Patent Description:
A significant number of requirements are applied to nonwoven consumer wipes. They must have sufficient strength and abrasion resistance for the purported use, they must have sufficient absorption capacity, and they must have sufficient biodegradability so as not to cause a long lasting environmental load. Legislation will become stricter and consumer awareness will rise. For consumer wipes for personal hygiene, an additional requirement of rising importance is water dispersibility, since too durable wipes tend to cause clogging problems in sewage systems.

Imprinting patterns on nonwoven material is desirable for a number of reasons. Apart from the obvious decorative aspect, patterns may convey information in a variety of ways; see international patent application No. <CIT>.

Wet laying is a web forming process which is a fast, economical, and environmentally friendly method. All the water used for wet laying is filtered and reused. The wet laying process provides better product performance as compared to the air lay process, because it can process short fiber such as wood pulp, and other natural, manmade and synthetic fiber. Wet laying of natural fibers provides better uniformity of the web and low linting due to strong hydrogen bonding between the fibers. The initial steps of wet laying a nonwoven web is analogous to papermaking. Wet laid webs require binding to provide strength. If the furnish includes thermoplastic material, heat may be used to partly melt that material, thereby consolidating the web. The presence of thermoplastics, however, is not desirable from a biodegradability point of view. If a binder is used, biodegrability is required of the binder as well, and this brings additional technical limitations. Therefore, it is desirable to provide nonwoven fabrics based on cellulosic materials such as manmade fibers exemplified by viscose, lyocell and natural fibers such as pulp. Avoiding binders is an additional advantage from an economical and ecological point of view.

Hydroentangling is a widely used method for consolidating webs in the production of nonwoven. The fibers are entangled by means of high pressure water jets. If the web is carried on a support having a patterned structure, the hydroentanglement process may leave a permanent pattern in the web, whereby the process may be referred to as hydroembossing.

In international patent application publication No. <CIT>, a process is disclosed for forming a nonwoven web from an aqueous fiber suspension, hydraulically entangling the web and subjecting it to further hydroentanglement from both sides using a drum. The fiber suspension comprises synthetic staple fibers and cellulosic fibers. The web is carried through the hydroentangling process supported on one or several foraminous belts.

In <CIT> is disclosed a method for producing a nonwoven material by hydroentangling a fiber mixture, wherein a web is wetlaid and hydroentangled. The web contains spunlaid filaments, natural fibers and synthetic staple fibers. After the initial hydroentanglement, spunlaid filaments are laid on top of the first web; a second fibrous web is wetlaid on top of the filaments; and the resulting web is hydroentangled from both sides in turn.

