fibers with a DH of 96% and up to 5% by weight of polyethylene terephthalate (PET) fibers to aid in bonding. For multilayer articles, the DH was considered the average DH of the two layers. Articles with average DH of 92% (D fiber nonwoven / E fiber nonwoven), 93% (D fiber nonwoven / F fiber nonwoven), 93.5% (D fiber nonwoven / G fiber nonwoven), 97% (E fiber nonwoven / F fiber nonwoven), and 97.5% (E fiber nonwoven / G fiber nonwoven) were prepared from combining two nonwoven webs of different compositions but the same basis weight.

[0327] Multilayer articles comprising two different nonwoven webs were tested for horizontal water absorption and absorbency capacity and rate according to the method presented herein. Tests were performed multiple times on multilayer articles with a first orientation in which the higher DH layer was facing up, and a second orientation in which the lower DH layer was facing up. No discernible difference in water absorption rate was found between the two orientations.

[0328] The liquids tested on the various nonwoven webs were DI water, hexane, synthetic blood, and synthetic urine. Synthetic blood was a 94% water mixture of hemoglobin, amino acids, proteins, and other non-hazardous components. Synthetic urine was a 97% water mixture of urea, magnesium sulfate heptahydrate, calcium chloride dihydrate, and sodium chloride.

[0329] The articles showed the same trend as in Example 1, with the Washburn slope increasing with increasing mean DH.

[0330] As shown in Figure 13, for all liquids except hexane, the Washburn slope, water uptake rate, and absorbency increased as the average DH of the multilayer article increased. For hexane, the Washburn slope, water uptake rate, and absorbency rate increased slightly and remained relatively stable as the DH of the multilayer article increased. The data in Figure 13 was collected on a calendered article when the nonwoven web was oriented with the higher DH side facing up and the lower DH side exposed to the liquid.

[0331] As shown in Figure 14, nonwoven performance depended on the average DH of the article and the type of bonding. Higher LAC% values ​​were observed for the air-through bonded nonwovens compared to their calender-bonded counterparts. This trend suggests that a higher degree of bonding, such as calender bonding (which has higher temperatures, pressures, and longer residence times than the air-through method), reduces the LAC of the article. The labels on the x-axis of Figure 14 refer to the following nonwoven webs of the present disclosure: "E Blend" is a single-layer nonwoven web made of E fibers (from Example 1); "E Blend, 1.75% PET" is a single-layer nonwoven web containing E fibers and 1.75 wt.% PET fibers; "E Blend, 2.5% PET" is a single-layer nonwoven web containing E fibers and 2.5 wt.% PET fibers; "E Blend, 5% PET" is a single-layer nonwoven web containing E fibers and 5 wt.% PET fibers; "E Multilayer" is a two-layer nonwoven web (from Example 2) in which each layer is made of E fibers; "E / F Blend" is a two-layer nonwoven article in which one layer is made of E fibers and one layer is made of F fibers; and "E / G Blend" is a two-layer nonwoven article in which one layer is made of E fibers and one layer is made of G fibers. A nonwoven web containing only cotton pill material was also tested for comparison.

[0332] Example 4

[0333] A single-layer nonwoven web was prepared from a blend of polyvinyl alcohol fiber (fiber E) and polylactic acid (PLA) fiber or cotton fiber. In the nonwoven web, the polyvinyl alcohol fiber comprised 50 wt.% of the total fiber weight, and the other 50 wt.% was PLA fiber or cotton fiber. The polyvinyl alcohol fiber was carded together with the PLA fiber or cotton fiber and calendered at 40 psi and 140°C. The resulting nonwoven web had a basis weight of approximately 50 gsm.

[0334] Thus, Example 4 demonstrates the preparation of a heterogeneous nonwoven web containing water soluble and water insoluble fibers.

[0335] The foregoing description has been set forth for clarity of understanding only, and no unnecessary limitations should be understood therefrom, as modifications within the scope of the present disclosure may be apparent to those skilled in the art.

