U.S. patent application number 11/147936 was filed with the patent office on 2005-10-13 for hydroentangled textile and use in a personal cleansing implement.
This patent application is currently assigned to Unilever Home & Personal Care USA, Division of Conopco, Inc.. Invention is credited to Bergquist, Paul Roland, Grissett, Gregory Aaron, Lagatol, Shauna Mary, Macedo, Filomena Augusta, Urbaez, Jesus Antonio, Williams, David Robert.
Application Number | 20050227566 11/147936 |
Document ID | / |
Family ID | 32682416 |
Filed Date | 2005-10-13 |
United States Patent
Application |
20050227566 |
Kind Code |
A1 |
Bergquist, Paul Roland ; et
al. |
October 13, 2005 |
Hydroentangled textile and use in a personal cleansing
implement
Abstract
A non-woven hydroentangled textile is described formed in
cross-section with a central area of low mass fiber density
surrounded on both sides by areas of higher mass density. Further,
a personal cleansing article is described wherein the
hydroentangled textile is associated with a personal cleansing
composition that includes a lathering surfactant. The composition
is deposited onto, impregnated into or at least is partially
enclosed by the textile. Also described is a process for producing
the textile involving feeding into a hydroentangling unit a loose
random assembly of fibers both above and below a fibrous screen
modifying textile substrate.
Inventors: |
Bergquist, Paul Roland;
(Southport, CT) ; Lagatol, Shauna Mary; (Westwood,
NJ) ; Urbaez, Jesus Antonio; (Waterbury, CT) ;
Williams, David Robert; (Monroe, CT) ; Grissett,
Gregory Aaron; (Milford, CT) ; Macedo, Filomena
Augusta; (Naugatucik, CT) |
Correspondence
Address: |
UNILEVER INTELLECTUAL PROPERTY GROUP
700 SYLVAN AVENUE,
BLDG C2 SOUTH
ENGLEWOOD CLIFFS
NJ
07632-3100
US
|
Assignee: |
Unilever Home & Personal Care
USA, Division of Conopco, Inc.
|
Family ID: |
32682416 |
Appl. No.: |
11/147936 |
Filed: |
June 8, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11147936 |
Jun 8, 2005 |
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10645885 |
Aug 21, 2003 |
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60436904 |
Dec 27, 2002 |
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Current U.S.
Class: |
442/408 |
Current CPC
Class: |
B32B 27/36 20130101;
B32B 5/022 20130101; Y10T 442/197 20150401; Y10T 442/659 20150401;
B32B 5/26 20130101; B32B 27/34 20130101; B32B 2250/24 20130101;
B32B 2262/0253 20130101; A61K 8/0208 20130101; A61Q 19/10 20130101;
B32B 2262/0261 20130101; Y10T 442/2508 20150401; Y10T 428/24992
20150115; D04H 1/498 20130101; A47K 7/03 20130101; D04H 5/03
20130101; B32B 2323/04 20130101; B32B 2555/00 20130101; B32B
2305/18 20130101; B32B 2323/10 20130101; B32B 27/12 20130101; Y10T
442/2525 20150401; B32B 27/18 20130101; B32B 2262/0284 20130101;
B32B 27/08 20130101; B32B 27/32 20130101; Y10T 442/666 20150401;
B32B 7/02 20130101; D04H 1/492 20130101; Y10T 442/2279 20150401;
B32B 2377/00 20130101; Y10T 442/689 20150401; B32B 2367/00
20130101 |
Class at
Publication: |
442/408 |
International
Class: |
D04H 001/46; D04H
003/10; D04H 005/02 |
Claims
1. A non-woven hydroentangled textile formed in cross-section with
a central area of low mass fiber density surrounded on both sides
by areas of higher mass fiber density.
2. The textile according to claim 1 which cannot be separated into
multiple layers after formation without destruction of the
textile.
3. The textile according to claim 1 wherein the areas of higher
mass fiber density on both sides relative to the central area of
low mass fiber density have a basis weight ratio ranging from about
10:1 to about 1:2.
4. The textile according to claim 3 wherein the ratio ranges from
about 6:1 to 1:1.
5. The textile according to claim 1 wherein the Air Permeability
ranges from about 300 to about 1,000.
6. A process for the manufacture of a non-woven hydroentangled
textile comprising: (i) feeding a fibrous screen modifying textile
substrate into a hydroentangling unit; (ii) feeding a loose random
assembly of fibers into the hydroentangling unit, a portion of the
assembly of fibers being deposited over and another portion of the
assembly of fibers being deposited under the screen modifying
textile substrate thereby forming a layered fibrous assembly; (iii)
applying a high velocity water jet to the layered fibrous assembly
within the hydroentangling unit; and (iv) transporting a resultant
hydroentangled layered fibrous assembly to a drying area.
