U.S. patent application number 11/591113 was filed with the patent office on 2008-05-01 for multi-layer nonwoven having a printed layer and products made therefrom.
Invention is credited to Martin Patrick Lacey, Michael Sean Pratt, Philip Andrew Sawin, Michael Jan Trinkaus.
Application Number | 20080102725 11/591113 |
Document ID | / |
Family ID | 39110633 |
Filed Date | 2008-05-01 |
United States Patent
Application |
20080102725 |
Kind Code |
A1 |
Lacey; Martin Patrick ; et
al. |
May 1, 2008 |
Multi-layer nonwoven having a printed layer and products made
therefrom
Abstract
A multi-layered nonwoven having a printed layer comprises a pair
of outer layers, with each of the outer layers comprising a carded
web. An inner layer is disposed between the outer layers and
includes printed indicia, which may be in the form of text,
graphics, colors, or other suitable indicia. The inner layer is
bonded to each of the outer layers by hydroentanglement. A method
of making such a nonwoven may include the steps of providing a pair
of outer layers comprising carded webs, providing a pulp inner
layer having printed indicia, positioning the inner layer between
the outer layers, passing the outer layers and the inner layer
together through a hydroentangling system to secure the inner layer
to each of the outer layers to form a web, and drying the web.
Inventors: |
Lacey; Martin Patrick;
(Amberley Village, OH) ; Pratt; Michael Sean; (St.
Bernard, OH) ; Trinkaus; Michael Jan; (Bad Soden,
DE) ; Sawin; Philip Andrew; (Wyoming, OH) |
Correspondence
Address: |
THE PROCTER & GAMBLE COMPANY;INTELLECTUAL PROPERTY DIVISION - WEST BLDG.
WINTON HILL BUSINESS CENTER - BOX 412, 6250 CENTER HILL AVENUE
CINCINNATI
OH
45224
US
|
Family ID: |
39110633 |
Appl. No.: |
11/591113 |
Filed: |
November 1, 2006 |
Current U.S.
Class: |
442/327 ;
264/500; 442/381; 442/408 |
Current CPC
Class: |
D04H 1/492 20130101;
D04H 1/4374 20130101; B32B 5/06 20130101; D04H 1/498 20130101; Y10T
442/659 20150401; Y10T 442/60 20150401; D04H 1/425 20130101; Y10T
442/689 20150401 |
Class at
Publication: |
442/327 ;
442/381; 442/408; 264/500 |
International
Class: |
D04H 13/00 20060101
D04H013/00 |
Claims
1. A nonwoven formed from multiple layers and having a printed
layer and comprising: a fibrous layer; a printed layer disposed
adjacent the fibrous layer, the printed layer having indicia; and
wherein the printed layer is bonded to the fibrous layer by
hydroentanglement.
2. The nonwoven of claim 1, wherein the printed layer comprises a
pulp material.
3. The nonwoven of claim 1, wherein the indicia includes text or
graphics.
4. The nonwoven of claim 1, wherein at least a portion of the
printed layer is colored.
5. The nonwoven of claim 1, wherein the printed layer is
hydroentangled to the fibrous layer in a first direction and in a
second direction.
6. The nonwoven of claim 1, wherein the nonwoven forms a web, and
wherein the web is dried.
7. The nonwoven of claim 6, wherein the web is moistened.
8. The nonwoven of claim 1, wherein the fibrous layer comprises
synthetic fibers formed of staple fibers.
9. The nonwoven of claim 1, wherein the fibrous layer is formed of
spun fibers.
10. The nonwoven of claim 1, wherein the fibrous layer is formed of
continuous fibers.
11. The nonwoven of claim 1, wherein the fibrous layer comprises
polypropylene fibers and rayon fibers in a ratio of about 3:2.
12. A nonwoven formed from multiple layers and having a printed
layer and comprising: a fibrous layer; a printed layer disposed
adjacent the fibrous layer, wherein the printed layer is colored;
and wherein the printed layer is bonded to the fibrous layer by
hydroentanglement.
13. A nonwoven having a printed layer and comprising: a pair of
outer layers, at least one of the outer layers comprising a fibrous
layer; an inner layer disposed parallel to the outer layers and
having printed indicia; and wherein the inner layer is secured to
each of the outer layers by hydroentanglement.
14. The nonwoven of claim 13, wherein the second layer is disposed
immediately adjacent to the first layer and comprises a pulp
material.
15. The nonwoven of claim 13, wherein the indicia includes at least
one of text, graphics, or colors.
16. The nonwoven of claim 13, wherein the inner layer is
hydroentangled to the outer layers in a first direction and in a
second direction.
17. The nonwoven of claim 13, wherein the fibrous layer comprises
carded fibers.
