U.S. patent application number 11/439738 was filed with the patent office on 2006-11-23 for method of making a dual performance nonwoven and the products therefrom.
Invention is credited to Rick Augustine, Patrick Barge, Nick Carter, Mike Disotelle, Karl Kelly, Mark Landreth, Imad Qashou.
Application Number | 20060260736 11/439738 |
Document ID | / |
Family ID | 31978652 |
Filed Date | 2006-11-23 |
United States Patent
Application |
20060260736 |
Kind Code |
A1 |
Qashou; Imad ; et
al. |
November 23, 2006 |
Method of making a dual performance nonwoven and the products
therefrom
Abstract
The present invention is directed to a cleaning laminate, which
comprises an abrasive side that facilitates loosening of
particulates, such as dust and dirt, and an opposing, soft
absorbent side. The laminate is formed by hydroentanglement on a
three-dimensional image transfer device.
Inventors: |
Qashou; Imad; (Cornelius,
NC) ; Augustine; Rick; (Sherrills, NC) ;
Kelly; Karl; (Holly Spring, NC) ; Landreth; Mark;
(Mooresville, NC) ; Barge; Patrick; (Cornelius,
NC) ; Disotelle; Mike; (Mooresville, NC) ;
Carter; Nick; (Mooresville, NC) |
Correspondence
Address: |
WOOD, PHILLIPS, KATZ, CLARK & MORTIMER
500 W. MADISON STREET
SUITE 3800
CHICAGO
IL
60661
US
|
Family ID: |
31978652 |
Appl. No.: |
11/439738 |
Filed: |
May 23, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10657439 |
Sep 8, 2003 |
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11439738 |
May 23, 2006 |
|
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60408658 |
Sep 6, 2002 |
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Current U.S.
Class: |
156/148 ;
264/103; 264/257 |
Current CPC
Class: |
A45D 2200/1036 20130101;
B32B 37/153 20130101; B32B 2305/20 20130101; B32B 7/12 20130101;
B32B 27/36 20130101; D04H 1/4374 20130101; B32B 5/26 20130101; B32B
2377/00 20130101; B32B 2367/00 20130101; A47L 13/16 20130101; D04H
1/46 20130101; B32B 27/32 20130101; B32B 5/24 20130101; D04H 1/495
20130101; A45D 2200/1018 20130101; B32B 2250/24 20130101; B32B
5/022 20130101; D04H 1/498 20130101; B32B 7/08 20130101; B32B 27/34
20130101; A45D 37/00 20130101; B32B 2432/00 20130101 |
Class at
Publication: |
156/148 ;
264/103; 264/257 |
International
Class: |
D04H 13/00 20060101
D04H013/00 |
Claims
1. A method of making a dual performance nonwoven laminate having
an abrasive side and an opposing absorbent side comprising steps
of: a. providing an absorbent precursor web; b. providing a
polymeric resin that is usable in a spunbond process; c. providing
a three-dimensional image transfer device; d. extruding said
polymeric resin into meltblown filaments; e. collecting said
filaments onto said absorbent precursor web to form a laminate; f.
advancing said laminate onto said three-dimensional image transfer
device wherein said filaments are facing hydraulic jets and said
absorbent web is facing the three-dimensional image transfer
device; and hydroentangling said laminate so as to provide for a
dual performance nonwoven laminate comprising an abrasive side and
an opposing absorbent side.
2. A method of making a dual performance nonwoven laminate having
an abrasive side and an opposing absorbent side comprising steps
of: a. providing an absorbent precursor web; b. providing a
three-dimensional image transfer device; c. providing a meltblown
precursor web solely made from resin usable in a spunbond process;
d. juxtaposing said absorbent precursor web with said precursor
meltblown web; e. advancing said precursor webs onto said
three-dimensional transfer device wherein said meltblown web is
facing hydraulic jets and said absorbent web is facing said
three-dimensional transfer device; and hydroentangling said
precursor webs so as to provide for a dual performance nonwoven
laminate comprising an abrasive side and an opposing absorbent
side.
3. A method of making a dual performance nonwoven laminate having
an abrasive side and an opposing absorbent side comprising steps
of: a. providing an absorbent precursor web; b. providing a
three-dimensional image transfer device; c. providing a meltblown
precursor web solely made from resin usable in a spunbond process;
d. juxtaposing said absorbent precursor web with said precursor
meltblown web; e. advancing said precursor webs onto said
three-dimensional transfer device wherein said absorbent web is
facing hydraulic jets and said meltblown web is facing said
three-dimensional transfer device; and hydroentangling said
precursor webs so as to provide for a dual performance nonwoven
laminate comprising an abrasive side and an opposing absorbent
side.