7. A personal cleansing article comprising: a) a non-woven
hydroentangled textile formed in cross-section with a central area
of low basis weight surrounded on both sides by areas of higher
basis weight; and (b) a personal cleansing composition comprising a
lathering surfactant deposited onto, impregnated into or at least
being partially enclosed by the textile.
8. The article according to claim 7 wherein the lathering
surfactant is present in amount from about 0.1 to about 30% by
weight of the composition.
9. The article according to claim 7 wherein the personal cleansing
composition further comprises from about 0.1 to about 35% by weight
of a water-soluble or water-insoluble skin conditioning agent.
10. The article according to claim 7 wherein the personal cleansing
composition further comprises effervescent ingredients capable of
generating a foam upon contact with water.
11. The article according to claim 7 wherein the effervescent
ingredients comprise an acid and a bicarbonate salt.
12. The article according to claim 7 wherein the areas of higher
basis weight on both sides relative to the central area of low
basis weight have a basis weight ratio ranging from about 10:1 to
about 2:1.
13. The article according to claim 12 wherein the ratio ranges from
about 6:1 to 2:1.
14. The article according to claim 7 wherein the textile cannot be
separated into multiple layers after formation without destruction
of the textile.
15. The article according to claim 7 wherein the textile has an Air
Permeability ranging from about 300 to about 1,000.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention concerns a new non-woven textile and use of
this textile in a personal cleansing implement.
[0003] 2. The Related Art
[0004] Hydroentanglement is a process utilized to form non-woven
fabrics. The conventional process involves delivery of a loose,
random assembly of relatively open fibers to a hydroentanglement
unit via a series of fiber card machines. The loose, random
assembly of fibers is conveyed through a series of high-velocity
water jets aimed at curling and entangling the loose assembly of
fibers about each other. Entanglement therefore provides strength
and dimensional stability.
[0005] The primary method of structure development to achieve a
surface texture occurs on a forming belt or screen onto which the
loose fibers are deposited. These forming belts or screens are
constructed of woven metal or plastic wires usually in plain weave
configuration. For screens with large diameter wires, an open
screen structure is created. Water jet forces onto the open screen
structures at the wire intersections or knuckles move fiber away
creating an opening or aperture in the subsequent non-woven
structure. Open areas within the screen permit fiber entangling to
occur. Hydroentanglement can either consolidate a fibrous web to
impart strength, modify surface texture or act as both a web
consolidation and surface texturing mechanism.
[0006] Certain types of personal care products require use of a
non-woven substrate. These are applied to the skin delivering a
lathering surfactant. In this context, there has been a need for a
non-woven substrate with areas of low-mass fiber density surrounded
by areas of greater-mass fiber density. In particular, a non-woven
structure was sought based on a bonded fibrous assembly with
improved coverage and loft.
SUMMARY OF THE INVENTION
[0007] A non-woven hydroentangled textile is provided formed in
cross-section with a central area of low mass fiber density
surrounded above and below (i.e. sandwiched) by areas of higher
mass fiber density.
[0008] Furthermore, there is provided a personal care cleansing
product formed from:
[0009] (i) a non-woven hydroentangled textile formed in
cross-section with a central area of low mass fiber density
surrounded above and below by areas of higher mass fiber density;
and
[0010] (ii) a personal cleansing composition comprising lathering
surfactant deposited onto, impregnated into or at least being
partially enclosed by the textile.
[0011] Still further, there is provided a process for the
manufacture of a non-woven hydroentangled textile which
includes:
[0012] (i) feeding a fibrous screen modifying textile substrate
into a hydroentangling unit;
[0013] (ii) feeding a loose random assembly of fibers into the
hydroentangling unit, a portion of the assembly of fibers being
deposited over and another portion of the assembly of fibers being
deposited under the screen modifying textile substrate thereby
forming a layered fibrous assembly;
[0014] (iii) applying a high velocity water jet to the layered
fibrous assembly within the hydroentangling unit; and
[0015] (iv) transporting a resultant hydroentangled layered fibrous
assembly to a drying area.