18. The nonwoven of claim 13, wherein the fibrous layer comprises
continuous fibers.
19. The nonwoven of claim 13, wherein the synthetic web comprises
high opacity polypropylene fibers and rayon fibers.
20. An absorbent product having indicia and comprising: a wearable
garment having an absorbent layer; a fibrous layer; a printed layer
disposed adjacent the fibrous layer, the printed layer having
indicia; wherein the printed layer is bonded to the fibrous layer
by hydroentanglement; and wherein the hydroentangled layers are
coupled to the garment.
21. A nonwoven wipe having indicia and comprising: a nonwoven
substrate comprising a fibrous layer; a printed layer disposed
adjacent the fibrous layer, the printed layer having indicia;
wherein the printed layer is bonded to the fibrous layer by
hydroentanglement to form the wipe.
22. The nonwoven wipe of claim 21, including a second nonwoven
substrate comprising a fibrous layer, the printed layer disposed
between the fibrous layers, and wherein the printed layer is bonded
to both of the fibrous layers by hydroentanglement to form the
wipe.
23. A wipe product having indicia and comprising: a wearable mitt
having a fibrous layer; a printed layer disposed adjacent the
fibrous layer, the printed layer having the indicia; wherein the
printed layer is bonded to the fibrous layer by hydroentanglement;
and wherein the hydroentangled layers form at least a portion of
the wearable mitt.
24. A bib product having indicia and comprising: a bib having a
fibrous layer; a printed layer disposed adjacent the fibrous layer,
the printed layer having the indicia; wherein the printed layer is
bonded to the fibrous layer by hydroentanglement; and wherein the
hydroentangled layers form at least a portion of the bib.
25. An absorbent diaper having indicia and comprising: an absorbent
layer; a fibrous layer; a fastener securable to a landing zone; a
printed layer disposed adjacent the fibrous layer, the printed
layer having indicia, at least a portion of the indicia disposed in
the landing zone; and wherein the printed layer is bonded to the
fibrous layer by hydroentanglement.
26. A method of manufacturing a nonwoven comprising the steps of:
providing a fibrous layer; providing a pulp layer having printed
indicia; positioning the pulp layer adjacent the fibrous layer;
passing the layers together through a hydroentangling system to
secure the layers to one another.
27. The method of claim 26, including the step of drying the
layers.
28. The method of claim 26, including the steps of providing a
second fibrous layer, and positioning the printed layer between the
fibrous layers prior to hydroentangling.
29. The method of claim 26, including the step of passing the
layers through the hydroentangling system multiple times.
30. The method of claim 29, wherein the step of passing the layers
through the hydroentangling system comprises directing water jets
in a first direction, then a second direction different than the
first direction.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to substrates
including nonwoven substrates and, more specifically, to a nonwoven
substrate comprising a multi-layer structure in which one of the
layers includes printed indicia or colors, or both.
BACKGROUND OF THE INVENTION
[0002] Consumers use a wide variety of substrate products including
wet and dry disposable wipes, diapers, feminine protection
products, and other substrate products, in a variety of
applications. Such substrates products are constructed from
substrate materials which may be cut and formed into a variety of
configurations, depending on the desired end use of the product
being manufactured. During manufacture, the web is cut to the
desired size and shape and, if desired, joined to other materials
or moistened with a lotion or other suitable substance.
[0003] In the case of wipe products, the wipes may be wet or dry
wipes. During manufacture, a nonwoven or other suitable web is cut
to the desired size and, if desired, moistened with a lotion or
other suitable substance. The resulting wipe, whether wet or dry,
is used by consumers to clean bodily exudates, such as urine,
feces, or menses from babies, hospital patients, the infirm, women,
etc. Such wipes also are used in home and institutional cleaning
applications, such as for cleaning floors, sinks, tubs, and other
fixtures or surfaces.
[0004] Nonwovens preferably have a number of advantageous
properties. For example, for manufacturing purposes, the structural
integrity and the uniformity of the web are considerations in order
to minimize web breakage or other quality control issues. The feel
and softness of the finished wipe are additional considerations, as
is the flexibility or drape of the finished wipe.
[0005] Many nonwovens typically are disposed of after use. Thus in
order to keep the costs down for the resulting end product, the
manufacture of the nonwoven should be relatively cost-effective.
The average consumer may have second thoughts about using a product
that holds itself out as disposable if the cost per article is too
high. Nevertheless, manufacturers as well as consumers may desire
additional features that make the nonwovens and the end products
more attractive to manufacturers, retailers, and purchasers.
Unfortunately, cost considerations and the above-described desired
physical properties often present a hindrance to incorporating
additional features into the finished nonwoven and/or the resulting
end product.