[0336] All patents, publications, and references cited herein are incorporated herein by reference in their entirety. In the event of a conflict between the present disclosure and the incorporated patents, publications, and references, the present disclosure shall control. The present invention provides, for example, the following items. (Item 1) a first layer comprising a first nonwoven web comprising a first plurality of fibers having a first diameter; a second layer comprising a second nonwoven web comprising a second plurality of fibers having a second diameter; a first interface including at least a portion of the first nonwoven web and at least a portion of the second nonwoven web, wherein the portion of the first nonwoven web and the portion of the second nonwoven web are fused together; and A nonwoven composite article comprising: The nonwoven composite article, wherein the second diameter is smaller than the first diameter, and the first plurality of fibers, the second plurality of fibers, or both, comprise a water soluble polyvinyl alcohol fiber-forming material. (Item 2) Item 10. The nonwoven composite article of item 1, wherein the porosity of the first nonwoven web and the porosity of the second nonwoven web are different. (Item 3) 3. The nonwoven composite article of claim 1 or 2, wherein the article further comprises a third layer of a third nonwoven web comprising a third plurality of fibers. (Item 4) Item 4. The nonwoven composite article of item 3, wherein the second layer is disposed between the first layer and the third layer, and at least a second portion of the second nonwoven web and at least a portion of the third nonwoven web are fused together to form a second interface. (Item 5) 5. The nonwoven composite article of claim 3 or 4, wherein the third nonwoven web comprises pores, the pores of the third nonwoven web having a different size than the pores of the second nonwoven web and the pores of the first nonwoven web. (Item 6) Item 6. The nonwoven composite article of item 5, wherein the pores of the first nonwoven web are larger than the pores of the second nonwoven web, and the pores of the second nonwoven web are larger than the pores of the third nonwoven web. (Item 7) Item 11. The nonwoven composite article of any preceding item, wherein the portion of the first nonwoven web and the portion of the second nonwoven web that form the first interface are heat-fused or solvent-fused. (Item 8) 8. The nonwoven composite article of any one of items 4 to 7, wherein the portion of the second nonwoven web and the portion of the third nonwoven web forming the second interface are heat-fused or solvent-fused. (Item 9) 9. The nonwoven composite article of item 7 or 8, wherein the first interface, the second interface, or both, are solvent-fused, and the solvent comprises one or more selected from the group of water, ethanol, methanol, DMSO, and glycerin. (Item 10) 10. The nonwoven composite article of any one of the preceding items, wherein the first plurality of fibers comprises the water soluble polyvinyl alcohol fiber-forming material. (Item 11) 2. The nonwoven composite article of any one of the preceding items, wherein the second plurality of fibers comprises the water soluble polyvinyl alcohol fiber-forming material. (Item 12) 12. The nonwoven composite article of any one of items 3 to 11, wherein the third plurality of fibers comprises a water soluble polyvinyl alcohol fiber-forming material. (Item 13) 2. The nonwoven composite article of any one of the preceding items, wherein the water-soluble polyvinyl alcohol fiber-forming material comprises one or more selected from the group consisting of polyvinyl alcohol homopolymers and polyvinyl alcohol copolymers. (Item 14) 14. The nonwoven composite article of item 13, wherein the polyvinyl alcohol copolymer comprises anionically modified polyvinyl alcohol. (Item 15) Item 15. The nonwoven composite article of item 14, wherein the anionically modified polyvinyl alcohol comprises one or more selected from the group consisting of (alkyl)acrylate-modified polyvinyl alcohol, maleate-modified polyvinyl alcohol, and sulfonate-modified polyvinyl alcohol. (Item 16) 10. The nonwoven composite article of any one of the preceding items, wherein the first plurality of fibers comprises one or more water-soluble fiber-forming materials selected from the group consisting of polyacrylate, polyvinylpyrrolidone, polyethyleneimine, guar gum, acacia gum, xanthan gum, carrageenan, water-soluble starch, water-soluble cellulose, cellulose ether, cellulose ester, and cellulose amide. (Item 17) 10. The nonwoven composite article of any one of the preceding items, wherein the second plurality of fibers comprises one or more water-soluble fiber-forming materials selected from the group consisting of polyacrylate, polyvinylpyrrolidone, polyethyleneimine, guar gum, acacia gum, xanthan gum, carrageenan, water-soluble starch, water-soluble cellulose, cellulose ether, cellulose ester, and cellulose amide. (Item 18) 18. The nonwoven composite article of any one of items 3 to 17, wherein the third plurality of fibers comprises one or more water soluble fiber-forming materials selected from the group consisting of polyacrylate, polyvinylpyrrolidone, polyethyleneimine, guar gum, acacia gum, xanthan gum, carrageenan, water soluble starch, water soluble cellulose, cellulose ether, cellulose ester, and cellulose amide. (Item 19) 10. The nonwoven composite article of any one of the preceding items, wherein the first plurality of fibers comprises a water-insoluble fiber-forming material. (Item 20) 10. The nonwoven composite article of any one of the preceding items, wherein the second plurality of fibers comprises a water-insoluble fiber-forming material. (Item 21) 12. The nonwoven composite article of any one of items 3 to 11, wherein the third plurality of fibers comprises a water-insoluble fiber-forming material. (Item 22) 22. The nonwoven composite article of any one of items 19 to 21, wherein the water insoluble fiber-forming material comprises one or more selected from the group of cotton, hemp, jute, flax, ramie, sisal, bagasse, Basho