BRIEF DESCRIPTION OF THE DRAWING
[0016] Further features and advantages of the present invention
will become more apparent from consideration of the drawing in
which FIG. 1 is the sole FIGURE illustrating the process according
to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Now there has been developed a non-woven hydroentangled
water-insoluble fabric which is a bonded fibrous assembly with
improved coverage and loft. This textile has in cross-section an
area of low mass fiber density (apertured) surrounded by areas of
greater mass fiber density on either side. This modified
hydroentangled arrangement is achieved by incorporating a screen
modifying substrate in the normal hydroentangling process. In this
system an apertured screen is utilized to obtain a non-apertured
non-woven.
[0018] Conventional web formation techniques utilize a series of
card machines to present a random loose fibrous assembly to the
high velocity water jets. A screen modifying substrate labeled by
some as a "scrim" according to the present invention is
incorporated between two card machines. This results in a layered
fibrous assembly comprised of both staple and continuous filament
fibers. The presence of the fiber screen modifying substrate allows
a certain amount of staple fibers to be entangled with a screen
modifying substrate over the forming wire intersections (knuckles).
This reduces the aperture forming capabilities of the forming belt
or screen. Some embodiments may utilize four or more card machines
and may even have more than one scrim.
[0019] The fibrous screen modifying substrate can be one comprised
of randomly laid bonded continuous fibers. These fibers may be
formed of polyethylene terephthalate (PET), polypropylene (PP),
polyamide (PA), polyethylene (PE) and fiber combinations thereof.
The fiber denier may range from about 0.1 to about 15, preferably
from about 1 to about 7 denier. Substrate basis weight may range
from about 5 to about 50 g/m.sup.2, preferably from about 10 to
about 25 g/m.sup.2, optimally from about 12 to about 18
g/m.sup.2.
[0020] A larger mass density above the screen modifying substrate
improves product texture. The resultant non-woven structure is
thereby comprised of areas of low-mass fiber density surrounded by
areas of greater-mass fiber density. Larger mass density below the
screen modifying substrate allows greater control in terms of
aperture. The basis weight of loose, random assembly of fibers used
above the screen modifying substrate may range from about 5 to
about 100 g/m.sup.2, preferably from about 20 to about 60
g/m.sup.2, optimally from about 35 to about 45 g/m.sup.2.
Similarly, the basis weight of loose, random assembly of fibers
used below the screen modifying substrate may range from about 5 to
about 100 g/m.sup.2, preferably from about 20 to about 60
g/m.sup.2, optimally from about 35 to about 45 g/m.sup.2.
Advantageously the total amount of the basis weight of fiber
deposited above and below the central area (screen modifying
substrate) may range from about 20 to about 150 g/m.sup.2, more
preferably from about 30 to about 100 g/m.sup.2, and optimally from
about 40 to about 85 g/m.sup.2. In a preferred embodiment the basis
weight above and below the screen modifying substrate may range
respectively in a ratio from about 3:1 to about 1:3, preferably
about 2:1 to about 1:2, but optimally is substantially identical in
a ratio of about 1:1.
[0021] Advantageously the amount of total basis weight (above and
below the central area) to that of the screen modifying substrate
may range from about 10:1 to about 1:2, preferably from about 6:1
to about 1:1, optimally from about 4:1 to about 2:1.
[0022] The hydroentangled textiles of the present invention may
include a textured pattern, especially on an outer surface which
has been in direct contact with the forming belt (screen). Peak to
valley ratios may vary widely. Variation can be a function of the
amount of loose random fibers deposited onto the scrim. Other
factors include the degree of entanglement energy (water jet
pressure against loose random fiber assembly applied prior to the
hydroentangling unit) and the aperturing energy (water jet pressure
within the hydroentangling unit). Still further, topography can be
dependent upon the size of aperture openings within the forming
belt (screen).
[0023] Forming belts or screens utilized during hydroentangling can
be constructed of woven metal or plastic wires usually in plain
weave configuration. Forming belts with open screen structures are
incorporated during product manufacture. The degree of screen
structure openings can be varied to modify product texture and
form. Smaller screen structures (or openings) will decrease the
variable mass fiber density obtained in product structures.
[0024] Water jet pressures during the hydroentanglement may range
from about 50 to about 5000 psi, preferably from about 200 to about
3000 psi, optimally from about 1000 to about 2000 psi.
[0025] FIG. 1 illustrates the process for producing the non-woven
textile according to the present invention. Card machines 2, 4
serve as a storage and dispensing reservoir of loose, random fibers
(e.g. polypropylene). A delivery role 6 feeds a non-woven spunlaced
web 8 serving as the fibrous screen modifying substrate. This
substrate is fed into a hydroentangling unit 10. Simultaneously a
stream of loose random fibers 12, 14 are delivered from respective
card machines 2, 4 above and below substrate 8. Together the
combination entering the hydroentangling unit 10 is a layered
fibrous assembly 16.