[0006] Moreover, because the web or other substrate used in
nonwovens is often incorporated into products which are used to
scrub surfaces (i.e. wipes) or used in skin-contact environments
(i.e. wipes, diapers, feminine protection products), it may be
difficult to add some attractive features, such as text, graphics,
colors or other indicia, and still maintain the desired degree of
image integrity and/or prevent or minimize the potential for
transfer of the inks and/or pigments used in creating the graphics
or other indicia to the skin. Further, it may be difficult to add
these desired features without unduly hampering the drape,
flexibility, and other desirable physical properties of the
nonwoven.
[0007] Thus, it would be desirable to provide nonwovens with text,
graphics, or colors, and to provide methods for making such
nonwovens.
SUMMARY OF THE INVENTION
[0008] Nonwovens are used in many product applications including
diapers, wipes, feminine protection products and the like. In order
to make these products most useful to consumers, such products will
frequently include a number of features that increase their
utility, ease of use, appropriateness of use, ancillary benefits,
etc. to best meet the needs of the consumers.
[0009] One example of a feature that some manufacturers, retailers
and consumers may find desirable is the addition of text, graphics,
or colors to the nonwoven and/or to the resulting end product. In
accordance with the disclosed example, constructing a printed or
colored nonwoven by hydroentangling a printed or colored layer with
a layer of nonwoven substrate may offer certain advantages over the
existing state-of-the-art printed nonwovens. For example,
nonwoven-based products, such as wipes, and absorbent articles are
often used for cleaning and/or scrubbing and/or for skin-contact
purposes. In such applications, it can be advantageous that the
printed indicia and/or colors be arranged so as to not be disposed
at the surface of the nonwoven itself. Thus, it may be desirable to
join a printed or colored layer to another layer such that the
printed or colored layer is not disposed on the outermost surfaces
of the resulting nonwoven.
[0010] For example, some nonwoven-based products, such as wipes,
are often used for cleaning and/or scrubbing. Thus, placing the
printed or colored elements inside the nonwoven may provide
increased abrasion-resistance of the printed elements.
Specifically, placing the printed or colored elements away from the
surface of the nonwoven helps to retain the integrity of the image
or the color, even in circumstances where the surface of the
nonwoven is disrupted due to scrubbing or other surface
abrasion.
[0011] Separately, for skin-contact products such as absorbent
articles and wipes intended for use on the body (for example, baby
wipes, cosmetic wipes, topical-applicator wipes, and other such
products), placing the printed or colored elements internally or
within the nonwoven reduces the potential transfer to the skin of
the inks, dyes, pigments and the like used in the printing or
coloring process. This aspect may offer particular advantages in
the context of baby wipes, where safety concerns can be
particularly important to consumers.
[0012] Additionally, in accordance with the disclosed example,
joining the printed or colored layer to a nonwoven layer by
hydroentanglement may offer certain advantages. Although it may be
contemplated to bond a printed layer to a nonwoven layer as a means
of removing the printed image from the outermost surface of the
resulting nonwoven using conventional bonding methods such as
adhesive-bonding or thermal-bonding, these alternative bonding
techniques typically impart the finished nonwoven with undesirable
properties, such as increased stiffness, reduced drapability, and
reduced flexibility. Nonwoven products based on stiff and/or
inflexible nonwovens can be undesirable to consumers, particularly
for skin-contact products such as wipes, and absorbent articles.
Furthermore, these conventional bonding techniques may have the
disadvantage of requiring the use of adhesives and/or specific
thermoplastic polymeric additives to achieve the required
lamination. These additional components may add unnecessary cost
and complexity to the manufacturing of the nonwovens, and these
components have the potential to interact negatively with applied
lotions or other treatments.
[0013] In accordance with an aspect of the invention, a multi-layer
nonwoven may comprise at least one layer that is printed, or
colored, or both, bonded to a nonwoven by hydroentanglement. In
further accordance with a preferred form, a multi-layered nonwoven
may be incorporated into a wipe or absorbent article made from
nonwovens, with the nonwoven or the end product having text,
graphics, images, colors, or any other suitable indicia.
[0014] In accordance with another aspect of the invention, the
printed layer may comprise a pulp material, and the indicia may
include text, graphics, or both, and also may include colors. The
printed layer may be hydroentangled to a synthetic layer, such as a
fibrous layer. The layer or layers of synthetic fibers may comprise
discrete staple synthetic fibers, essentially continuous filaments,
or combinations thereof. Such layers of synthetic fibers may be
formed by many forming processes known to those skilled in the art,
such as carding, wet-laying, air-laying, or spunmelt formation. The
printed layer may be hydroentangled to one or more other layers,
such as the synthetic layer, in a first direction and then in a
second direction. The resultant nonwoven may be hydroentangled once
again, in either the first or second directions, or in a third
direction.