4. (canceled)
5. (canceled)
6. (canceled)
7. A method of making a dual performance nonwoven laminate having
an abrasive side and an opposing side according to claim 1, wherein
said method further comprises a step of impregnating said laminate
with a cleaning agent.
8. A method of making a dual performance nonwoven laminate having
an abrasive side and an opposing side according to claim 2, wherein
said method further comprises a step of impregnating said laminate
with a cleaning agent.
9. A method of making a dual performance nonwoven laminate having
an abrasive side and an opposing side according to claim 3, wherein
said method further comprises a step of impregnating said laminate
with a cleaning agent.
10. A method of making a dual performance nonwoven laminate having
an abrasive side and an opposing side according to claim 1, wherein
said absorbent web is selected from the group consisting of a
continuous filament web, a carded, staple fiber web, and mixtures
thereof.
11. A method of making a dual performance nonwoven laminate having
an abrasive side and an opposing side according to claim 2, wherein
said absorbent web is selected from the group consisting of a
continuous filament web, a carded, staple fiber web, and mixtures
thereof.
12. A method of making a dual performance nonwoven laminate having
an abrasive side and an opposing side according to claim 3, wherein
said absorbent web is selected from the group consisting of a
continuous filament web, a carded, staple fiber web, and mixtures
thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a division of U.S. Ser. No. 10/657,439,
filed Sep. 8, 2003, which claims the benefit of priority
Provisional Application No. 60/408,658, filed Sep. 6, 2002, the
disclosures of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to a cleaning
laminate, and specifically to a dual performance cleaning laminate
comprising two functionally diverse surfaces, wherein said laminate
has an abrasive side that facilitates the process of loosening
particulates, such as dust and dirt, and an opposing soft,
absorbent side, such material being imminently suitable for
application in cleaning and cleansing applications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a diagrammatic view of a forming apparatus for
forming a nonwoven cleaning laminate in accordance with the
principles of the present invention;
[0004] FIG. 2 is a photomicrograph of the abrasive side of the
nonwoven cleaning laminate in practicing the present invention;
[0005] FIG. 3 is a photomicrograph of the soft, absorbent side of
the nonwoven cleaning laminate in practicing the present
invention;
[0006] FIG. 4 is a photomicrograph on a macroscopic scale of the
abrasive side of the nonwoven cleaning laminate in practicing the
present invention; and
[0007] FIG. 5 is a photomicrograph on a macroscopic scale of the
soft, absorbent side of the nonwoven cleaning laminate in
practicing the present invention.
DETAILED DESCRIPTION
[0008] While the present invention is susceptible of embodiment in
various forms, there will hereinafter be described, presently
preferred embodiments, with the understanding that the present
disclosure is to be considered as an exemplification of the
invention, and is not intended to limit the invention to the
specific embodiments disclosed herein.
[0009] The nonwoven laminate of the present invention is comprised
of coarse denier meltblown filaments, wherein a spunbond resin is
utilized with a conventional meltblown process so as to capture
thicker filaments. In general, the meltblown process utilizes a
molten polymer is extruded under pressure through orifices in a
spinneret or die. Traditionally, high velocity air impinges upon
and entrains the filaments as they exit the die. Usually the energy
of this step is such that the formed filaments are greatly reduced
in diameter and are fractured so that microfibers of finite length
are produced. Utilizing a spunbond resin with a lower melt flow
rate, as well as lowering the air pressure, however, allows the
collected filaments to take on a thicker diameter, providing the
overall collective web with a desirable coarse texture. The process
to form either a single layer or a multiple-layer fabric is
continuous, that is, the process steps are uninterrupted from
extrusion of the filaments to form the first layer until the bonded
web is wound into a roll. Methods for producing these types of
fabrics are described in U.S. Pat. No. 4,041,203, hereby
incorporated by reference. The resultant filaments may be of
various cross-sectional profiles, which are not considered a
limitation to the practice of the present invention.
[0010] In a particular embodiment, a polypropylene spunbond resin,
commercially known as PP3155 made available by Exxon Chemical
Company was utilized. The aforementioned resin had a 35 MFR and was
extruded at an average die temperature of 562.degree. Fahrenheit
with an approximate throughput of 7.1 grams/hole/min. Further, the
distance between the meltblown die and the collective surface was
around the order of 19 inches. The resultant meltblown filaments
have a denier between that of 5 and 50 microns. Suitable polymers
that may be used in the meltblowing process of the present
invention include those selected from the group consisting of
polyolefins, polyesters, polyetheresters, and polyamide.
[0011] Optionally, prior to extrusion, the single polymeric resin
can be compounded with various melt-additives, so as to assist with
the processing conditions, enhance the performance of the web, or
enhance the appearance of the web, such additives including, but
not limited to thermal stabilizers, colorants, and aromatics.
[0012] The dual purpose cleaning wipe of the present invention also
comprises a soft, absorbent layer capable of picking up liquids and
particulates. A nonwoven of this nature may be a fibrous nonwoven
layer or a continuous filament nonwoven layer. In general,
continuous filament nonwoven fabric formation involves the practice
of the spunbond process. A spunbond process involves supplying a
molten polymer, which is then extruded under pressure through a
large number of orifices in a plate known as a spinneret or die.
The resulting continuous filaments are quenched and drawn by any of
a number of methods, such as slot draw systems, attenuator guns, or
Godet rolls. The continuous filaments are collected as a loose web
upon a moving foraminous surface, such as a wire mesh conveyor
belt. When more than one spinneret is used in line for the purpose
of forming a multi-layered fabric, the subsequent webs are
collected upon the uppermost surface of the previously formed web.
The web is then at least temporarily consolidated, usually by means
involving heat and pressure, such as by thermal point bonding.
Using this means, the web or layers of webs are passed between two
hot metal rolls, one of which has an embossed pattern to impart and
achieve the desired degree of point bonding, usually on the order
of 10 to 40 percent of the overall surface area being so
bonded.
[0013] When staple fibers are utilized to form the absorbent
nonwoven layer, the fibers may begin in a bundled form as a bale of
compressed fibers. In order to decompress the fibers, and render
the fibers suitable for integration into a nonwoven fabric, the
bale is bulk-fed into a number of fiber openers, such as a garnet,
then into a card. The card further frees the fibers by the use of
co-rotational and counter-rotational wire combs, then depositing
the fibers into a lofty batt. The lofty batt of staple fibers can
then optionally be subjected to fiber reorientation, such as by
air-randomization and/or cross-lapping, depending upon the ultimate
tensile properties of the resulting nonwoven fabric. The fibrous
batt is integrated into a nonwoven fabric by application of
suitable bonding means, including, but not limited to, use of
adhesive binders, thermobonding by calender or through-air oven,
and hydroentanglement.
[0014] In one embodiment, the absorbent precursor web and the
meltblown precursor web are juxtaposed and hydroentangled on a
three-dimensional image transfer device. Such three-dimensional
image transfer devices are disclosed in U.S. Pat. No. 5,098,764,
which is hereby incorporated by reference. The two precursor webs
may be advanced onto the three-dimensional image transfer device so
that the meltblown precursor web is facing the hydraulic jets of
the hydroentanglement process and the absorbent precursor web is in
contact with the three-dimensional transfer device. Hydroentangling
the precursor webs in this manner allows for the meltblown
filaments to become more integrated into the absorbent precursor
web. Further, the meltblown filaments fragment with the force of
the water through the meltblown web. The resultant laminate is more
drapeable due to the fragmented meltblown filaments.
[0015] In a second embodiment, the absorbent precursor web and the
meltblown precursor web are juxtaposed and hydroentangled on a
three-dimensional image transfer device. The two precursor webs may
be advanced onto the three-dimensional image transfer device so
that the absorbent precursor web is facing the hydraulic jets of
the hydroentanglement process and the meltblown web is in contact
with the three-dimensional transfer device. Hydroentangling the
precursor webs in this manner allows for the meltblown filaments to
remain substantially more intact. The resultant laminate is stiffer
due to minimal fragmentation of the meltblown filaments.
[0016] In a third embodiment, the meltblown filaments are extruded
and collected directly onto the absorbent precursor web and then
subsequently hydroentangled on a three-dimensional image transfer
device.
[0017] Optionally, the dual performance nonwoven laminate may
comprise an additional layer, including, but not limited to a
microporous film, a supportive member, such as a spunbond or mesh
scrim, or a barrier layer of sorts. Further, the laminate may be
comprised of apertures of varying shapes and sizes wherein the
apertures extend either partially or entirely though the laminate.
Further still, the laminate may optionally be impregnated with a
cleaning agent or placed within a tub or other packaging means
containing the desired cleaning agent.
[0018] The dual performance cleaning laminate embodying the
principles of the present invention are suitable as a dry or wet
wipe substrate for cleaning both domestic and industrial surfaces,
and further for use in skin/facial cleaning. The present nonwoven
fabric wipe can be provided in forms that are suitable for use as a
dry wipe to absorb liquid, and to provide extra scrubbing effect,
as needed.
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