[0026] Prior to entering the hydroentangling unit 10, optionally
there may be a pre-entangling step wherein water jet pressure is
applied to the layered fibrous assembly 16 in order to add strength
thereto. Within the hydroentangling unit, the layered fibrous
assembly 16 is subjected to a high velocity water spray from jets
18 as the layered fibrous assembly 16 is supported on a forming
belt (screen) 20. The forming belt 20 then transports the
hydroentangled layered fibrous assembly to a drying unit 22.
Therein water is removed and the resultant hydroentangled textile
is completed.
[0027] The non-woven textile of the present invention although
constructed of a fibrous screen modifying substrate 8 and
sandwiched between a random assembly of fibers 12, 14 is considered
to be a single layered substrate. The reason is that subsequent to
hydroentanglement, the textile cannot be separated into its
component parts (i.e. substrate 8 and fibers 12, 14) without
destruction of the textile. The basis weight for the textile of
this invention may range from about 15 to about 200 g/m.sup.2,
preferably from about 60 to about 150 g/m.sup.2, and optimally from
about 80 to about 110 g/m.sup.2.
[0028] For purposes of this invention, the fibrous screen modifying
substrate 8 may be either a spunlace or a carded/chemically bonded
spunbond non-woven water-insoluble material. Sources for the
substrate 8 can be spunbonded scrim available from Reemay
Corporation of Tennessee, Superior Nonwovens of South Carolina, and
PGI Corporation of South Carolina. The loft of textiles according
to the present invention may range from a density of from about
0.00005 to about 0.1 g/cm.sup.3, preferably from about 0.001 to
about 0.09 g/cm.sup.3 and a thickness from about 0.1 to about 5
cm.
[0029] As used herein, "non-woven" means that the layer does not
comprise fibers which are woven into a fabric but the layer need
not comprise fibers at all, e.g. formed films, sponges, foams or
scrims. When the layer comprises fiber, the fibers can either be
random (i.e. randomly aligned) or they can be carded (combed to be
oriented in primarily one direction).
[0030] Textiles of the present invention may be utilized as
implements in personal care cleansing products which may be
appropriate for single use purposes. In these products, the textile
may be impregnated or coated with a lathering surfactant and
optionally skin conditioners. Representative of this technology are
disclosures found in U.S. Pat. No. 6,280,757 (McAtee et al.), U.S.
Pat. No. 5,980,931 (Fowler et al.), WO 00/42961 (Smith) and WO
01/08542 (Cen et al.), all herein incorporated by reference.
Alternatively, the textile can be incorporated into a sachet with
at least one wall of the sachet formed from a textile of the
present invention and optionally other walls of the sachet formed
from a variety of other water-insoluble woven or non-woven fabrics.
A lathering surfactant and optionally conditioners may in dry
particulate form be enclosed within the sachet. These products are
exemplified and described in U.S. Pat. No. 6,063,390 (Farrell et
al.) herein incorporated by reference.
[0031] An advantage of textiles according to the present invention
in the context of personal cleansing sachets or pillows as
described in U.S. Pat. No. 6,063,390 is that powdered surfactant
and other powdered ingredients are prevented during dry storage
from escaping through apertures in the textile. These apertures are
sufficiently small to retain powder but sufficiently large to allow
water to penetrate the sachet to activate surfactant and other
ingredients (such as effervescent compounds) in the personal
cleansing wash process. Additionally, the textile of the present
invention on its outer surface exhibits a looser high loft
structure with advantages for enhancing lathering of the surfactant
and a softer feel when rubbed on the skin. A preferred embodiment
of a personal cleansing article using the textile of the present
invention is one which includes:
[0032] (i) an effervescent cleansing composition capable of
generating foam upon contact with water; and
[0033] (ii) a pouch formed of first and second water-insoluble
substrates, at least one being water permeable, the first and
second water-insoluble substrates forming therebetween an area
housing the cleansing composition, and at least one of the
substrates being a textile of construction according to the present
invention.
[0034] Effervescent cleansing compositions which may be deposited
into the pouch of the pillow includes a first component which is an
acidic material and a second component which is an alkaline
material. The acidic material is preferably citric acid and the
alkaline material is preferably a bicarbonate such as sodium
bicarbonate. Amounts of the acid and alkaline materials may each
range from about 1 to about 80%, preferably from about 15 to about
40% by weight of the total composition within the sachet.