[0015] The resulting nonwoven may form a web, and the web may be
dried. The dried web may be used in the construction of a
nonwoven-based absorbent article product such as a disposable
diaper or feminine protection product. The web also may be used as
a wipe product in the dry state. If desired, the web may be
moistened with a lotion or other suitable substance or
preparation.
[0016] In accordance with an aspect of the invention, the at least
one layer of synthetic fibers may comprise staple fibers of
polypropylene and rayon. The ratio of the polypropylene fibers to
the rayon fibers may be about 60% to 40%. The polypropylene fibers
may have a denier of about 1.5 and a length of about 1.50 inches
(38 mm), and wherein the rayon fibers have a denier of about 1.5
and a length of about 1.57 inches (40 mm).
[0017] In accordance with another aspect of the invention, a
multi-layered nonwoven having indicia may comprise a pair of outer
layers, each of the outer layers comprising a carded web of staple
or continuous fibers, and an inner layer disposed between the outer
layers and having printed indicia. The inner layer is secured to at
least one of the outer layers by hydroentanglement.
[0018] In accordance with a further aspect of the invention, a
multi-layered nonwoven having indicia comprises a pair of outer
layers, each of the outer layers formed of a web of staple or
continuous fibers comprising a mix of polypropylene fibers and
rayon fibers, a printed center layer disposed between the outer
layers and having indicia, the center layer comprising a pulp
material, and a bond formed by hydroentanglement to secure the
printed the center layer to each of the outer layers.
[0019] In accordance with a further aspect of the invention, a
method of manufacturing a nonwoven comprises the steps of providing
a pair of outer layers comprising carded webs, providing a pulp
inner layer having printed indicia, positioning the inner layer
between the outer layers, passing the outer layers and the inner
layer together through a hydroentangling system to secure the inner
layer to each of the outer layers to form a web, and drying the
web.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] While the specification concludes with claims particularly
pointing out and distinctly claiming the subject matter that is
regarded as the present invention, it is believed that the
invention will be more fully understood from the following
description taken in conjunction with the accompanying drawings.
Some of the figures may have been simplified by the omission of
selected elements for the purpose of more clearly showing other
elements. Such omissions of elements in some figures are not
necessarily indicative of the presence or absence of particular
elements in any of the exemplary embodiments, except as may be
explicitly delineated in the corresponding written description.
None of the drawings are necessarily to scale.
[0021] FIG. 1 is a plan view of a multi-layer nonwoven having a
printed inner layer assembled in accordance with the teachings of a
disclosed example of the present invention and taking the form of a
wipe.
[0022] FIG. 2 is an enlarged fragmentary cross-sectional view of
the nonwoven of FIG. 1 and illustrating a two layer nonwoven prior
to bonding the layers to one another.
[0023] FIG. 3 is an enlarged cross-sectional view of the two layer
nonwoven of FIG. 2 after bonding the layers to one another.
[0024] FIG. 4 is an enlarged fragmentary cross-sectional view
similar to FIG. 2 but illustrating a three layer nonwoven prior to
bonding the layers to one another.
[0025] FIG. 5 is an enlarged cross-sectional view of the three
layer nonwoven of FIG. 4 after bonding the layers to one
another.
[0026] FIG. 6 is a schematic illustration of the nonwoven
undergoing an exemplary hydroentanglement bonding process.
[0027] FIG. 7 is a schematic illustration similar to FIG. 4 and
illustrating the nonwoven undergoing an exemplary second pass
through the hydroentanglement bonding process.
[0028] FIG. 8 is a schematic illustration similar to FIGS. 6 and 7
and illustrating the nonwoven undergoing an exemplary third pass
through the hydroentanglement bonding process.
[0029] FIG. 9 is a wearable garment on the form of a diaper
assembled in accordance with the teachings of the present invention
and incorporating a printed layer.
[0030] FIG. 10 is a wearable garment on the form of a feminine
protection product assembled in accordance with the teachings of
the present invention and incorporating a printed layer.
[0031] FIG. 11 is a nonwoven product in the form of a mitt and
assembled in accordance with the teachings of the present invention
and incorporating a printed layer.
[0032] FIG. 12 is a nonwoven product in the form of a bib and
assembled in accordance with the teachings of the present invention
and incorporating a printed layer.