In international patent application publication No. <CIT> is disclosed an apparatus for consolidating and imposing a structure on a nonwoven web. The web is conveyed between two parallel bands, at least one of which is a structure-imposing band, and the web is subjected to hydroentanglement within a structure-imposing zone. The web can be subjected to further hydroentanglement operations before or after the structure-imposing zone, using rolls which can also impose a structure on one side of the web. Document <CIT> discloses a water-decomposable fibrous sheet includes fibers containing fibrillated rayon. The fibrillated rayon has primary fibers of a predetermined fiber length and microfibers extending from the primary fibers. The fibrillated rayon includes a first type of fibrillated rayon having a degree of beating of at most <NUM> cc, of which the length of the primary fibers falls between <NUM> and <NUM> at the peak of its self-weighted, average fiber length distribution profile curve, and a second type of fibrillated rayon having a degree of beating of at most <NUM> cc, of which the length of the primary fibers falls between <NUM> and <NUM> at the peak of its self-weighted, average fiber length distribution profile curve. The microfibers extending from the first and second, types of fibrillated rayon are entangled with and/or hydrogen-bonded to at least either of other microfibers and other fibers. Document <CIT> presents a water-decomposable non-woven including a first regenerated cellulose fiber having a fiber length of <NUM> or more to <NUM> or less, a second regenerated cellulose fiber having a fiber length of <NUM> or more to <NUM> or less, and a natural fiber having a fiber length of <NUM> or less, in which at least the second cellulose fiber is entangled with at least one of the first regenerated cellulose fiber, the second regenerated cellulose fiber and the natural fiber. This water-decomposable non-woven is bulky with soft touch, and is also excellent in both water decomposability and wet strength. Document <CIT> discloses a porous web structure including a first broad outer macroscopic surface and a second broad outer macroscopic surface opposite the first broad outer macroscopic surface thereby defining an absorbent fibrous region extending lengthwise in a longitudinal direction between the first and second broad outer macroscopic surfaces. The absorbent fibrous region has a thickness extending in a transverse direction that is perpendicular to the longitudinal direction. A formed fibrous feature defines a cavity extending at the first broad outer macroscopic surface. The formed fibrous feature has a wave formed of the fibrous region extending into a mouth of the cavity and a pocket defined by the cavity extending beyond the wave such that the wave overhangs the pocket. Document <CIT> presents nonwoven fibrous structures with a high interfacial pore size and substrates made therefrom. The substrates may be used, for example, in wipes. In one embodiment, the wipes include a hydromolded pattern on one side. The hydromolded pattern has an average pore-size of the interface between two stacked wipes that is greater than <NUM> microns in radius. In addition, a method for manufacturing nonwoven fibrous structures with high interfacial pore size is also provided. Document <CIT> discloses a reflectively patterned, fibrous, sided nonwoven material comprising a first set of fibers hydraulically needled with a web of a second set of fibers, the first set of fibers primarily containing short fibers and the second set of fibers primarily containing one of (a) substantially continuous filaments, (b) long fibers, and (c) short fibers having an average fiber length at least twice the average fiber length of the first set of fibers. The material has a first surface predominately comprising the first set of fibers and an opposing second surface predominately comprising the second set of fibers. A method of patterning a sided nonwoven web and a reflectively patterned, sided nonwoven material also are disclosed.

Thus, patterning in the prior art is conventionally carried out using thermal calendering or belt patterning. Changing a belt is time consuming. After changing a belt, tension adjustment in order to prevent belt breakage adds to the task. The path of a belt is not consistent; it may run straight or bend, and a pattern needs to survive variability in belt curvature. Current patterning techniques using a belt involves a risk of clogging of dewatering holes, since additional material is added on top of the belt. As patterning is usually done without prior entanglement of the web, there is also a risk of creating holes in the nonwoven, since patterning moves the fibers. This is particularly serious when producing low basis weight products. A belt patterning unit is long, so if there would be two different hydroentangling units, the size of the machine would grow significantly.

Thermal calendering is associated with other drawbacks. The presence of synthetic fibers makes it possible to create sharp patterns by melting those fibers. However, biodegradable fibers will not melt at the usual temperatures. Pressure is the main factor in creating the pattern, and heat can only enhance the effect. The resolution in the pattern is necessarily affected. Patterns created in biodegradable material usually suffer significantly when moistened.

When thermal calendering is used, pattern retention is very weak or nonexistent in fabrics comprising no thermoplastic fiber as the product is wetted. Hydroentanglement and hydroembossing of a wet laid web according to the prior art does not produce a nonwoven material having a pattern of sufficently high definition for the purposes mentioned above. Moreover, prior art wet laid patterned nonwovens tend to lose the patterning when wetted with various liquids and lotions used for sealedly packed wet wipe products.

The term "nonwoven web or fabric" as used herein refers to a web having a structure of fibers or filaments which are interlaid without exhibiting a regular pattern as in a woven fabric.

Short cut fiber (regenerated/synthetic) as referred to herein is in the range of <NUM> to <NUM>. It can be used in wetlaid and airlaid production.

Regenerated fiber is a fiber created by converting cellulose to a soluble cellulosic derivative and subsequently regenerating it to fiber. Examples are lyocell, tencel, rayon and viscose.

Natural fiber is a cellulose fiber of natural origin. Examples are wood pulp and fiber from hemp, flax, cotton, jute, bamboo, sisal and kapok.

The term "machine direction" as used herein refers to the direction of travel of the forming support receiving fibers during formation of the web.

The term "cross machine direction" as used herein refers to the direction perpendicular to the machine direction as above.

A slosh box is a device designed especially for disintegration tests according to FG502 of the INDA/EDANA guidelines.

According to the method of the present invention, a fiber suspension is prepared and subjected to wet laying on a wire.

The resulting fiber suspension to be subjected to wet laying according to the present invention has a composition comprising about <NUM> % - <NUM>% by weight of regenerated short cut fibers and about <NUM>% - <NUM>% by weight of natural fibers. The short cut fibers comprise <NUM>% - <NUM>% of fibers of a length in the range <NUM> - <NUM> and <NUM>% - <NUM> % of fibers of a length in the range <NUM> -<NUM>.

Preferably, the natural fibers have a length in the range <NUM> to <NUM>. Preferably, the natural fibers have a diameter in the range <NUM> to <NUM> dtex.

Using this suspension, a first web is wet laid on a wire.

The wetlaid layer is subsequently consolidated using hydroentanglement. The initial wet laying can be carried out on the same wire as the hydroentanglement, or separate wires may be employed. The tensile strength of the web following the consolidation should be at least <NUM>/<NUM>. This strength is sufficient to allow the removal of the web from the wire.

The web is thus self-supporting and is transferred to a hydroembossing station comprising a roll having a surface pattern which is imposed on the web, forming a high definition three-dimensional pattern. The hydroembossing can occur from either side of the web relative to the initial hydroentanglement.

Preferably, the pattern is on a sleeve which is detachable from the roll. The pattern resolution and the hydroembossing parameters in combination with the degree of consolidation in the web at the time it reaches the roll provide a pattern which is of sufficiently high definition and persistence to satisfy the requirements of information coding and permanency in the wet state, for example when a product is lotionised in conversion to packaging.

The consolidation of the web following wet laying, carried out through hydroentangling, shall provide a tensile strength which preserves the web in a consistent shape as it is lifted from the forming wire. Too little consolidation may cause, apart from the obvious risk of web breakage, holes in the web. Excessive consolidation does not leave sufficient formability in the web for the subsequent hydroembossing step carried out on a roll.

A high definition pattern as used herein refers to a pattern exhibiting a contrast between differing areas which is sufficient for machine reading, e.g. using methods disclosed in International Patent Application No. <CIT>.

Advantageously, the fiber suspension has a solids content in the range <NUM>,<NUM>% to <NUM>%.

The short cut fibers in the suspension have a diameter in the range <NUM> dtex to <NUM> dtex, preferably in the range <NUM> - <NUM> dtex.

Preferably, the appropriate degree of consolidation is a consequence of using the composition set out above and the following parameters:.

Following hydroentanglement and dewatering on a wire, the tensile strength of the web is in the range <NUM> to <NUM> % of its final tensile strength.

Following the hydroentanglement and dewatering step, the web is transferred to a hydroembossing roll having a surface pattern which is imposed on the web, forming a high definition three-dimensional pattern. Preferably, the pattern is on a sleeve supported by the roll. Inside the roll there will be a partial vacuum for removing excess water from the hydroembossing through provided openings. Preferably, <NUM> to <NUM> nozzle bars are used for hydroembossing the web.

In a high definition pattern, fibers have been moved from their initial location in the plane of the web, creating a three-dimensional structure which is more distinct than the two-dimensional patterns that can be created using belt hydroembossing or thermal calendaring.

In the following discussion, the top surface of the fabric is the surface that faces the sleeve during the hydroembossing operation; the bottom surface is the one exposed to the water jets.

For considering the three-dimensional structure of the web of the present invention, the base level is defined as the level of the bottoms of the deepest depressions in the fabric, i.e. the level of the thinnest areas in the fabric. The distance of the base level from the bottom surface of the fabric according to the invention is at least <NUM>; thus, the thickness of the fabric at its thinnest points is at least <NUM>.

The embossing level is the level on the top surface which is farthest from the base level. In this context, a pattern in a nonwoven web is considered a three-dimensional high definition pattern if the patterned area is at least <NUM> above the base level. In the present context, this dimension is denoted the height of the pattern. More preferably, the patterned area is at least <NUM>; most preferably at least <NUM> above the base level of the fabric. The angle of inclination in a high definition three-dimensional pattern as used herein is the angle of the slope of the elevated portions of the fabric relative to the plane of the base level. In a three-dimensional high definition pattern, the angle of inclination of the rise from the base level to the embossing level is in the range <NUM>° to <NUM>°; preferably in the range <NUM>° - <NUM>°. Such a pattern is machine readable.