[0035] A wide variety of lathering surfactants may be used with the
textile of this invention in any of its personal cleansing
embodiments. Useful lathering surfactants include sodium lauryl
sulfate, sodium lauryl ether sulfate, sodium lauroyl sarcosinate,
sodium cocoyl taurate, sodium cocoyl isethionate, sodium alkyl
amido propyl betaine, sodium C.sub.14-C.sub.16 olefin sulfonate,
sodium lauryl sulfoacetate and any combinations thereof. The
lathering surfactants may be of the anionic, cationic, nonionic,
amphoteric, zwitterionic varieties and any combinations thereof.
Amounts of the surfactant may range from about 0.1 to about 30%,
preferably from about 1 to about 25%, optimally from about 8 to
about 20% by weight of the total composition placed onto or in
combination with the textile in personal cleansing products.
[0036] Conditioners whether water soluble or water insoluble or
combinations thereof may be included in the composition used with
the textile implement according to the present invention.
Conditioners may be natural or synthetic esters, silicone oils,
hydrocarbons, starches, fatty acids, cationic polymers and mixtures
thereof. Typically the conditioners may range in amount from about
0.1 to about 35% by weight of the total composition.
[0037] Except in the operating and comparative examples, or where
otherwise explicitly indicated, all numbers in this description
indicating amounts of material ought to be understood as modified
by the word "about".
[0038] The term "comprising" is meant not to be limiting to any
subsequently stated elements but rather to encompass non-specified
elements of major or minor functional importance. In other words
the listed steps, elements or options need not be exhaustive.
Whenever the words "including" or "having" are used, these terms
are meant to be equivalent to "comprising" as defined above.
EXAMPLE
[0039] Personal cleansing pillows were constructed similar to those
described in WO 03/022230, herein incorporated by reference. A
powder similar to that described under Table II of the
aforementioned patent application was placed as a powdered
substance within the pouch of the pillows. A water-permeable wall
of the aforementioned pillow was constructed with a non-woven
hydroentangled textile according to the present invention. This
Example correlates the Air Permeability of hydroentangled textile
with different weight ratios of fiber for high (total above and
below) to low mass fiber density areas and to evaluate Lather
Release. For these experiments, the amounts of high mass density
fiber was about equivalent in the areas above and below the low
mass density fiber of the central area.
1 Weight Ratio Total Weight Air Sample (high/low) (g/m.sup.2)
Permeability* I 3 82 266 II 2.5 71.5 477 III 1.5 51 678 IV 4 102
371 V 4.1667 103 348 VI 2.875 102 250 VII 3375 61 529 *Measured
according to ASTM D737-96.
[0040] Lather Release was measured in the following manner. A
thermometer was attached to a sink faucet to read water
temperature. The temperature of the water was then adjusted to
100.degree. F. (38.degree. C.) and maintained at that temperature.
A sample pillow was taken in hand and placed in a stream of water
for 3 seconds. The pillow was rotated in the hands so that both
sides of the pillow would be exposed. Again the pillow was held in
the water stream for another 3 seconds. As the pillow left the
water stream, a timer was set to measure length of time required
for full lather release. These times were noted and visual
observations recorded. "Lather Release" was rated on the following
scale:
[0041] Very good=0.2 seconds and represents full Lather Release
instantaneously on both sides of the pillow; moderate billowing
pressure should be noted;
[0042] Good=1-2 second with full Lather Release on both sides of
the pillow;
[0043] Fair=2-4 seconds with slower Lather Release and different
release rates seen from one side to another;
[0044] Poor=3-6 seconds with slow Lather Release, and high
billowing internal pillow pressure.
[0045] The above procedure for each sample was repeated for 3-5
pillows of the same type. A combination of time and consensus from
an expert panel based on the above procedure was utilized to
provide the Lather Release description in the Table below.
2 Sample Air Permeability Lather Release I 266 Poor II 477 Good III
678 Very Good IV 371 Fair V 348 Fair VI 250 Poor VII 529 Very
Good
[0046] Best Performance was achieved with Samples III and VII.
These correlated with the highest level of Air Permeability.
Consequently, the non-woven textile of the present invention should
have a structure with an Air Permeability above 250, preferably at
least 300 and optimally at least 500. The preferred range is from
about 300 to about 1,000. It is to be noted that if the system
becomes too Air Permeable, a powder held within the pillow would
undesirably escape prior to being activated with water.
* * * * *