DETAILED DESCRIPTION OF THE INVENTION
[0033] As used herein, the term "absorbent article" refers to
devices which absorb and contain body exudates, and, more
specifically, refers to devices which are placed against or in
proximity to the body of the wearer to absorb and contain the
various exudates discharged from the body. The term "disposable" is
used herein to describe absorbent articles which are not intended
to be laundered or otherwise restored or reused as an absorbent
article (i.e., they are intended to be discarded after a single use
and, preferably, to be recycled, composted or otherwise disposed of
in an environmentally compatible manner). A "unitary" absorbent
article refers to an absorbent article which is formed of separate
parts united together to form a coordinated entity so that it does
not require separate manipulative parts like a separate holder and
liner. As used herein, the term "diaper" refers to an absorbent
article generally worn by infants and incontinent persons that is
worn about the lower torso of the wearer. It should be understood,
however, that the present invention is also applicable to other
absorbent articles such as incontinent briefs, incontinent
undergarments, diaper holders and liners, feminine hygiene
garments, medical wraps, bibs, bandages, and the like. Exemplary
absorbent articles are shown in FIGS. 9 and 10, described in
greater detail below.
[0034] Referring now to the drawings, FIG. 1 illustrates a nonwoven
10 assembled in accordance with the teachings of the present
invention. The nonwoven 10 is formed of a generally planar sheet or
web 12 and includes an upper surface 14, a lower surface 16
(obscured in FIG. 1), and a plurality of edges 15a, 15b, 15c, and
15d. The relative dimensions of the edges 15a-15d, and hence the
overall shape of the nonwoven 10 as shown in FIG. 1 is exemplary
only. In accordance with the disclosed example, the nonwoven 10
includes indicia 18, which may take the form of text 20 or graphics
22, or both. Other forms of indicia 18 may be contemplated. The
text 20 may take the form of messages, logos, brand names,
instructions, or any other suitable text. The graphics 22 may take
the form of logos, cartoon characters, pictures, drawings, or any
other suitable graphics. Those of skill in the art may contemplate
still further exemplary forms for the text 20 and the graphics 22.
In the example of FIG. 1, the nonwoven 10 takes the form of a wipe
11.
[0035] Referring now to FIGS. 2 and 3, the nonwoven 10 is shown in
cross-section. For ease of illustration, the thickness of the
nonwoven 10 has been exaggerated. The nonwoven 10 includes upper
and lower surfaces 14, 16, and is formed of multiple layers,
including an upper layer 24 and a lower layer 28 forming an
unbonded two layer sandwich 30 (FIG. 2). In FIG. 2, the layers 24
and 28 are shown prior to being bonded together by
hydroentanglement. In the completed nonwoven 10 of FIG. 3, the
upper and lower layers 24 and 28 have been bonded or connected
together using hydroentanglement. Therefore, the upper and lower
layers 24 and 28 have been compressed relative to their initial
state, as will be explained in further detail below. Also, the
lower layer 28 includes the indicia 18 discussed above with respect
to FIG. 1. Consequently, after hydroentanglement, the indicia 18 is
visible through the upper layer 24 as can be seen when viewing FIG.
1. The lower layer 28 also may be partially or completely
colored.
[0036] Referring again to FIG. 2, the layers 24 and 28 are shown
prior to hydroentanglement. For ease of illustration, the thickness
of the various layers has been exaggerated. The layer 24 is a web
made of staple or continuous fibers. In the example of FIG. 2, the
layer may be formed of a blend of high opacity polypropylene fibers
(HOPP) and rayon fibers. Alternatively, other fibers of the type
commonly employed in this technology may be used, or continuous
fibers of the type commonly employed in spunbond technology may be
used. For example, such other fibers may include, by way of example
rather than limitation, regular polypropylene fibers, polyester
fibers, cotton fibers, or bi-component fibers. The fibers may be
natural fibers and may include cellulosic natural fibers, such as
fibers from hardwood sources, softwood sources, or other non-wood
plants. The natural fibers may comprise cellulose, starch and
combinations thereof. Non-limiting examples of suitable cellulosic
natural fibers include, but are not limited to, wood pulp, typical
northern softwood Kraft, typical southern softwood Kraft, typical
CTMP, typical deinked, corn pulp, acacia, eucalyptus, aspen, reed
pulp, birch, maple, radiata pine and combinations thereof. Other
sources of natural fibers from plants include, but are not limited
to, albardine, esparto, wheat, rice, corn, sugar cane, papyrus,
jute, reed, sabia, raphia, bamboo, sidal, kenaf, abaca, sunn, rayon
(also known as viscose), lyocell, cotton, hemp, flax, ramie and
combinations thereof. Yet other natural fibers may include fibers
from other natural non-plant sources, such as, down, feathers,
silk, cotton and combinations thereof. The natural fibers may be
treated or otherwise modified mechanically or chemically to provide
desired characteristics or may be in a form that is generally
similar to the form in which they can be found in nature. The
fibers may be synthetic fibers and may include, but not limited to,
those selected from the group consisting of polyesters (e.g.,
polyethylene terephthalate), polyolefins, polypropylenes,
polyethylenes, polyethers, polyamides, polyesteramides,
polyvinylalcohols, polyhydroxyalkanoates, polysaccharides, and
combinations thereof. Further, the synthetic fibers can be a single
component (i.e., single synthetic material or mixture makes up
entire fiber), bi-component (i.e., the fiber is divided into
regions, the regions including two or more different synthetic
materials or mixtures thereof and may include co-extruded fibers
and core and sheath fibers) and combinations thereof. Any or all of
the synthetic fibers may be treated before, during, or after
manufacture to change any desired properties of the fibers. In the
instance where it is desirable that the substrate be biodegradable,
as in products intended to be flushed down the toilet, the fibers
may be comprised of rayon, cotton, or other biodegradable fibers.