Angles and dimensions in nonwoven fabric structures may be determined using laser triangulation technology. Further, angles and dimensions of the embossing tool may be determined.

As fibres are moved from their original location during hydroembossing using a sleeve, the grammage of the patterned portions of the fabric, i.e. the portions of the fabric receiving the displaced fiber increases at least <NUM> %; preferably <NUM>-<NUM> %, more preferably <NUM>-<NUM> %. Thus, the patterned areas contain at least <NUM> % more fiber than the non-patterned areas.

Inside the roll there will be a partial vacuum for removing excess water from the hydroembossing. There will be from <NUM> to <NUM> hydroentanglement units hydroembossing the web.

The web is subsequently subjected to drying using e.g. an air dryer, a can dryer, an omega dryer or combinations of these.

Preferably, the basis weight of the finished nonwoven fabric according to the invention is in the range <NUM> to <NUM> gsm.

In at least one embodiment, the suspension may be laid on the wire on top of a second, previously unwound web which is of the spunlace, wetlaid or tissue type. In at least one embodiment, a third layer of unwound material of the types mentioned above may be applied on top of the first, wetlaid layer.

In at least one embodiment, the suspension may be laid on the wire in several steps. Further, layers can be added using air laying or carding technology.

The nonwoven fabric according to the invention wetted with liquid <NUM> times the weight of dry nonwoven fabric and aged for more than one week had a slosh box dispersibility of more than <NUM>% in <NUM> and <NUM>% in <NUM>, similar to dry toilet tissue. Overall, the dispersibility ranges for a fabric according to the invention are from <NUM>% to <NUM>% for a <NUM> slosh box test. All slosh box tests were carried out according to EDANA & INDA FG502 (GD4) Guidelines.

In the following example, the short cut fibers are viscose. A first group of short cut fiber has a length of <NUM>, and a second group of short cut fiber has a length of <NUM>. The dtex of the short cut fiber is either <NUM> or <NUM>. Further, the compositions comprise softwood pulp. The results set out in Table <NUM> clearly show, that when only shorter regenerated short cut fibers are used (Sample A), the tensile strength values are clearly inferior to those of samples B, C and D. When only longer regenerated shortcut fibers are used (sample E), decreased dispersibility is obtained. The weak strength and <NUM>% slosh box (<NUM>) values are due to the <NUM>% lower basis weight. When combining <NUM> and <NUM> short cut fibers, good strength values are obtained with dispersibility on par with dry toilet paper.

Table <NUM> shows test results of various nonwoven fabric made with different compositions compared to dry toilet tissue. Samples B, C and D are in accordance with the invention.

International Water Services Flushability Group (IWSFG) (PAS) <NUM>: Disintegration Test Method-Slosh Box, is a modified version of the INDA/EDANA slosh box test.

Claim 1:
A nonwoven fabric having a three-dimensional pattern obtained by a hydroembossing roll and comprising a wetlaid web comprising about <NUM>% - <NUM>% by weight of regenerated short cut fibers having a dtex in the range <NUM> to <NUM> dtex, and about <NUM>% -<NUM>% by weight of natural fibers, whereby the fibers have been hydroentangled using water jets with psi (<NUM> MPa) to <NUM> psi (<NUM> MPa), wherein <NUM>% - <NUM>% of the short cut fibers are in the range <NUM> -<NUM> and <NUM>%-<NUM>% are in the range <NUM> -<NUM> and wherein the natural fiber is selected from the group consisting of wood pulp, hemp, flax, cotton, jute, bamboo, sisal, jute, and kapok; which nonwoven fabric, when wetted with liquid <NUM> times the weight of dry nonwoven fabric and aged for more than one week, has a slosh box dispersibility according to EDANA & INDA FG502 (GD4) Guidelines of more than <NUM>% in <NUM> and <NUM>% in <NUM>, or which nonwoven fabric, when wetted with liquid <NUM> times the weight of dry nonwoven fabric and aged for more than one week has a slosh box dispersibility according to IWSFG Test Methods of more than <NUM>% in <NUM>.