fiber, white pine, silk, sinew, catgut, wool, sea silk, mohair, angora, cashmere, collagen, actin, nylon, dacron, rayon, bamboo fiber, modal, diacetate fiber, triacetate fiber, polypropylene, polycarbonate, polybutylene terephthalate, polyethylene terephthalate, polyamide, thermoplastic polyurethane, elastomeric polypropylene, and viscose. (Item 23) 10. The nonwoven composite article of any one of the preceding items, wherein the first plurality of fibers comprises a blend of fiber-forming materials. (Item 24) 10. The nonwoven composite article of any one of the preceding items, wherein the second plurality of fibers comprises a blend of fiber-forming materials. (Item 25) 25. The nonwoven composite article of any one of items 3 to 24, wherein the third plurality of fibers comprises a blend of fiber-forming materials. (Item 26) 10. The nonwoven composite article of any preceding claim, wherein one or more of the first plurality of fibers, the second plurality of fibers, and the third plurality of fibers comprise one or more fiber-forming materials selected from the group consisting of natural fiber-forming materials, plant-based fiber-forming materials, bio-based fiber-forming materials, biodegradable fiber-forming materials, and compostable fiber-forming materials. (Item 27) The nonwoven fabric composite article of any one of the preceding items, wherein the first nonwoven fabric web has a toughness ratio (machine direction:cross direction (MD:CD)) in the range of about 0.5 to about 1.5, about 0.75 to about 1.5, about 0.80 to about 1.25, about 0.90 to about 1.1, or about 0.95 to about 1.05. (Item 28) The nonwoven composite article of any one of the preceding items, wherein the second nonwoven web has a toughness ratio (MD:CD) in the range of about 0.75 to about 1.5, about 0.80 to about 1.25, about 0.90 to about 1.1, or about 0.95 to about 1.05. (Item 29) 29. The nonwoven composite article of any one of items 3 to 28, wherein the third nonwoven web has a toughness ratio (MD:CD) ranging from about 0.75 to about 1.5, from about 0.80 to about 1.25, from about 0.90 to about 1.1, or from about 0.95 to about 1.05. (Item 30) 10. The nonwoven composite article of any preceding claim, wherein one or more of the first plurality of fibers, second plurality of fibers, and third plurality of fibers comprise bicomponent fibers. (Item 31) 31. The nonwoven composite article of item 30, wherein the bicomponent fiber comprises a core of fiber-forming material surrounded by a sheath of fiber-forming material, the sheath fiber-forming material having a higher solubility in water than the core fiber-forming material. (Item 32) 10. The nonwoven composite article of any preceding claim, wherein one or more of the first plurality of fibers, the second plurality of fibers, and the third plurality of fibers further comprise one or both of a plasticizer and a surfactant. (Item 33) 2. The nonwoven composite article of any one of the preceding items, wherein the nonwoven composite further comprises one or both of an active agent and an absorbent material. (Item 34) Item 34. The nonwoven composite article of item 33, wherein one or more of the first plurality of fibers, second plurality of fibers, and third plurality of fibers comprise one or both of the active agent and the absorbent material. (Item 35) 35. The nonwoven composite article of item 33 or item 34, wherein the active agent comprises one or more selected from the group consisting of enzymes, oils, fragrances, colorants, odor absorbers, fragrances, insecticides, fertilizers, oxidizers, activators, acid catalysts, metal catalysts, ion scavengers, detergents, disinfectants, surfactants, bleaches, bleaching components, and fabric softeners. (Item 36) Item 36. The nonwoven composite of item 35, wherein the perfume is encapsulated. (Item 37) 2. The nonwoven composite article of any one of the preceding items, wherein the first layer comprises a carded layer and the second layer comprises a meltspun layer. (Item 38) 38. The nonwoven composite article of any one of items 3 to 37, wherein the third layer comprises a carded layer. (Item 39) 37. The nonwoven composite article of any one of the preceding items, wherein the first layer comprises a carded layer and the second layer comprises an airlaid layer comprising cellulosic fibers. (Item 40) 40. The nonwoven composite article of any one of items 3 to 36 or 39, wherein the third layer comprises a meltspun layer. (Item 41) The first layer has a thickness of about 30 g / m 2 ~about 70g / m 2 41. The nonwoven composite article of item 39 or 40, having a basis weight of (Item 42) The composite article has a mass of about 5 g / m 2 ~Approx. 150g / m 2 , about 5g / m 2 ~Approx. 125g / m 2 , about 5g / m 2 ~about 100g / m 2 , about 5g / m 2 ~about 70g / m 2 , about 5g / m 2 ~about 50g / m 2 , or about 5 g / m 2 ~about 30g / m 2 41. The nonwoven composite article of any one of the preceding items, having a basis weight of (Item 43) The first layer has a thickness of about 5 g / m 2 ~about 15g / m 2 Item 43. The nonwoven composite article of item 42, having a basis weight of (Item 44) The third layer has a thickness of about 5 g / m 2 ~about 15g / m 2 44. The nonwoven composite article of any one of items 3 to 43, having a basis weight of (Item 45) Item 10. The nonwoven composite article of any one of the preceding items, wherein the second layer is present in the composite article in an amount of about 2.5 wt.% to about 10 wt.%, based on the total weight of the composite article. (Item 46) 46. ​​The nonwoven composite article of any one of items 3 to 45, wherein the third layer comprises about 2.5 wt.% to about 10 wt.% of the composite article, based on the total weight of the composite article. (Item 47) 3. The nonwoven composite article of any one of the preceding items, wherein the first plurality of fibers have a diameter of from about 10 microns to about 300 microns, optionally from about 50 microns to about 300 microns, and optionally from greater than 100 microns to about 300 microns. (Item 48) 2. The nonwoven composite article of any preceding claim, wherein the fiber diameter of the first plurality of fibers is substantially uniform. (Item 49) 2. The nonwoven composite article of any one of the preceding items, wherein the first plurality of fibers, the second plurality of fibers, the third plurality of fibers, or a combination thereof has a tenacity of from about 3 cN / dtex to about 10 cN / dtex, optionally from about 7 cN / dtex to about 10 cN / dtex, from about 4 cN / dtex to about 8 cN / dtex, or from about 6 cN / dtex to about 8 cN / dtex. (Item 50) 2. The nonwoven composite article of any preceding claim, wherein the nonwoven composite article has improved modulus, tensile strength, elongation, toughness, or a combination thereof, in the machine direction, cross direction, or both, compared to an identical article including only the first layer. (Item 51) Item 51. The nonwoven composite article of item 50, wherein the nonwoven composite article has improved modulus, tensile strength, elongation, toughness, or a combination thereof, in both the machine direction and cross direction compared to an identical article including only the first layer. (Item 52) 52. A flushable wet wipe comprising the nonwoven composite article of any one of items 1 to 51. (Item 53) 53. The flushable wet wipe according to item 52, further comprising a cleansing lotion comprising an aqueous emulsion comprising an emollient and an emulsifier. (Item 54) 54. The flushable wet wipe according to item 53, wherein the cleaning lotion comprises one or more selected from the group consisting of fragrances, preservatives, enzymes, colorants, oil absorbents, insecticides, ion scavengers, detergents and disinfectants. (Item 55) an absorbent core having a wearer side and an outer side; and liquid acquisition layer A wearable absorbent article comprising: The wearable absorbent article, wherein the liquid acquisition layer comprises a nonwoven web comprising a plurality of fibers comprising a water-soluble polyvinyl alcohol fiber-forming material. (Item 56) 56. The absorbent article according to item 55, wherein the liquid acquisition layer is provided on the wearer-facing side of the absorbent core. (Item 57) 57. The absorbent article according to item 55 or 56, wherein the liquid acquisition layer is provided on the outer surface of the absorbent core. (Item 58) 58. The absorbent article of any one of items 55 to 57, wherein the liquid acquisition layer is wrapped around the absorbent core. (Item 59) 59. The absorbent article according to any one of items 55 to 58, wherein the liquid acquisition layer is in contact with the absorbent core. (Item 60) 60. The absorbent article of any one of items 55 to 59, further comprising an intervening layer disposed between the acquisition layer and the absorbent core. (Item 61) 61. The absorbent article of any one of items 55 to 60, wherein the liquid acquisition layer is in contact with the absorbent core on the outer surface of the absorbent core, and an intervening layer is provided between the acquisition layer and the absorbent core on the wearer-facing side of the absorbent core. (Item 62) The liquid acquisition layer is a first layer of a nonwoven web comprising a first plurality of fibers; a second layer of nonwoven web comprising a second plurality of fibers; and Optionally, a third layer of a nonwoven web comprising a third plurality of fibers. a nonwoven composite comprising: Including, 62. The absorbent article of any one of items 55 to 61, wherein one or more of the first layer of nonwoven web, the second layer of nonwoven web, and the third layer of nonwoven web comprise a nonwoven web comprising a water soluble polyvinyl alcohol fiber-forming material. (Item 63) The liquid acquisition layer comprises the nonwoven composite article of any one of items 1 to 43. 63. The absorbent article of any one of items 55 to 62. (Item 64) 52. Use of the nonwoven composite article of any one of items 1 to 51 in flushable wet wipes. (Item 65) 52. Use of the nonwoven composite article of any one of items 1 to 51 in a wearable absorbent article. (Item 66) 52. A method of forming the nonwoven composite article of any one of the preceding claims, the method comprising: depositing a second layer comprising the second nonwoven web onto the first layer comprising the first nonwoven web under conditions sufficient to fuse at least the portion of the first nonwoven web to the portion of the second nonwoven web, thereby forming a first interface. (Item 67) Item 67. The method of item 66, further comprising depositing a third layer comprising the third nonwoven web onto the second layer comprising the second nonwoven web under conditions sufficient to fuse at least the second portion of the second nonwoven web to at least the portion of the third nonwoven web, thereby forming a second interface. (Item 68) 68. The method of claim 66 or 67, wherein the conditions sufficient to fuse at least the portion of the first nonwoven web to the portion of the second nonwoven web, fuse at least the second portion of the second nonwoven web to the portion of the third nonwoven web, or both, comprise heat fusing or solvent fusing. (Item 69) Item 69. The method of item 68, wherein heat fusing comprises contacting the portion of the first nonwoven web with the portion of the second nonwoven web, contacting the second portion of the second nonwoven web with the portion of the third nonwoven web, or both, and wherein one of the first nonwoven web or second nonwoven web, or one of the second nonwoven web or third nonwoven web, is in a heated state. (Item 70) 70. The method of claim 69, wherein heat fusing comprises contacting the portion of the first nonwoven web with the portion of the second nonwoven web while the second nonwoven web is in a heated state. (Item 71) 70. The method of claim 69, wherein heat fusing comprises contacting the second portion of the second nonwoven web with the portion of the third nonwoven web while the second nonwoven web is in a heated state. (Item 72) Item 69. The method of item 68, wherein solvent fusing comprises applying a solvent to the portion of the first nonwoven web, the portion of the second nonwoven web, or both, before depositing the second nonwoven web onto the first nonwoven web. (Item 73) Item 69. The method of item 68, wherein solvent fusing comprises applying a solvent to the second portion of the second nonwoven web, the portion of the third nonwoven web, or both, before depositing the third nonwoven web onto the second nonwoven web. (Item 74) Item 73. The method of item 72, wherein solvent fusing comprises applying a solvent to the portion of the first nonwoven web before depositing the second nonwoven web. (Item 75) Item 74. The method of item 73, wherein solvent fusing comprises applying a solvent to the second portion of the second nonwoven web prior to depositing the third nonwoven web. (Item 76) 76. The method of any one of items 72 to 75, wherein the portion of the first nonwoven web, the second portion of the second nonwoven web, or both, are at least partially soluble in the solvent. (Item 77) 77. The method of any one of items 72 to 76, wherein the solvent comprises one or more selected from the group consisting of water, ethanol, methanol, DMSO and glycerin. (Item 78) 78. The method of any one of items 66 to 77, wherein the first layer comprises a carded nonwoven web. (Item 79) 79. The method of any one of items 67 to 78, wherein the third layer comprises a carded nonwoven web. (Item 80) 80. The method of any one of items 66 to 79, wherein the second layer comprises a meltspun nonwoven web. (Item 81) 79. The method of any one of items 67 to 78, wherein the third layer comprises a meltspun nonwoven web. (Item 82) Item 82. The method of item 81, wherein the second layer comprises a nonwoven web comprising a cellulose fiber-forming material. (Item 83) 1. A liquid-containing nonwoven article, comprising: a core nonwoven web comprising a first plurality of fibers comprising a first polyvinyl alcohol fiber-forming material, said core nonwoven web comprising a liquid, said liquid comprising an active agent; and an outer nonwoven web comprising a second plurality of fibers comprising a second polyvinyl alcohol fiber-forming material; Including, A liquid-containing nonwoven article wherein the core nonwoven web is encapsulated within the outer nonwoven web. (Item 84) Item 84. The liquid-containing nonwoven article of item 83, wherein the outer nonwoven web envelops a first nonwoven web. (Item 85) Item 84. The liquid-containing nonwoven article of item 83, wherein the outer nonwoven web has the form of a sleeve or envelope, and the core nonwoven web is disposed within the sleeve or envelope. (Item 86) 86. The liquid-containing nonwoven article of any one of items 83 to 85, wherein the core nonwoven web and the outer nonwoven webs have at least one dimension that is the same length. (Item 87) 87. The liquid-containing nonwoven article of any one of items 83 to 86, wherein the core nonwoven is saturated with the liquid. (Item 88) 88. Any one of items 83 to 87, wherein the weight of the core nonwoven web containing the liquid is 2 to 10 times the weight of the core nonwoven web before the addition of the liquid containing the active agent. A liquid-containing nonwoven article as described above. (Item 89) 89. The liquid-containing nonwoven article of any one of items 83 to 88, wherein the core nonwoven web contains from about 5 to about 30 g of liquid, from about 5 to about 25 g of liquid, from about 8 to about 20 g of liquid, from about 8 to about 19 g of liquid, from about 10 to about 19 g of liquid, or from about 12 to about 18 g of liquid. (Item 90) 90. The liquid-containing nonwoven article of any one of items 83 to 89, wherein the core nonwoven web containing the liquid has a liquid weight of from about 30 gsm to about 2000 gsm, from about 40 gsm to about 1750 gsm, from about 50 gsm to about 1500 gsm, from about 60 gsm to about 1200 gsm, from about 100 gsm to about 1000 gsm, from about 200 gsm to about 800 gsm, or from about 300 gsm to about 600 gsm. (Item 91) 91. The liquid-containing nonwoven article of any one of items 83 to 90, wherein the core nonwoven web has a dry basis weight in the range of from about 15 gsm to about 200 gsm, from about 20 gsm to about 175 gsm, from about 25 gsm to about 150 gsm, or from about 30 gsm to about 120 gsm. (Item 92) 92. The liquid-containing nonwoven article of any one of items 83 to 91, wherein the outer nonwoven web has a basis weight of from about 15 gsm to about 400 gsm, from about 20 gsm to about 300 gsm, from about 25 gsm to about 250 gsm, from about 30 gsm to about 210 gsm, or from about 30 gsm to about 140 gsm. (Item 93) 93. The liquid-containing nonwoven article of any one of items 83 to 92, wherein the outer nonwoven web has a thickness of about 0.5 mm to about 6.0 mm, about 0.75 mm to about 4.5 mm, or about 1.0 to about 3.0 mm. (Item 94) 94. The liquid-containing nonwoven article of any one of items 83 to 93, wherein the core nonwoven web is a single ply or is comprised of multiple layers of nonwoven webs. (Item 95) 95. The liquid-containing nonwoven article of any one of items 83 to 94, wherein at least a portion of the core nonwoven web is in contact with at least a portion of the outer nonwoven webs. (Item 96) 96. The liquid-containing nonwoven article of any one of items 83 to 95, wherein the liquid-containing nonwoven article has edges, and the core nonwoven web and the outer nonwoven webs are sealed on at least two edges or at least three edges. (Item 97) 97. The liquid-containing nonwoven article of any one of items 83 to 96, further comprising indicia or patterns on the outer nonwoven web, such as from inkjet printing or embossing. (Item 98) 98. The liquid-containing nonwoven article of any one of items 83 to 97, wherein the nonwoven article has a shape selected from the group consisting of a quadrilateral, triangle, circle, star, heart, octagon, pentagon, hexagon, heptagon, oval, crescent, semicircle, cross, trefoil, quatrefoil, teardrop, five-pointed star, six-pointed star, eight-pointed star, crown, snowflake, shield, cloud, arrow, and combinations of the foregoing. (Item 99) 99. The liquid-containing nonwoven fabric article of any one of items 83 to 98, having a thickness of about 2 to about 50 mm, about 3 to about 45 mm, about 4 to about 40 mm, about 5 to about 35 mm, about 5 to about 30 mm, or about 5 to about 25 mm. (Item 100) The maximum length in any dimension is approximately 7 inches (17.78 cm), approximately 6 inches (15. 99. The liquid-containing nonwoven article of any one of items 83 to 99, wherein the length of the nonwoven article is about 5 inches (12.70 cm), about 24 inches (12.70 cm), or about 4 inches (10.16 cm). (Item 101) 101. The liquid-containing nonwoven article of any one of items 83 to 100, wherein the maximum length in any dimension is at least about 0.5 inches (1.27 cm), at least about 1 inch (2.54 cm), or at least about 1.5 inches (3.81 cm). (Item 102) 102. The liquid-containing nonwoven article of any one of items 83 to 101, wherein the first polyvinyl alcohol fiber-forming material and the second polyvinyl alcohol fiber-forming material are independently selected from polyvinyl alcohol homopolymers, polyvinyl alcohol copolymers, and combinations of the foregoing. (Item 103) 103. The liquid-containing nonwoven article of item 102, wherein the polyvinyl alcohol copolymer comprises anionically modified polyvinyl alcohol. (Item 104) 104. The liquid-containing nonwoven article of item 103, wherein the anionically modified polyvinyl alcohol comprises an (alkyl)acrylate-modified polyvinyl alcohol, a maleate-modified polyvinyl alcohol, a sulfonate-modified polyvinyl alcohol, or a combination thereof. (Item 105) 105. The liquid-containing nonwoven article of any one of items 83 to 104, wherein the first plurality of fibers or the second plurality of fibers further comprise one or more fiber-forming materials selected from the group of polyacrylate, polyvinylpyrrolidone, polyethyleneimine, guar gum, acacia gum, xanthan gum, carrageenan, water soluble starch, water soluble cellulose, cellulose ether, cellulose ester, and cellulose amide. (Item 106) 106. The liquid-containing nonwoven article of any one of items 83 to 105, wherein the first polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol homopolymer. (Item 107) 107. The liquid-containing nonwoven article of any one of items 83 to 106, wherein the second polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol homopolymer. (Item 108) 108. The liquid-containing nonwoven article of any one of items 83 to 107, wherein the first polyvinyl alcohol fiber forming material and the second polyvinyl alcohol fiber forming material are the same. (Item 109) 108. The liquid-containing nonwoven article of any one of items 83 to 107, wherein the first polyvinyl alcohol fiber forming material and the second polyvinyl alcohol fiber forming material have a difference in viscosity, degree of hydrolysis, degree of copolymerization, or a combination thereof. (Item 110) 109. The liquid-containing nonwoven article of any one of items 83 to 109, wherein the active agent comprises one or more selected from the group of enzymes, oils, fragrances, colorants, odor absorbers, fragrances, insecticides, fertilizers, oxidizers, activators, acid catalysts, metal catalysts, ion scavengers, detergents, disinfectants, surfactants, bleaches, bleaching components, and fabric softeners. (Item 111) 111. A method for preparing a liquid-containing nonwoven article according to any one of items 83 to 110, comprising: contacting the core nonwoven web with the liquid containing an active agent; covering the core nonwoven web with the outer nonwoven web; and sealing the outer nonwoven web to enclose the core nonwoven web. A method comprising: (Item 112) Item 112. The method of item 111, further comprising folding the core nonwoven web over itself 2 to 50 times, 3 to 45 times, 4 to 40 times, 5 to 35 times, or 6 to 30 times. (Item 113) 113. The method of claim 111 or 112, wherein the contacting step comprises gravure coating, dip coating, slot die coating, wire coating, flood coating, spray coating, immersion in a bath of the liquid containing the activator, or a combination thereof. (Item 114) Item 114. The method of item 112 or 113, wherein the folding step is performed after the contacting step, and the contacting step comprises gravure coating, dip coating, slot die coating, wire coating, flood coating, spray coating, or a combination thereof. (Item 115) Item 114. The method of item 112 or 113, wherein the folding step is performed before the contacting step, and the contacting step comprises immersion in a bath of the liquid containing the active agent. (Item 116) 116. The method of any one of items 111 to 115, further comprising preparing the outer nonwoven web by plying, stacking, folding or laminating multiple layers of nonwoven webs. (Item 117) 117. The method of any one of items 111 to 116, wherein the step of covering the core nonwoven web with the outer nonwoven web comprises wrapping the core nonwoven web with the outer nonwoven web, inserting the core nonwoven web into an envelope comprising the outer nonwoven web, or inserting the core nonwoven web into a sleeve comprising the outer nonwoven web. (Item 118) 118. The method of any one of items 111 to 117, wherein the outer nonwoven web comprises a machine direction and a cross direction, and the sealing step comprises sealing the outer nonwoven web along two or more points in the machine direction. (Item 119) Item 119. The method of item 118, wherein the sealing step further comprises sealing at least one lateral end. (Item 120) 120. The method of any one of items 111 to 119, wherein the sealing step comprises heat sealing or solvent welding. (Item 121) Item 121. The method of item 120, wherein the solvent welding comprises a polar solvent solution. (Item 122) 122. The method of any one of items 111 to 121, wherein the nonwoven article is prepared as an in-line process. (Item 122) 123. The method of any one of items 118 to 122, further comprising cutting the nonwoven article in the cross direction along the seal in the machine direction to provide unit quantities including a flange. (Item 123) Item 123. The method of item 122, wherein the flange is at least 1 mm and not more than 10 mm.

Claims

1. 1. A liquid-containing nonwoven article, comprising: a core nonwoven web comprising a first plurality of fibers comprising a first polyvinyl alcohol fiber-forming material, said core nonwoven web containing a liquid comprising a non-aqueous liquid that does not dissolve said core nonwoven web, said liquid comprising an active agent; and an outer nonwoven web comprising a second plurality of fibers comprising a second polyvinyl alcohol fiber-forming material; Including, A liquid-containing nonwoven article, wherein the core nonwoven web is encapsulated in the outer nonwoven web, and the active agent comprises one or more selected from the group consisting of enzymes, oils, perfumes, colorants, odor absorbers, fragrances, insecticides, fertilizers, oxidizing agents, acid catalysts, metal catalysts, ion scavengers, detergents, disinfectants, surfactants, bleaching agents, bleaching components, and fabric softeners.

2. The liquid-containing nonwoven article of claim 1 , wherein the outer nonwoven web wraps around the core nonwoven web.

3. 10. The liquid-containing nonwoven article of claim 1, wherein the outer nonwoven web has the form of a sleeve or envelope, and the core nonwoven web is disposed within the sleeve or envelope.

4. The liquid-containing nonwoven article of any one of claims 1 to 3, wherein the core nonwoven web and the outer nonwoven webs have at least one dimension that is the same length.

5. 5. The liquid-containing nonwoven article of any one of claims 1 to 4, wherein the weight of the core nonwoven web containing the liquid is 2 to 10 times the weight of the core nonwoven web before the addition of the liquid containing the active agent.

6. The liquid-containing nonwoven article of any one of claims 1 to 5, wherein the core nonwoven web containing the liquid has a liquid weight of from 30 gsm to 2000 gsm.

7. The liquid-containing nonwoven article of any one of claims 1 to 6, wherein the core nonwoven web has a dry basis weight in the range of 15 gsm to 200 gsm.

8. The liquid-containing nonwoven article of any one of claims 1 to 7, wherein the outer nonwoven web has a basis weight of from 15 gsm to 400 gsm.

9. The liquid-containing nonwoven article of any one of claims 1 to 8, wherein the outer nonwoven web has a thickness of from 0.5 mm to 6.0 mm.

10. 10. The liquid-containing nonwoven article of any one of claims 1 to 9, wherein the core nonwoven web is a single ply or is comprised of multiple layers of nonwoven webs.

11. 11. The liquid-containing nonwoven article of any one of claims 1 to 10, wherein at least a portion of the core nonwoven web is in contact with at least a portion of the outer nonwoven web.

12. 12. The liquid-containing nonwoven article of any one of claims 1 to 11, wherein the liquid-containing nonwoven article has edges, and the core nonwoven web and the outer nonwoven web are sealed at at least two edges or at least three edges.

13. 13. The liquid-containing nonwoven article of any one of claims 1 to 12, further comprising indicia or a pattern on the outer nonwoven web.

14. A liquid-containing nonwoven article as described in claim 13, wherein the markings or patterns on the outer nonwoven web are from inkjet printing or embossing.

15. 15. The liquid-containing nonwoven article of any one of claims 1 to 14, wherein the liquid-containing nonwoven article has a shape selected from the group consisting of a quadrilateral, a triangle, a circle, a star, a heart, an octagon, a pentagon, a hexagon, a heptagon, an oval, a crescent, a semicircle, a cross, a trefoil, a quatrefoil, a teardrop, a five-pointed star, a six-pointed star, an eight-pointed star, a crown, a snowflake, a shield, a cloud, an arrow, and combinations of the foregoing.

16. The liquid-containing nonwoven article of any one of claims 1 to 15, wherein the liquid-containing nonwoven article has a thickness of 2 to 50 mm.

17. 17. The liquid-containing nonwoven article of any one of claims 1 to 16, wherein the maximum length in any dimension is 7 inches (17.78 cm), 6 inches (15.24 cm), 5 inches (12.70 cm), or 4 inches (10.16 cm).

18. 18. The liquid-containing nonwoven article of any one of claims 1 to 17, wherein the maximum length in any dimension is at least 0.5 inches (1.27 cm), at least 1 inch (2.54 cm), or at least 1.5 inches (3.81 cm).

19. 19. The liquid-containing nonwoven article of any one of the preceding claims, wherein the first polyvinyl alcohol fiber-forming material and the second polyvinyl alcohol fiber-forming material are independently selected from polyvinyl alcohol homopolymers, polyvinyl alcohol copolymers, and combinations of the foregoing.

20. 20. The liquid-containing nonwoven article of claim 19, wherein the polyvinyl alcohol copolymer comprises anionically modified polyvinyl alcohol.

21. 21. The liquid-containing nonwoven article of claim 20, wherein the anionically modified polyvinyl alcohol comprises an (alkyl)acrylate-modified polyvinyl alcohol, a maleate-modified polyvinyl alcohol, a sulfonate-modified polyvinyl alcohol, or a combination thereof.

22. 22. The liquid-containing nonwoven article of any one of the preceding claims, wherein the first plurality of fibers or the second plurality of fibers further comprise one or more fiber-forming materials selected from the group of polyacrylate, polyvinylpyrrolidone, polyethyleneimine, guar gum, acacia gum, xanthan gum, carrageenan, water-soluble starch, water-soluble cellulose, cellulose ether, cellulose ester, and cellulose amide.

23. 23. The liquid-containing nonwoven article of any one of the preceding claims, wherein the first polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol homopolymer.

24. 24. The liquid-containing nonwoven article of any one of the preceding claims, wherein the second polyvinyl alcohol fiber-forming material comprises a polyvinyl alcohol homopolymer.

25. 25. The liquid-containing nonwoven article of any one of the preceding claims, wherein the first polyvinyl alcohol fiber forming material and the second polyvinyl alcohol fiber forming material are the same.

26. 25. The liquid-containing nonwoven article of any one of the preceding claims, wherein the first polyvinyl alcohol fiber-forming material and the second polyvinyl alcohol fiber-forming material have a difference in viscosity, degree of hydrolysis, degree of copolymerization, or a combination thereof.

27. 27. A method for preparing the liquid-containing nonwoven article of any one of claims 1 to 26, comprising: contacting the core nonwoven web with the liquid containing the active agent; covering the core nonwoven web with the outer nonwoven web; and sealing the outer nonwoven web to enclose the core nonwoven web. A method comprising:

28. 28. The method of claim 27, further comprising folding the core nonwoven web over itself 2 to 50 times.

29. 29. The method of claim 27 or 28, wherein the contacting step comprises gravure coating, dip coating, slot die coating, wire coating, flood coating, spray coating, immersion in a bath of the liquid containing the activator, or a combination thereof.

30. 30. The method of claim 28 or 29, wherein the folding step occurs after the contacting step, and the contacting step comprises gravure coating, dip coating, slot die coating, wire coating, flood coating, spray coating, or a combination thereof.

31. 30. The method of claim 28 or 29, wherein the folding step occurs before the contacting step, and the contacting step comprises immersion in a bath of the liquid containing the active agent.

32. 32. The method of any one of claims 27 to 31, further comprising preparing the outer nonwoven web by plying, stacking, folding or laminating multiple layers of nonwoven webs.

33. 33. The method of any one of claims 27 to 32, wherein the step of covering the core nonwoven web with the outer nonwoven web comprises wrapping the core nonwoven web with the outer nonwoven web, inserting the core nonwoven web into an envelope comprising the outer nonwoven web, or inserting the core nonwoven web into a sleeve comprising the outer nonwoven web.

34. 34. The method of any one of claims 27 to 33, wherein the outer nonwoven web comprises a machine direction and a cross direction, and the sealing step comprises sealing the outer nonwoven web along two or more points in the machine direction.

35. 35. The method of claim 34, wherein the sealing step further comprises sealing at least one of the lateral edges.

36. 36. The method of any one of claims 27 to 35, wherein the sealing step comprises heat sealing or solvent welding.

37. 37. The method of claim 36, wherein the solvent welding comprises a polar solvent solution.

38. 38. The method of any one of claims 27 to 37, wherein the liquid-containing nonwoven article is prepared as an in-line process.

39. 35. The method of claim 34, further comprising cutting the liquid-containing nonwoven article in the cross direction along the seal in the machine direction to provide unit quantities including a flange.

40. 40. The method of claim 39, wherein the flange is at least 1 mm and no more than 10 mm.

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