The fibers may also have various cross-sectional shapes, including
but not limited to round, rectangular, oval, tri-lobal, or other
cross-sectional shapes.
[0037] Referring still to FIG. 2, the layer 28 (which has indicia
18 as discussed above) is disposed adjacent the layer 24. It will
be noted that in the state illustrated in FIG. 2, the layer 24 may
be uncompressed, such that the web or substrate is relatively
fluffy. The layer 28 may be formed from a thin paper or other pulp
material. In accordance with the disclosed example, the layer 28
may be formed of a single ply of, for example, a printed multi-ply
toilet paper of the type that is commercially available.
Alternatively, a single ply of a printed paper towel of the type
that is commercially available may be used for the layer 28, and
still other forms of printed paper or pulp products may be used for
the layer 28. The layer 28 may be printed in a prior processing
step (not shown) of the type commonly employed in the manufacture
of printed toilet paper. In accordance with the disclosed example,
the layer 28 is manufactured with the addition of wet strength
resins of the type commonly used in the manufacture of toilet
paper, tissues, or paper towels. It will be understood that the
indicia 18, such as the above-described text 20, graphics 22, or
both, will be carried by the layer 28. Further, the indicia 18 may
be printed on the layer 28 using known printing processes, such as
printing processes normally employed to print indicia on toilet
paper. For example, the indicia 18 may be printed using any
suitable printing process, such as ink jet printing, lithography,
flexography, gravure, screen printing, letterpress, plateless
printing, or any other suitable process. In the example of FIG. 2,
the two layers 24 and 28 are shown disposed adjacent one another to
form the unbonded or unconnected two layer sandwich 30.
[0038] Referring now to FIGS. 4 and 5, a nonwoven 110 assembled in
accordance with the teachings of another disclosed example is
shown. Again, for ease of illustration the thickness has been
exaggerated. The nonwoven 110 includes upper and lower surfaces
114, 116, and is formed of three layers including an upper layer
124, a lower layer 126, and an inner layer 128. In the completed
nonwoven of FIG. 5, the upper and lower layers 124, 126, and the
inner layer 128 have been bonded or connected together using
hydroentanglement. Therefore, in the view of FIG. 5, the upper and
lower layers 124, 126 have been compressed relative to their
initial state, as will be explained in further detail below. Also,
the inner layer 128 includes the indicia 18 discussed above with
respect to FIG. 1. Consequently, after hydroentanglement, the
indicia 18 may be visible through one or both of the layers 124,
126. The layer 128 also may be partially or completely colored.
Further, in the example of FIGS. 4 and 5, the upper and lower
layers 124 and 126 may be formed of a blend of high opacity
polypropylene fibers (HOPP) and rayon fibers. Alternatively, other
fibers of the type commonly employed in this technology may be
used, or continuous fibers of the type commonly employed in
spunbond technology may be used. The fibers may be any of the
fibers previously described above. For example, such other fibers
may include, by way of example rather than limitation, regular
polypropylene fibers, polyester fibers, cotton fibers, or
bi-component fibers. The fibers may also have various
cross-sectional shapes, including but not limited to round,
rectangular, oval, tri-lobal, or other cross-sectional shapes. The
stacked layers form a three layer sandwich 130, and after
hydroentanglement (described below with respect to FIG. 8), the
sandwich 130 will form a web 112.
[0039] Referring now to FIG. 6, the three layer sandwich 130 is
shown being routed through a hydroentanglement machine 32 in a
direction generally indicated by the reference arrow A. The two
layer sandwich 30 shown in FIGS. 2 and 3 may be hydroentangled in
the same or similar manner. The hydroentanglement machine 32
directs pressurized streams or jets 34 of water toward the sandwich
30. Although only a single set of jets 34 is shown, it will be
understood that the jets 34 may include a plurality of streams or
jets caused by individual water nozzles spaced apart in a direction
generally transverse to the direction A, such that a plurality of
the water jets extends across a width of the sandwich 130. The
hydroentanglement machine 32 may include a plurality of stations,
with a first station 35 shown in FIG. 6. Also, it will be
understood that the first station 35 may include a first row of
water jets 35a and a second row of water jets 35b spaced apart
along the direction A. The sandwich 130 may be supported by a
support 136. The support 136 may be a web or other suitable belt,
or any other suitable structure. Further, it will be understood
that the support 136 need not be continuous. Upon passing through
the first station 35 of the hydroentanglement machine 32, the
sandwich 130 will be compressed as the fibers of the upper layer
124 become entangled with the inner layer 128. The lower layer 126
also may be compressed slightly during this first pass through the
hydroentanglement process, although the lower layer 126 may not get
compressed quite as much as the upper layer 124.
[0040] Referring now to FIG. 7, the sandwich 130 is next shown
being routed through a second station 38 of the hydroentanglement
machine 32, again in the direction A and presumably downstream of
the first station 35. As shown in FIG. 7, the sandwich 130 is
oriented differently such that the water jets at the second station
38 are directed at the lower layer 126. It will be understood that
the sandwich 130 may be turned over by routing the sandwich over a
roller (not shown). Alternatively, the sandwich 30 may be turned
over by using other conventional means, or the orientation of the
second station 38 may be flipped over relative to the orientation
of the first station 35. In any event, water jets 39 at the second
station 38 are directed in a different and generally opposite
direction relative to the sandwich 130 compared to the direction of
the water jets 34 at the first station 35. In other words, the
water jets 39 are now directed toward the lower layer 126 rather
than at the upper layer 124. The arrangement of the individual jets
may be similar to those discussed above with respect to FIG. 6,
such that the jets may extend across a width of the sandwich 130.
Further, the second station 38 may have a first set of jets 38a and
a second set of jets 38b. Upon passing through the second station
38 of the hydroentanglement machine 32, the sandwich 130 will now
be further compressed, as the fibers of both the upper and lower
lays 124 and 126 are now further entangled with the fibers of the
inner layer 128.
[0041] Referring now to FIG. 8, the sandwich 130 is next shown
being routed through a third station 40 of the hydroentanglement
machine 32, again in the direction A and presumably downstream of
the prior stations. As shown in FIG. 8, the sandwich 130 is once
again oriented differently, such that the water jets at the third
station 38 are again directed at the upper layer 124. Water jets 41
at the third station 40 may be directed in a direction generally
the same as at the first station 35. Again, the arrangement of the
individual jets may be similar to those discussed above with
respect to FIGS. 6 and 7. Further, the third station 40 may have a
first set of jets 40a and a second set of jets 40b. Upon passing
through the third station 40 of the hydroentanglement machine 32,
the sandwich 130 is now fully compressed into the web 112 of the
nonwoven 110, with the fibers of both the upper and lower layers
124 and 126 now further entangled with the fibers of the inner
layer 128. The resulting web 112 is next fed into a dryer 42.
[0042] It can be appreciated by one of ordinary skill in the art
that the hydroentanglement stations 35, 38 and 40 need not be
discrete hydroentanglement stations but can also be the same
hydroentanglement station wherein the web 130 may be wound and
un-wound between subsequent hydroentanglements.
[0043] In the example of FIGS. 6-8, the water jets are oriented in
a direction generally perpendicular to the plane of the sandwich or
web. Other orientations may be chosen.
[0044] In the event the dried web is to be made into a wet wipe
product, the web 112 may next be fed into a moistening station 44.
The moistening station 44 may be configured to add any sort of
lotions, etc., conventionally added to wet wipe products. Whether
wet or dry, the web 112 may be cut and trimmed as necessary in
order to make a nonwoven 110 having the desired size.
[0045] Referring now to FIG. 9, the nonwovens 10 or 110 may be
incorporated into an absorbent article or other wearable garment
50. In the example of FIG. 9, the wearable garment 50 takes the
form of a diaper 52. The indicia 18 on the nonwoven 10 or 110 may
be positioned within the diaper 52 so as to be visible on an
outside surface 54, on an inside surface 56, or on any other
suitable surface on the diaper 52. The diaper 52 may include an
absorbent layer of the type commonly employed in the art, and the
diaper 52 may be conventional in all other respects. In the
embodiment of FIG. 9, the diaper 52 includes a fastening system 200
comprising a hook and loop type fastener, or any other suitable
fastener, such as a tape fastener. As used herein, the term "hook
and loop type fasteners" refers to fastening means comprising a
"hook" component (hereinafter referred to as an "engaging
component") and a complementary loop component (hereinafter
referred to as a "landing component"). The term "hook" is used to
designate a material having engaging elements. Thus, the hook
fastening material may also be referred to as a male fastener. It
should also be understood that the use of the term "hook" should be
non-limiting in the sense that the engaging elements may comprise
any shapes as are known in the art so long as they are adapted to
engage a complementary landing component. The fastening system 200
may include a component 202 that is securable to a landing zone
204. In the example of FIG. 9, at least a portion of the landing
zone 204 may include the indicia 18. The nonwoven may be desirable
in the application to the landing zone where iterative attachment
and removal of the "hook" component to the nonwoven of the landing
zone would otherwise disrupt the indicia 18 included on the landing
zone, if the indicia were printed on the surface of the nonwoven
rather than incorporated into the nonwoven as described.
[0046] Referring now to FIG. 10, the absorbent article or wearable
garment 50 may take the form of a feminine protection product 58,
with the nonwoven 10 or 110 incorporated into the feminine
protection product 58. The indicia 18 on the nonwoven 10 or 110 may
be positioned within the feminine protection product 58 so as to be
visible on an outside surface 60, on an inside surface 62, or on
any other suitable surface on the feminine protection product 58.
The feminine protection product 58 may include an absorbent layer
of the type commonly employed in the art, and the feminine
protection product 58 may be conventional in all other
respects.
[0047] Referring now to FIG. 11, the nonwovens 10 or 110 may be
incorporated into a mitt 70. The indicia 18 on the nonwoven 10 or
110 may be positioned on the mitt 70 so as to be visible on an
outside surface 74, on an inside surface 76, or on any other
suitable surface on the mitt 70. The mitt 70 may be conventional in
all other respects.
[0048] Referring now to FIG. 12, the nonwovens 10 or 110 may be
incorporated into a bib 80. The indicia 18 on the nonwoven 10 or
110 may be positioned on the bib 80 so as to be visible on an
outside surface 84, on an inside surface 86, or on any other
suitable surface on the bib 80. The bib 80 may be conventional in
all other respects.
QUANTITATIVE EXAMPLE
[0049] The fibers for the carded webs for use in a test batch are
pre-mixed by hand in a box. The ratio of high opacity polypropylene
(HOPP) to rayon is 60% HOPP to 40% rayon, or a ratio of 3:2. The
HOPP fibers may be obtained from FIBERVISIONS, Product No.
6801060330211. The fibers are 1.5 denier, white, having a thickness
of 0.060 inches and a cut length of 1.5 inches (38 mm). The rayon
fibers may be obtained from Liberty Fibers Corp., type 8191, with
dull regular luster. The denier for the rayon fibers is 1.50 dpf
(1.7 dtex) cut to a length of 1.57 inches (40 mm). The fibers are
used to make the carded webs.
[0050] The fiber mixture is fed using a feed system manufactured by
Befama. The pre-blended fibers are fed into the system and formed
into carded webs, each web having a basis weight of approximately
15 grams per square meter.
[0051] The carded webs are fed onto foam boards and cut to length
with scissors. A sheet of 4-color printed UK Charmin Ultra single
ply tissue is used, having a basis weight of 21.8 grams per square
meter. The tissue is laid on top of one of the carded webs. Another
carded web sample is then placed on top and the edges were trimmed
to remove excess web.
[0052] The web "sandwiches" are fed individually into a Fleissner
Aqua Jet hydroentangler system. The belt speed is 10 m/min. The
first jet head encountered by the web contains a jet strip with 40
holes per inch, arranged in a single row. The holes are 0.12 mm in
diameter and the pressure is 35 bar. The second jet is operated at
70 bar and contains 40 holes per inch, but the holes are 0.10 mm in
diameter. Each web is passed through the system 3 times alternating
the side that faces the jets each time.
[0053] Following the hydroentanglement process, the webs are dried
in a Pyradia Thru Air Dryer. The webs are placed onto the belt and
then fed into the dryer (zone 1 set at 110.degree. C. and zone 2
was set at 115.degree. C.). The webs are dried for approximately 5
minutes and then removed from the dryer.
[0054] In accordance with the disclosed example, on the resulting
nonwoven 10, whether wet or dry, the indicia 18 on the inner layer
28 is visible through one or both of the outer layers 24, 26. In
the Quantitative Example discussed above, the resulting nonwoven 10
exhibited good image integrity/resolution as well as good web
integrity and overall uniformity. Also, when the nonwoven 10 is
assembled in accordance with the teachings of the disclosed
example, any subsequent printing steps may be eliminated, resulting
in greater production efficiencies. As a possible alternative
embodiment, the upper and lower layers 24, 26, along with the inner
layer 28, may be joined by stitching, embossing, or possibly by a
suitable adhesive. Also, although the disclosed examples illustrate
adjacent layers coupled or connected directly to one another, the
layers also may suitably be coupled together with one or more
intervening layers disposed between the printed layer and one or
more of the carded webs.
[0055] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm.
[0056] All documents cited in the Detailed Description of the
invention are, in relevant part, incorporated herein by reference;
the citation of any document is not to be construed as an admission
that it is prior art with respect to the present invention.
[0057] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and the scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *