U.S. patent application number 12/810308 was filed with the patent office on 2010-10-28 for protruded non-woven sheet towel for improving of cleaning and water absorbing capability.
This patent application is currently assigned to Jae Hun SHIM. Invention is credited to Seong Sik Kim, Jae Hun Shim.
Application Number | 20100269283 12/810308 |
Document ID | / |
Family ID | 40996442 |
Filed Date | 2010-10-28 |
United States Patent
Application |
20100269283 |
Kind Code |
A1 |
Shim; Jae Hun ; et
al. |
October 28, 2010 |
PROTRUDED NON-WOVEN SHEET TOWEL FOR IMPROVING OF CLEANING AND WATER
ABSORBING CAPABILITY
Abstract
A nonwoven towel having protrusions and improved cleaning and
water-absorbing capacity, suitable for use as wet towels, wet
tissues, handkerchiefs, makeup removers, dishwashing sponges or
electrostatic dustcloths. Absorbent nonwoven fabric made of fibers
having a denier of 0.1-10 is press punched with heated pins, so
that the nonwoven fabric has fibrous wrinkled protrusions having a
height of 0.1-5 mm on one surface thereof to thus have a reduced
fiber density and has recesses structured by perforations having a
perforation rate of 5-50% caused by the punching in the other
surface thereof. The portion of the nonwoven fabric not punched
fluffs, thus reducing fiber density. This nonwoven towel is used in
a manner such that two layers thereof are pressed through embossing
so that the protrusions are disposed outwards, or absorbent
nonwoven fabric or paper tissue is sandwiched between the two
layers thereof and then the three-layered composite is pressed
through embossing. The nonwoven towel is imparted with enhanced
absorbing capacity through corona treatment and reduced lint
through embossing treatment, with embossed unevenness.
Inventors: |
Shim; Jae Hun; (Gongju-si,
KR) ; Kim; Seong Sik; (Gongju-si, KR) |
Correspondence
Address: |
CHRISTOPHER PAUL MITCHELL
888 16TH ST., NW, SUITE 800
WASHINGTON
DC
20006
US
|
Assignee: |
SHIM; Jae Hun
Gongju-si, Chungcheongnam-do
KR
|
Family ID: |
40996442 |
Appl. No.: |
12/810308 |
Filed: |
December 18, 2008 |
PCT Filed: |
December 18, 2008 |
PCT NO: |
PCT/KR2008/007525 |
371 Date: |
June 23, 2010 |
Current U.S.
Class: |
15/209.1 |
Current CPC
Class: |
A61K 8/8111 20130101;
A47L 17/04 20130101; A61Q 1/14 20130101; A61K 8/0208 20130101; A47L
13/16 20130101; A47L 13/40 20130101 |
Class at
Publication: |
15/209.1 |
International
Class: |
A47L 25/00 20060101
A47L025/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 24, 2007 |
KR |
10-2007-0136069 |
Dec 5, 2008 |
KR |
10-2008-0123281 |
Claims
1. A non woven towel having protrusions and improved cleaning and
water-absorbing capacity, which is two-layered and is suitable for
use as any one selected from among a wet towel, a wet tissue, a
handkerchief, a makeup remover, a dishwashing sponge and an
electrostatic dustcloth, manufactured by: press punching a nonwoven
fabric made of fibers having a denier of 0.1-10 selected from among
a polyolefin-based hydrophobic nonwoven fabric having a basis
weight of 5-80 g/including a polypropylene-based hydrophobic
nonwoven fabric not subjected to hydrophilic treatment and an
absorbent nonwoven fabric having a basis weight of 5-80 g/, using
heated pins, so that the nonwoven fabric has fibrous wrinkled
protrusions having a height of 0.1-5 mm on one surface thereof to
thus have a reduced fiber density and has recesses structured by
perforations having a perforation rate of 5-50% caused by the
punching in a surface of the nonwoven fabric opposite the surface
having the fibrous wrinkled protrusions, and fibers of a portion of
the nonwoven fabric other than a portion which is pin punched are
fluffed out thus reducing a fiber density, thereby preparing a
nonwoven fabric having protrusions and improved cleaning and
water-absorbing capacity; stacking two layers of the nonwoven
fabric having protrusions one on another; and pressing the two
layers of the nonwoven fabric along an embossing pattern of an
embossing roll, thus imparting an embossing pressed pattern and
unevenness and reducing lint of the nonwoven fabric because of the
embossing pressed pattern.
2. A nonwoven towel having protrusions and improved cleaning and
water-absorbing capacity, which is three-layered and is suitable
for use as any one selected from among a wet towel, a wet tissue, a
handkerchief, a makeup remover, a dishwashing sponge and an
electrostatic dustcloth, manufactured by: press punching a nonwoven
fabric made of fibers having a denier of 0.1-10 selected from among
a polyolefin-based hydrophobic nonwoven fabric having a basis
weight of 5-80 g/including a polypropylene-based hydrophobic
nonwoven fabric not subjected to hydrophilic treatment and an
absorbent nonwoven fabric having a basis weight of 5-80 g/, using
heated pins, so that the nonwoven fabric has fibrous wrinkled
protrusions having a height of 0.1-5 mm on one surface thereof to
thus have a reduced fiber density and has recesses structured by
perforations having a perforation rate of 5-50% caused by the
punching in a surface of the nonwoven fabric opposite the surface
having the fibrous wrinkled protrusions, and fibers of a portion of
the nonwoven fabric other than a portion which is pin punched are
fluffed out thus reducing a fiber density, thereby preparing a
nonwoven fabric having protrusions and improved cleaning and
water-absorbing capacity; sandwiching a layer of absorbent nonwoven
fabric or paper tissue between two layers of the nonwoven fabric
having protrusions; and pressing the three layers along an
embossing pattern of an embossing roll, thus imparting an embossing
pressed pattern and unevenness and reducing lint of the nonwoven
fabric because of the embossing pressed pattern.
3. A nonwoven towel having protrusions and improved cleaning and
water-absorbing capacity, which is single-layered and is suitable
for use as any one selected from among a wet towel, a wet tissue, a
handkerchief, a makeup remover, a dishwashing sponge and an
electrostatic dustcloth, manufactured by: press punching a nonwoven
fabric made of fibers having a denier of 0.1-10 selected from among
a polyolefin-based hydrophobic nonwoven fabric having a basis
weight of 5-80 g/including a polypropylene-based hydrophobic
nonwoven fabric not subjected to hydrophilic treatment and an
absorbent nonwoven fabric having a basis weight of 5-80 g/, using
heated pins, so that the nonwoven fabric has fibrous wrinkled
protrusions having a height of 0.1-5 mm on one surface thereof to
thus have a reduced fiber density and has recesses structured by
perforations having a perforation rate of 5-50% caused by the
punching in a surface of the nonwoven fabric opposite the surface
having the fibrous wrinkled protrusions, and fibers of a portion of
the nonwoven fabric other than a portion which is pin punched are
fluffed out thus reducing a fiber density, thereby preparing a
nonwoven fabric having protrusions and improved cleaning and
water-absorbing capacity.
4. A nonwoven towel having protrusions and enhanced cleaning and
water-absorbing capacity, which is single-layered and is suitable
for use as any one selected from among a wet towel, a wet tissue, a
handkerchief, a makeup remover, a dishwashing sponge and an
electrostatic dustcloth, manufactured by: press punching a nonwoven
fabric made of fibers having a denier of 0.1-10 selected from among
a polyolefin-based hydrophobic nonwoven fabric having a basis
weight of 5-80 g/including a polypropylene -based hydrophobic
nonwoven fabric not subjected to hydrophilic treatment and an
absorbent nonwoven fabric having a basis weight of 5-80 g/, using
heated pins, so that the nonwoven fabric has fibrous wrinkled
protrusions having a height of 0.1-5 mm on one surface thereof to
thus have a reduced fiber density and has recesses structured by
perforations having a perforation rate of 5-50% caused by the
punching in a surface of the nonwoven fabric opposite the surface
having the fibrous wrinkled protrusions, and fibers of a portion of
the nonwoven fabric other than a portion which is pin punched are
fluffed out thus reducing a fiber density, thereby preparing a
nonwoven fabric having protrusions and improved cleaning and
water-absorbing capacity; and pressing a layer of the nonwoven
having protrusions with an embossing pattern, thus imparting an
embossing pressed pattern and unevenness and reducing lint of the
nonwoven fabric because of the embossing pressed pattern.
5. The nonwoven towel according to claim 1, wherein the
polyolefin-based hydrophobic nonwoven fabric is subjected to corona
treatment to enhance water absorptiveness.
6. The nonwoven towel according to claim 1, wherein the pin
punching is performed at a low speed of 50 m/min or less.
7. The nonwoven towel according to claim 1, wherein the absorbent
nonwoven fabric is a polyolefin-based hydrophilic nonwoven fabric
including a polypropylene-based nonwoven fabric obtained by coating
a surface of the nonwoven fabric with a hydrophilic agent, an air
through nonwoven fabric, an air-laid nonwoven fabric, a spunlace
nonwoven fabric, a polyester nonwoven fabric, and a
polyolefin-based nonwoven fabric containing viscose fibers or
polyester fibers.
8. The nonwoven towel according to claim 1, wherein the
polyolefin-based hydrophobic nonwoven fabric is a polyolefin-based
spunbond nonwoven fabric (S), a polyolefin-based meltblown nonwoven
fabric (M), a nonwoven fabric (SMS, SMMS) made by layering a
polyolefin-based spunbond nonwoven fabric (S) and a
polyolefin-based meltblown nonwoven fabric (M), or a
polyolefin-based thermal bond nonwoven fabric.
9. The nonwoven towel according to claim 1, wherein the embossing
is performed using an embossing roll of an ultrasonic sealer.
10. The nonwoven towel according to claim 1, wherein the surface of
the nonwoven fabric having protrusions is imparted with embossed
unevenness.
11. The nonwoven towel according to claim 2, wherein the
polyolefin-based hydrophobic nonwoven fabric is subjected to corona
treatment to enhance water absorptiveness.
12. The nonwoven towel according to claim 3, wherein the
polyolefin-based hydrophobic nonwoven fabric is subjected to corona
treatment to enhance water absorptiveness.
13. The nonwoven towel according to claim 4, wherein the
polyolefin-based hydrophobic nonwoven fabric is subjected to corona
treatment to enhance water absorptiveness.
14. The nonwoven towel according to claim 2, wherein the pin
punching is performed at a low speed of 50 m/min or less.
15. The nonwoven towel according to claim 3, wherein the pin
punching is performed at a low speed of 50 m/min or less.
16. The nonwoven towel according to claim 4, wherein the pin
punching is performed at a low speed of 50 m/min or less.
17. The nonwoven towel according to claim 2, wherein the absorbent
nonwoven fabric is a polyolefin-based hydrophilic nonwoven fabric
including a polypropylene-based nonwoven fabric obtained by coating
a surface of the nonwoven fabric with a hydrophilic agent, an air
through nonwoven fabric, an air-laid nonwoven fabric, a spunlace
nonwoven fabric, a polyester nonwoven fabric, and a
polyolefin-based nonwoven fabric containing viscose fibers or
polyester fibers.
18. The nonwoven towel according to claim 3, wherein the absorbent
nonwoven fabric is a polyolefin-based hydrophilic nonwoven fabric
including a polypropylene-based nonwoven fabric obtained by coating
a surface of the nonwoven fabric with a hydrophilic agent, an air
through nonwoven fabric, an air-laid nonwoven fabric, a spunlace
nonwoven fabric, a polyester nonwoven fabric, and a
polyolefin-based nonwoven fabric containing viscose fibers or
polyester fibers.
19. The nonwoven towel according to claim 4, wherein the absorbent
nonwoven fabric is a polyolefin-based hydrophilic nonwoven fabric
including a polypropylene-based nonwoven fabric obtained by coating
a surface of the nonwoven fabric with a hydrophilic agent, an air
through nonwoven fabric, an air-laid nonwoven fabric, a spunlace
nonwoven fabric, a polyester nonwoven fabric, and a
polyolefin-based nonwoven fabric containing viscose fibers or
polyester fibers.
20. The nonwoven towel according to claim 2, wherein the
polyolefin-based hydrophobic nonwoven fabric is a polyolefin-based
spunbond nonwoven fabric (S), a polyolefin-based meltblown nonwoven
fabric (M), a nonwoven fabric (SMS, SMMS) made by layering a
polyolefin-based spunbond nonwoven fabric (S) and a
polyolefin-based meltblown nonwoven fabric (M), or a
polyolefin-based thermal bond nonwoven fabric.
21. The nonwoven towel according to claim 3, wherein the
polyolefin-based hydrophobic nonwoven fabric is a polyolefin-based
spunbond nonwoven fabric (S), a polyolefin-based meltblown nonwoven
fabric (M), a nonwoven fabric (SMS, SMMS) made by layering a
polyolefin-based spunbond nonwoven fabric (S) and a
polyolefin-based meltblown nonwoven fabric (M), or a
polyolefin-based thermal bond nonwoven fabric.
22. The nonwoven towel according to claim 4, wherein the
polyolefin-based hydrophobic nonwoven fabric is a polyolefin-based
spunbond nonwoven fabric (S), a polyolefin-based meltblown nonwoven
fabric (M), a nonwoven fabric (SMS, SMMS) made by layering a
polyolefin-based spunbond nonwoven fabric (S) and a
polyolefin-based meltblown nonwoven fabric (M), or a
polyolefin-based thermal bond nonwoven fabric.
23. The nonwoven towel according to claim 5, wherein the
polyolefin-based hydrophobic nonwoven fabric is a polyolefin-based
spunbond nonwoven fabric (S), a polyolefin-based meltblown nonwoven
fabric (M), a nonwoven fabric (SMS, SMMS) made by layering a
polyolefin-based spunbond nonwoven fabric (S) and a
polyolefin-based meltblown nonwoven fabric (M), or a
polyolefin-based thermal bond nonwoven fabric.
24. The nonwoven towel according to claim 11, wherein the
polyolefin-based hydrophobic nonwoven fabric is a polyolefin-based
spunbond nonwoven fabric (S), a polyolefin-based meltblown nonwoven
fabric (M), a nonwoven fabric (SMS, SMMS) made by layering a
polyolefin-based spunbond nonwoven fabric (S) and a
polyolefin-based meltblown nonwoven fabric (M), or a
polyolefin-based thermal bond nonwoven fabric.
25. The nonwoven towel according to claim 12, wherein the
polyolefin-based hydrophobic nonwoven fabric is a polyolefin-based
spunbond nonwoven fabric (S), a polyolefin-based meltblown nonwoven
fabric (M), a nonwoven fabric (SMS, SMMS) made by layering a
polyolefin-based spunbond nonwoven fabric (S) and a
polyolefin-based meltblown nonwoven fabric (M), or a
polyolefin-based thermal bond nonwoven fabric.
26. The nonwoven towel according to claim 13, wherein the
polyolefin-based hydrophobic nonwoven fabric is a polyolefin-based
spunbond nonwoven fabric (S), a polyolefin-based meltblown nonwoven
fabric (M), a nonwoven fabric (SMS, SMMS) made by layering a
polyolefin-based spunbond nonwoven fabric (S) and a
polyolefin-based meltblown nonwoven fabric (M), or a
polyolefin-based thermal bond nonwoven fabric.
27. The nonwoven towel according to claim 2, wherein the embossing
is performed using an embossing roll of an ultrasonic sealer.
28. The nonwoven towel according to claim 4, wherein the embossing
is performed using an embossing roll of an ultrasonic sealer.
29. The nonwoven towel according to claim 2, wherein the surface of
the nonwoven fabric having protrusions is imparted with embossed
unevenness.
Description
TECHNICAL FIELD
[0001] The present invention relates to nonwoven towels having
protrusions, and more particularly, to a nonwoven towel having
protrusions and improved cleaning and water-absorbing capacity, in
which nonwoven fabric has fibrous wrinkled protrusions thereon,
thus imparting the functionality of many small protrusions of a
fiber towel, and has therein recesses structured by perforations
caused by punching, thus realizing cleaning and water-absorbing
capacity.
[0002] The nonwoven towel having protrusions according to the
present invention is adapted for use as a wet towel, a wet tissue,
a handkerchief, a makeup remover, a dishwashing sponge, an
electrostatic dustcloth and so on, and is classified depending on
whether the fibrous wrinkled protrusions and the perforations
caused by the punching are respectively present on and in the
nonwoven fabric. Specifically, the nonwoven towel according to the
present invention has fibrous wrinkled protrusions and thus
exhibits skin cleansing, wiping, cleaning, dishwashing, and
dewatering abilities.
BACKGROUND ART
[0003] A disposable wet towel or a disposable wet tissue is widely
used in city life.
[0004] The disposable wet towel composed of a fabric which cleans
is not repeatedly used but is discarded after a single use, thus
blocking the use of the wet towel as a propagation path of
bacteria. The disposable wet towel is provided for wiping the hand
of a user in a restaurant and so on, wiping the excretion of a baby
in the course of caring for the baby, and wiping the body of a
patient as part of treatment in a hospital.
[0005] 1) A problem of a conventional disposable nonwoven wet towel
or tissue is that the surface of a nonwoven tissue should be
layered with protrusions of fibers of nonwoven fabric. Examples of
nonwoven fabric used for manufacturing nonwoven products such as
disposable wet tissues or towels include spunlace nonwoven fabric,
hydrophilic treated polypropylene (PP) meltblown nonwoven fabric,
and other hydrophilic treated PP nonwoven fabric. Below in the
present invention, PP indicates polypropylene.
[0006] The aforementioned nonwoven fabric has a flat surface and a
smooth texture, and thus has adhesion and cleaning capacity
inferior to those of a fiber towel having fibrous protrusions
thereon. Upon contact with the skin of a user, the nonwoven fabric
is smooth and does not have any scraping ability and thus gives a
different texture to the user.
[0007] With the goal of solving the above problem, the surface of
the nonwoven fabric is layered with an embossing pattern to
increase the adhesion of the conventional nonwoven wet towel.
[0008] The embossing pattern of the nonwoven wet towel is obtained
by forming recesses having a depth of about 50 to the surface of a
nonwoven fabric having a thickness of about 400. The recesses
formed as the embossing pattern in the surface of the nonwoven
fabric may improve adhesion and flexibility of the nonwoven fabric
to some degree but have very poor adhesion compared to the fibrous
wrinkled protrusions of a fiber towel.
[0009] 2) Another problem of the nonwoven wet towel is the
harmfulness of the chemicals contained therein. Korean Patent
Unexamined Publication No. 10-1998-0086503 points out the skin
troubles of a user caused by a nonwoven wet towel containing a
surfactant, a fungicide and a preservative.
[0010] The reason why the chemicals are contained in the nonwoven
wet towel is as follows. Inexpensive nonwoven fabric usable as a
replacement for a woven wet towel is PP-based nonwoven fabric
having a basis weight of 5 to 80 g/. The commercially available wet
towel or tissue is composed mainly of hydrophilic treated PP
meltblown nonwoven fabric. Also useful are PP spunbond nonwoven
fabric, nonwoven fabric obtained by layering PP spunbond and
meltblown nonwovens in a single process, and spunlace nonwoven
fabric. However, the PP-based nonwoven fabric consists of a
hydrophobic fiber layer having no ability to absorb water. When
water drops on the inclined surface of the PP nonwoven fabric not
subjected to hydrophilic treatment, water does not wet the surface
of the nonwoven fabric but flaws down. In order to cause the
hydrophobic PP nonwoven fabric to absorb water, the PP nonwoven
fabric should be coated with a hydrophilic agent. For hydrophilic
coating, the PP nonwoven fabric is dipped in a hydrophilic agent
solution and then dried in an oven or using hot air. The
hydrophilic agent is a surfactant series chemical similar to a
detergent such as soap or shampoo. When the hydrophilic treated wet
towel is used, a small amount of surfactant contained in the wet
towel is transferred to the skin and remains thereon. The
surfactant remaining on the skin negatively affects the skin of a
user, in particular, the skin of an infant or portions around the
lips having kw resistance.
[0011] 3) A further problem of the disposable wet towel is the use
of the chemicals contained in the wet towel. In order to prevent
the deterioration of the conventional wet tissue during the shelf
life storage period, chemicals such as a disinfecting agent, an
alcohol, a fungicide, a preservative and a surfactant for
increasing cleaning capacity are contained in a solution in which
the wet towel is dipped. The chemical such as the surfactant or the
alcohol functions to prevent the deterioration of the conventional
disposable wet tissue or towel during the shelf life storage period
and increase cleaning capacity thereof.
[0012] Further examples of the nonwoven fabric used for cleaning
purposes include kitchen towels, electrostatic dustcloths, makeup
removers and so on. The kitchen towel, the electrostatic dustcloth,
the makeup remover and so on are relatively expensive and have no
fibrous protrusions and poor cleaning capacity. Hence, there is a
need for a material being inexpensive and having improved cleaning
capacity.
DISCLOSURE OF INVENTION
Technical Problem
[0013] Accordingly, the present invention has been made keeping in
mind the above problems occurring in the related art, and the
present invention provides an absorbent nonwoven towel having
protrusions and improved cleaning capacity, which is of a novel
type for those using PP-based nonwoven fabric as a wet towel.
[0014] In addition, the present invention provides a nonwoven towel
having protrusions, in which fibrous wrinkled protrusions are
formed on the surface of nonwoven fabric so as to impart the
functionality of many small protrusions of a fiber towel.
[0015] In addition, the present invention provides a nonwoven towel
having protrusions, in which fibrous wrinkled protrusions are
arranged on the surface of nonwoven fabric, and thus, upon contact
with the skin, there is no difference in texture and adhesion and
scraping ability are improved.
[0016] In addition, the present invention provides a nonwoven towel
having protrusions, in which fibrous wrinkled protrusions are
arranged on the surface of nonwoven fabric, the nonwoven fabric is
fluffed out to reduce fiber density so as to increase cushioning
capacity, recesses are structured in the nonwoven fabric by
perforations caused by punching, and embossing treatment is
performed to thus form unevenness, thus increasing adhesion and
cleaning capacity.
[0017] In addition, the present invention provides an absorbent
nonwoven towel having protrusions, in which fibrous wrinkled
protrusions are formed on the surface of nonwoven fabric thus
increasing adhesion and cleaning capacity, thereby obviating a need
for an impurity such as a surfactant coming from a solution for
wetting a disposable nonwoven wet towel.
[0018] In addition, the present invention provides a nonwoven towel
having protrusions, in which fibrous wrinkled protrusions are
formed on the surface of nonwoven fabric thus improving the soft
touch, scraping ability and cleaning capacity and enhancing
water-absorbing capacity, thereby decreasing a need for hydrophilic
treatment.
[0019] In addition, the present invention provides a hydrophobic
nonwoven towel having protrusions with water-absorbing capacity, in
which fibrous wrinkled protrusions are formed on the surface of
hydrophobic nonwoven fabric, the density of the nonwoven fabric is
reduced, recesses are structured in the nonwoven fabric by
perforations caused by punching, and corona treatment is performed,
thus enhancing cleaning capacity.
[0020] In addition, the present invention provides a dishwashing
sponge which may be sanitarily used and which is capable of
reducing the amount of a detergent to be used, an electrostatic
dustcloth and other dustcloths which generate more static
electricity to easily remove dust, and a makeup remover and a
facial cleansing towel for easily removing makeup and makeup
residues from skin wrinkles, thanks to the improved cleaning
capacity of the nonwoven fabric having protrusions.
[0021] In addition, the present invention provides a nonwoven towel
having protrusions and enhanced cleaning and water-absorbing
capacity, which is suitable for use in novel types of disposable
wet towels, disposable wet tissues, handkerchiefs, makeup removers,
dishwashing sponges, and electrostatic dustcloths, which are
necessary for daily life.
Technical Solution
[0022] According to the present invention, there is provided a
nonwoven towel having protrusions and improved cleaning and
water-absorbing capacity, suitable for use as any one selected from
among a wet towel, a wet tissue, a handkerchief, a makeup remover,
a dishwashing sponge and an electrostatic dustcloth, manufactured
by press punching a nonwoven fabric made of fibers having a denier
of 0.1.about.10 selected from among a polyolefin-based hydrophobic
nonwoven fabric having a basis weight of 5.about.80 g/including a
polypropylene-based hydrophobic nonwoven fabric not subjected to
hydrophilic treatment and an absorbent nonwoven fabric having a
basis weight of 5.about.80 g/, using heated pins, so that the
nonwoven fabric has fibrous wrinkled protrusions having a height of
0.1.about.5 mm on one surface thereof and thus has a reduced fiber
density and has recesses structured by perforations having a
perforation rate of 5.about.50% caused by the punching in the
surface thereof opposite the surface having the fibrous wrinkled
protrusions, and fibers of a portion of the nonwoven fabric other
than a portion which is pin punched are fluffed out thus reducing a
fiber density, thereby preparing a nonwoven fabric having
protrusions and improved cleaning and water-absorbing capacity;
stacking two layers of the nonwoven fabric having protrusions one
on another; and pressing the two layers of the nonwoven fabric
along an embossing pattern of an embossing roll, thus imparting an
embossing pressed pattern and unevenness and reducing lint of the
nonwoven fabric because of the embossing pressed pattern.
[0023] The features and advantages of the present invention will be
more clearly understood from the following detailed description,
taken in conjunction with the accompanying drawing. The terms and
words used in the specification and claims must be regarded as
having concepts selected by the inventor as the best method of
illustrating the present invention, and must be interpreted as
having meanings and concepts adapted to the scope and sprit of the
present invention for purposes of understanding the technology of
the present invention.
Advantageous Effects
[0024] According to the present invention, the nonwoven towel
having protrusions has a reduced fiber density thanks to fibrous
wrinkled protrusions, recesses structured by perforations caused by
punching, increased elasticity thanks to the totally reduced fiber
density of the nonwoven fabric and embossed unevenness, and thus
exhibits improved cleaning and water-absorbing capacity at a lower
price, as compared to conventional cleaning nonwoven products.
[0025] Thus, products made of the nonwoven towel according to the
present invention are expected to increase the expediency of daily
life activities, be beneficial to the health, and reduce the use of
detergents.
BRIEF DESCRIPTION OF DRAWINGS
[0026] FIG. 1 is a schematic view showing a punching apparatus
according to the present invention;
[0027] FIG. 2 is a schematic view showing another punching
apparatus according to the present invention;
[0028] FIG. 3 is a schematic view showing a state in which the
nonwoven fabric is punched with a punch and a pocket according to
the present invention;
[0029] FIG. 4 is an enlarged cross-sectional view showing an
absorbent nonwoven towel having protrusions according to the
present invention;
[0030] FIG. 5 is an enlarged top plan view showing the absorbent
nonwoven towel having protrusions according to the present
invention; and
[0031] FIG. 6 is an enlarged cross-sectional view showing a
nonwoven towel composite having protrusions according to the
present invention.
MODE FOR THE INVENTION
[0032] Hereinafter, a detailed description will be given of a
nonwoven towel having protrusions and improved cleaning and
water-absorbing capacity according to the present invention, with
reference to the accompanying drawings.
[0033] Throughout the drawings, the same reference numerals refer
to the same or similar elements, and redundant descriptions are
omitted. In order to make the characteristics of the invention
clear and for the sake of description, a detailed description
pertaining to the other known techniques may be omitted.
[0034] According to a first embodiment of the present invention, a
single-layered nonwoven towel having protrusions is manufactured by
punching nonwoven fabric made of fibers having a denier of
0.1.about.10 so that the nonwoven fabric has absorbent fibrous
wrinkled protrusions having a height of 0.1.about.5 mm on one
surface thereof and thus has a reduced fiber density, and the
nonwoven fabric has recesses structured by perforations caused by
the punching in the surface of the nonwoven fabric opposite the
surface having the fibrous wrinkled protrusions, whereby the
nonwoven fabric is totally fluffed out.
[0035] According to a second embodiment of the present invention, a
two-layered nonwoven towel having protrusions is manufactured by
stacking two layers of the nonwoven fabric having protrusions one
on another so that the fibrous wrinkled protrusions thereof are
disposed outwards, the nonwoven fabric being selected from among
hydrophobic nonwoven fabric having protrusions and absorbent
nonwoven fabric having protrusions, and pressing them along an
embossing pattern of an embossing roll of an ultrasonic sealer,
thus imparting an embossed pattern and embossed unevenness to the
surfaces having fibrous wrinkled protrusions.
[0036] According to a third embodiment of the present invention, a
three-layered nonwoven towel having protrusions is manufactured by
stacking two layers of the nonwoven fabric having protrusions one
on another so that fibrous wrinkled protrusions thereof are
disposed outwards, sandwiching a layer of absorbent nonwoven fabric
or paper towel between the two layers of the nonwoven fabric having
protrusions, and pressing them along an embossing pattern of an
embossing roll of an ultrasonic sealer, thus imparting embossed
unevenness to the surface having fibrous wrinkled protrusions.
[0037] According to a fourth embodiment of the present invention, a
one or more-layered nonwoven towel having protrusions is
manufactured by pressing the nonwoven towel having fibrous wrinkled
protrusions along an embossing pattern of an embossing roll of an
ultrasonic sealer, thus imparting unevenness and reducing the lint
of the nonwoven fabric.
[0038] The hydrophobic polyolefin-based nonwoven fabric may be
increased in water absorptiveness through corona treatment.
[0039] The nonwoven fabric of the punched nonwoven towel having
protrusions enables the use of the hydrophobic polyolefin-based
nonwoven fabric as a wet towel or a wet tissue.
[0040] The nonwoven towel according to the present invention may be
applied in various objects including wet towels, wet tissues,
makeup removers, dishwashing sponges, handkerchiefs, and
electrostatic dustcloths.
[0041] Below, the present invention is described in more
detail.
[0042] Material for Nonwoven Towel Having Protrusions
[0043] The material for the nonwoven towel having protrusions is
hydrophobic nonwoven fabric or absorbent nonwoven fabric having a
basis weight of 5.about.80 g/.
[0044] Examples of the hydrophobic nonwoven fabric include
polyolefin-based nonwoven fabric, including polyolefin-based
spunbond nonwoven fabric (S), polyolefin-based meltblown nonwoven
fabric (M), nonwoven fabric (SMS, SMMS) resulting from layering of
polyolefin-based spunbond nonwoven fabric (S) and polyolefin-based
meltblown nonwoven fabric (M), and polyolefin-based thermal bond
nonwoven fabric.
[0045] The fiber material mainly used for the polyolefin-based
nonwoven fabric is PP, and the other examples thereof include
copolymers of propylene and ethylene, bi-component fibers of PP and
polyethylene, and polyethylene.
[0046] Examples of the absorbent nonwoven fabric include nonwoven
fabric obtained by coating the surface of the hydrophobic
polyolefin-based nonwoven fabric with a hydrophilic agent, spunlace
nonwoven fabric, air through nonwoven fabric, air-laid nonwoven
fabric, polyester nonwoven fabric, and polyolefin-based nonwoven
fabric containing viscose fibers or polyester fibers.
[0047] The nonwoven fabric adapted for the present invention is the
hydrophobic polyolefin-based nonwoven fabric or the absorbent
polyolefin-based nonwoven fabric which is inexpensive, has a high
fiber content and facilitates the formation of protrusions.
[0048] The polyolefin-based spunbond nonwoven fabric (S) is
manufactured by melting a PP material in an extruder, spinning the
molten resin from a spinning nozzle to obtain fibers having a
denier of 1.about.5, heat pressing the spun fibers into a sheet
form using a heated roll, and curing the sheet, thus obtaining a
nonwoven fabric in a sheet form having a high fiber density and
being thin.
[0049] The punched nonwoven fabric having protrusions according to
the present invention permits, even with the use of the hydrophobic
polyolefin-based nonwoven fabric not subjected to hydrophilic
treatment, the penetration of water, on account of the fibrous
wrinkled protrusions having a reduced fiber density in the form of
loop protrusions of elastic fibers of the nonwoven fabric, the
perforations of the nonwoven fabric and the totally reduced fiber
density of the punched nonwoven fabric. Further, the hydrophobic
nonwoven fabric is subjected to corona treatment to enhance
water-absorbing capacity and thus may be used as a wet towel and a
wet tissue.
[0050] In the present invention, in order to enhance the
penetration of water into the hydrophobic nonwoven towel having
protrusions not subjected to hydrophilic treatment, the hydrophobic
nonwoven fabric is subjected to corona treatment, thus increasing
water-absorbing capacity.
[0051] Typically, corona discharge treatment is mainly conducted on
the surface of a plastic film before printing, so that ink
efficiently attaches to the surface of the film.
[0052] In the present invention, the nonwoven fabric is subjected
to corona discharge treatment, whereby water efficiently attaches
and is absorbed by the nonwoven towel having protrusions. Actually,
when the nonwoven towel having protrusions is subjected to corona
discharge treatment, water-absorbing capacity is increased upon
contact of the nonwoven towel with water, and the contact angle of
water is increased upon dropping of water on the nonwoven
towel.
[0053] In the present invention, the nonwoven towel having
protrusions, which is the most economical, sanitary and
inexpensive, is a single-layered nonwoven towel having protrusions
obtained by heat pressing and pin punching hydrophobic PP spunbond
nonwoven fabric having about 5.about.80 g/, so that the nonwoven
fabric has fibrous wrinkled protrusions on one surface thereof and
recesses structured by perforations having a perforation rate of
5.about.50% caused by the punching in the other surface thereof,
totally reducing the fiber density of the nonwoven fabric; pressing
the nonwoven fabric with an embossing line thus reducing the lint
of the nonwoven fabric and imparting embossed unevenness; and
subjecting the nonwoven fabric to corona treatment, thus increasing
cleaning and water-absorbing capacity.
[0054] Also, when the two or more-layered nonwoven towel having
protrusions is formed, the fibrous wrinkled protrusions thereof are
preferably disposed outwards, as shown in FIG. 6.
[0055] This is considered to be because the surface of the nonwoven
fabric having the fibrous wrinkled protrusions exhibits good
cleaning capacity.
[0056] In order to further increase the water-absorbing capacity of
the nonwoven towel having protrusions, a nonwoven towel having
protrusions is manufactured from the absorbent nonwoven fabric.
[0057] Also, when the nonwoven towel having protrusions is provided
in the form of a three-layered composite, as shown in FIG. 3, the
hydrophobic or absorbent nonwoven fabric is pin punched thus
producing nonwoven fabric 24 having fibrous wrinkled protrusions
23, and a layer of absorbent nonwoven fabric 27 or paper tissue may
be sandwiched between two layers of the nonwoven fabric 24. When
paper tissue is sandwiched therebetween, water-absorbing capacity
becomes very good, and thus the resulting product may be used as a
handkerchief.
[0058] In this way, when the two or more-layered nonwoven towel
composite having protrusions is manufactured, the layers are
pressed by ultrasonic embossing, using a heated embossing roll or
using a hot melt adhesive. Preferably useful is ultrasonic
embossing facilitating the formation of unevenness.
[0059] Formation of Fibrous Wrinkled Protrusions on One Surface of
Nonwoven Fabric, Formation of Perforations and Reduction of Fiber
Density
[0060] The fibrous wrinkled protrusions are formed at a height of
0.1.about.5 mm on the surface of the nonwoven fabric to impart the
functionality of many small protrusions of a fiber towel. In the
present invention, the surface of the nonwoven fabric is heat
pressed and pin punched to form the fibrous wrinkled protrusions on
the surface thereof.
[0061] FIG. 1 shows the apparatus for punching the nonwoven fabric.
As shown in FIG. 1, the punching process for forming the fibrous
wrinkled protrusions is performed by unwinding nonwoven fabric 21
from a nonwoven fabric feeding roll 20, passing the nonwoven fabric
21 through a roll 11 having heated pin punches 11a and a roll 12
having heated pockets 12a thus press punching the nonwoven fabric,
and then rewinding the nonwoven towel having protrusions on a roll
22. In the punching process, the bundle of fibers of the nonwoven
fabric sheet is protruded in the form of loop protrusions from the
surface of the nonwoven fabric opposite the surface having the
perforations 23a.
[0062] In the protruding procedure, the elastic fibers are fluffed
out and thus constitute a bundle of loops of elastic fibers having
a reduced fiber density. Through this procedure, the nonwoven
fabric is manufactured into the absorbent nonwoven towel 24 having
protrusions in which the fibrous wrinkled protrusions 23 are formed
on one surface of the nonwoven fabric to be similar to the
protrusions of a woven towel.
[0063] FIG. 2 shows another punching roll. As shown in FIG. 2, the
punching process for protruding the fibrous wrinkled protrusions is
performed by unwinding PP nonwoven fabric 21 from a nonwoven fabric
feeding roll 20, passing it through a roll 11 having heated pin
punches 11a and a roll 12 having pockets 12a thus primarily
punching the nonwoven fabric, passing the punched nonwoven fabric
through the roll 11 having pin punches and a roll 13 having pockets
13a to thus secondarily punch it, and then rewinding the nonwoven
towel having protrusions on a roll 22. In the punching process, the
bundle of fibers of the nonwoven fabric sheet is protruded in the
form of loop protrusions from the surface of the nonwoven fabric
opposite the surface having the perforations 23a. In the protruding
procedure, the elastic fibers are fluffed out and thus constitute a
bundle of loops of elastic fibers having a low fiber density.
Through this procedure, the nonwoven fabric is manufactured into
the absorbent nonwoven towel 24 having protrusions in which the
fibrous wrinkled protrusions 23 are formed on one surface of the
nonwoven fabric to be similar to the protrusions of a woven
towel.
[0064] In the present invention, the nonwoven fabric is punched
using a pin punch roll set. In order to punch the nonwoven fabric
to thus form the fibrous wrinkled protrusions, the pin punch roll
is constructed such that pin punches with mountain-shaped ends are
arranged on the roll and then heated for thermal forming of the
nonwoven fabric. The detailed dimension of the pin punches is set
depending on the size and the height of the protrusions to be
formed on the nonwoven fabric.
[0065] As in FIG. 1, when the nonwoven fabric is heat pressed and
punched using the pin punch roll, the fibers of the nonwoven fabric
are pushed by the pin punches and protrude from the surface of the
nonwoven fabric opposite the surface having the perforations 23a
and are thus wrinkled in the form of loops. Such elastic fibers are
provided in the form of loop protrusions 23. The protrusions have a
height of 0.1.about.5 mm from the bottom of the nonwoven
fabric.
[0066] When the nonwoven fabric is heat pressed and punched using
the pin punch roll, the base pocket roll for supporting the
nonwoven fabric and protruding elastic fibers in the form of
protrusions is provided. The base pocket roll includes, in the
surface of the roll, forming pockets respectively corresponding to
the pin punches of the pin punch roll. The detailed dimension of
the pockets is set depending on the size and the height of the
protrusions of the elastic fibers to be formed on the nonwoven
fabric. The nonwoven fabric in a sheet form is heated and punched
between the heated pin punch roll and the heated pocket roll, and
the elastic fibers protrude in the bundle of loops and are cured,
thus forming the fibrous wrinkled protrusions having a desired
density and size on the surface of the nonwoven fabric.
[0067] In the present invention, the pin punch roll 11 having about
130,000 pin punches 11a arranged per about 1 square meter is used.
The pocket roll 12, 13 corresponding to the pin punch roll has
about 130,000 forming pockets 12a per about 1 square meter. The pin
punch roll 11 very precisely corresponds to the pocket roll 12, 13,
and these rolls are used to perform precise heat punching so that
the fibrous wrinkled protrusions which are the bundle of loops of
such elastic fibers are arranged on the surface of the nonwoven
fabric.
[0068] The flat nonwoven fabric sheet is punched between the heated
punch roll and the heated pocket roll so that the fibers fluff out
and are provided in the form of protrusions on one surface of the
nonwoven fabric. The distribution of the fibrous wrinkled
protrusions is determined by the density of the pin and the
diameter of the pin body in the pin punch roll.
[0069] The perforations are formed in the nonwoven fabric because
of the heat punching which forms the protrusions on one surface of
the nonwoven fabric. As such, the perforations distributed in the
nonwoven towel function to increase water-absorbing capacity and
improve cleaning capacity due to the recesses structured by the
perforations.
[0070] The fibrous wrinkled protrusions of the nonwoven fabric
formed using the pin punch roll and the pocket roll function to
impart the surface of the nonwoven fabric with a fiber texture
similar to that of a woven towel and adhesion. The loop protrusions
of the elastic fibers of the nonwoven fabric are formed with
microfibers having a denier of 0.1.about.10. Unlike a conventional
disposable wet towel or tissue which causes a different texture
upon contact with the skin of a user, the nonwoven towel according
to the present invention comes into close contact with the skin and
is very soft to the touch, resulting in no damage to the skin and
no irritation. Further, the fibrous wrinkled protrusions of the
nonwoven fabric exhibit superior adhesion and cleaning capacity,
and thus a need for a surfactant or a detergent is reduced. The
fibrous wrinkled protrusions formed on one surface of the nonwoven
fabric according to the present invention are brought into soft and
close contact with the skin and the skin wrinkles upon use, thus
exhibiting very good cleaning capacity and a touch softer than the
protrusions of a fiber towel.
[0071] Although the punching means includes the pin punch roll and
the pocket roll in the present invention, the same fibrous wrinkled
protrusions may also be formed using a pin punch plate and a pocket
plate.
[0072] Through the above process using the pin punches, one surface
of the nonwoven fabric has fibrous wrinkled protrusions and the
other surface thereof has perforations.
[0073] The perforation rate of the nonwoven fabric should be about
5% or more so that the fibrous wrinkled protrusions are efficiently
formed on the surface opposite the surface having the perforations.
The perforation rate of the nonwoven fabric is proportional to the
area of the fibrous wrinkled protrusions of the nonwoven fabric and
the area of the punching pin body.
[0074] It is difficult to mechanically obtain a perforation rate of
50% or more.
[0075] The perforation rate of the nonwoven fabric is calculated as
a ratio of the area of the punching pin body relative to the area
of the punching roll.
[0076] The surface of the nonwoven fabric opposite the surface
having fibrous wrinkled protrusions has recesses structured by the
perforations caused by the punching and manifests enhanced cleaning
capacity.
[0077] In the present invention, when the nonwoven fabric is pin
punched, the fiber density of the portion of the nonwoven fabric
which is not subjected to pin punching is also reduced. Upon pin
punching of the nonwoven fabric at a kw speed of 50 m/min or less,
the fiber density of the portion of the nonwoven fabric not
subjected to pin punching is reduced.
[0078] When the nonwoven fabric is pin punched at a low speed,
stress is applied to the portion of the nonwoven fabric not
subjected to pin punching, the bundle of fibers of the nonwoven
fabric is slightly fluffed out and thus the fiber density of the
nonwoven fabric is reduced.
[0079] By reducing the fiber density of the nonwoven fabric in this
way, the nonwoven fabric having protrusions has increased
cushioning capacity and higher water-absorbing and cleaning
capacity compared to before undergoing the punching process.
[0080] When the nonwoven fabric is pin punched at a speed of about
50 m/min or more, the time during which the nonwoven fabric is
pressed by the pins is short, and thus the degree of reduction in
fiber density of the nonwoven fabric is small and the fibrous
wrinkled protrusions are formed to be considerably kw. As the pin
punching speed decreases, the height of the fibrous wrinkled
protrusions increases and the fiber density of the entirety of the
nonwoven fabric is reduced.
[0081] The preferred pin punching speed is 30 m/min or less.
[0082] Formation of Embossed Unevenness and Effects Thereof
[0083] In the present invention, the nonwoven towel having fibrous
wrinkled protrusions is manufactured through punching using the pin
punch roll, and then pressed with an uneven embossing pattern using
an ultrasonic sealer.
[0084] The ultrasonic sealer is composed of an ultrasonic generator
and an embossing roll having a variety of patterns. Some ways of
forming the embossing pattern on the nonwoven towel having
protrusions according to the present invention are described
below.
[0085] The single-layered nonwoven towel having protrusions is
imparted with the embossing pattern using an ultrasonic sealer,
thus manufacturing a desired nonwoven towel.
[0086] In addition, two nonwoven towels having protrusions are
stacked one on another so that the fibrous wrinkled protrusions
thereof are disposed outwards, after which the stacked towels are
pressed with the embossing pattern using an ultrasonic sealer and
simultaneously the embossing pattern is formed on the surface of
the nonwoven fabric having the fibrous wrinkled protrusions, thus
manufacturing a double-sided nonwoven towel having protrusions and
an uneven pattern.
[0087] In addition, two nonwoven towels having protrusions are
respectively placed on both surfaces of a layer of absorbent
nonwoven fabric or paper tissue so that the fibrous wrinkled
protrusions thereof are disposed outwards, after which the
three-layered composite is pressed with the embossing pattern using
an ultrasonic sealer and simultaneously the embossing pattern is
formed on the surface of the nonwoven fabric having the fibrous
wrinkled protrusions, thus manufacturing a desired nonwoven towel
having protrusions and an uneven pattern. Also, the surface of the
two- or three-layered nonwoven towel having protrusions may include
the surface having perforations, if necessary.
[0088] The nonwoven towel having protrusions and an uneven pattern
includes a portion which is not pressed with the embossing pattern
to thus have a thickness of the nonwoven towel and a portion which
is pressed or laminated with the pattern to thus form a pressed
pattern. These two portions constitute the unevenness which causes
the difference in thickness of the nonwoven towel having
protrusions thus enhancing scraping ability and frictional force of
the nonwoven towel, resulting in increased cleaning capacity.
[0089] As for the uneven structure, the thickness of the PP
spunbond nonwoven fabric having a basis weight of 40 g/is about
300. When the pressed portion is formed in the nonwoven fabric in
the shape formed in the embossing roll using the ultrasonic sealer,
the thickness of the pressed portion is about 44, and the
difference in depth of the uneven structure is about 200.
[0090] For example, in the case where the embossing pattern of the
ultrasonic embossing roll is provided in the form of a diamond
line, the thickness of the pressed portion in the diamond line is
different from the thickness of the nonwoven towel having no
deformation, thus forming unevenness.
[0091] When the nonwoven towel having protrusions is imparted with
unevenness in this way, the cleaning capacity of the absorbent
nonwoven towel having protrusions is increased.
[0092] The embossing pattern may have a variety of shapes using
lines or dots, or may include letters.
[0093] Also, when the nonwoven towel having protrusions is imparted
with the embossing pattern, the fibers of the nonwoven fabric are
bonded along the embossing line, thus remarkably reducing the lint
of the nonwoven fabric generated by friction upon use of the
nonwoven towel having protrusions according to the present
invention. The generation of too much lint upon use of the nonwoven
towel having protrusions adversely affects the quality of nonwoven
products.
[0094] Typically, the cleaning capacity of nonwoven fabric is
superior when there is no lint in the nonwoven fabric.
[0095] In the present invention, although the lint of the nonwoven
fabric is described as being increased by the fibrous wrinkled
protrusions, the fluffing of the nonwoven fabric due to the total
reduction in fiber density, and the recesses structured by the
perforations caused by the punching, it may be adjusted through
embossing treatment.
[0096] For the embossing and the embossing pressing (lamination),
the heated embossing roll may be used in the present invention.
[0097] At least one layer of the nonwoven fabric having protrusions
is fed between the heated embossing roll and the confronting roll,
and then heat pressed along the embossing line, thus imparting the
nonwoven fabric having protrusions with the uneven pattern.
[0098] Cleaning Effects and Uses of Nonwoven Fabric having
Protrusions
[0099] The cleaning capacity of the nonwoven towel having
protrusions according to the present invention is enhanced by the
fibrous wrinkled protrusions, the fluffing of the entirety of the
nonwoven fabric, the recesses structured by the perforations caused
by the punching, the unevenness due to the embossing line, and the
increase in water-absorbing capacity resulting from corona
treatment.
[0100] The fibrous wrinkled protrusions of the nonwoven fabric
having a reduced fiber density are provided in the bundle of loops
of elastic fibers protruding from the nonwoven fabric sheet. The
fibrous wrinkled protrusions provided in the bundle of loops of
elastic fibers function to increase the contact area between the
elastic fiber strands and the skin wrinkles and enhance the
adhesion and the scraping ability between it and the skin. Upon
wiping of the skin using the nonwoven towel, such fibrous wrinkled
protrusions are responsible for separating impurities from the
skin, thus increasing cleaning efficiency.
[0101] The surface of the nonwoven fabric opposite the surface
having the fibrous wrinkled protrusions has perforations formed
through the punching process. Thanks to the recesses structured by
such perforations, the surface of the nonwoven fabric opposite the
surface having the fibrous wrinkled protrusions may exhibit
increased water-absorbing and cleaning capacity as compared to
before punching the nonwoven fabric.
[0102] The cleaning effects of the nonwoven towel having
protrusions according to the present invention are enhanced thanks
to the adhesion of the fibrous wrinkled protrusions formed on one
surface of the nonwoven fabric and the increase in elasticity of
the nonwoven fabric which has been fluffed out due to the reduction
in fiber density.
[0103] The nonwoven towels having such cleaning capacity are useful
as disposable sponges, electrostatic dustcloths, makeup removers,
handkerchiefs and so on.
[0104] In the case where the nonwoven towel having protrusions is
used as the dishwashing sponge, it exhibits superior dishwashing
effects and is effective for removing Kimchi stains from a plastic
kitchen board or plastic storage containers. Upon cleaning of a
frying pan, the nonwoven towel having protrusions manifests good
surface cleaning without causing damage to the coating surface of
the frying pan. Upon use of the nonwoven towel having protrusions
as a dishwashing sponge, the nonwoven towel having protrusions is
inexpensive and thus may be discarded after a single use, thus
achieving sanitary effects. Further, because the nonwoven towel
having protrusions is separatable recyclable waste, causing
environmental pollution is avoided and the use of detergent may be
reduced.
[0105] In the case where the nonwoven towel having protrusions
according to the present invention is used as an electrostatic
dustcloth, a lot of dust is caught in the fibrous wrinkled
protrusions having a low density, thus easily removing dust and
preventing the release of trapped dust. Thereby, the nonwoven towel
having protrusions may be conveniently used as an electrostatic
dustcloth. Upon use as a dustcloth, the nonwoven fabric subjected
to hydrophilic treatment generates a small amount of static
electricity, and thus the use of the hydrophobic nonwoven fabric
not subjected to hydrophilic treatment is preferable.
[0106] The dustcloth made of the hydrophobic nonwoven towel having
protrusions according to the present invention generates much more
static electricity than presently commercially available dustcloths
made of spunlace nonwoven fabric, and thus upon cleaning of hairs,
the use of the dustcloth made of the hydrophobic nonwoven towel
having protrusions according to the present invention is more
effective.
[0107] The electrostatic dustcloth according to the present
invention includes a dustcloth used for wiping a sink, a washstand,
pieces of furniture and so on. Upon cleaning of the sink, dirt
stains are easily removed, and upon cleaning of furniture, dirt
stains are easily removed and there is no damage caused to the
surface of the furniture.
[0108] Also upon use of the nonwoven towel having protrusions
according to the present invention as a makeup remover, the makeup
is removed from the skin mainly by the fibrous wrinkled protrusions
of the nonwoven fabric, and further, upon facial cleansing after
removal of the makeup, the makeup residue may be completely
removed.
[0109] Upon skin cleansing, because the fibrous wrinkled
protrusions and the low-density fibers around the perforations of
the nonwoven fabric are responsible for removing the impurities
from the skin wrinkles, the same effects as when using the soap may
be obtained even when soap is not used.
[0110] Also, when the skin and hair of a hospitalized patient who
has not bathed are wiped using the nonwoven towel having
protrusions according to the present invention as a replacement for
bathing, the patient s body may feel as clean as when it is
bathed.
[0111] Manufacture of Nonwoven Towel having Protrusions for Wet
Towel and Other Uses
[0112] The nonwoven towel having protrusions according to the
present invention is cut to the size of a disposable wet towel or
tissue, wet with water, and then packaged, and thus used as a
disposable wet towel or tissue.
[0113] Also, the nonwoven towel having protrusions according to the
present invention may be provided in the form of a towel roll
having perforated tear lines so that it may be torn in a
predetermined size, like a roll of toilet paper. In this case, a
consumer may directly wet the towel with water and then may use it
as a wet towel.
[0114] The nonwoven towel having protrusions is cut to a
predetermined size and thus may be used as a disposable makeup
remover, a facial cleansing wet towel used after removal of the
makeup, a dishwashing sponge, a handkerchief, and an electrostatic
dustcloth, or may be provided in the form of a towel roll having
perforated tear lines to tear it to a predetermined size, like a
roll of toilet paper.
[0115] In the nonwoven towel having protrusions according to the
present invention, the bundle of fibers of the nonwoven fabric
protrude in the form of protrusions of the towel on the surface of
the nonwoven fabric opposite the surface having perforations, and
the pin punched surface has recesses structured by the perforations
caused by the punching. Thereby, the fiber density of the entirety
of the nonwoven fabric is reduced, thus improving cleaning and
water-absorbing capacity. Also, thanks to the embossed unevenness,
the lint of the nonwoven fabric is reduced. The water-absorbing
capacity may be enhanced through corona treatment.
[0116] The nonwoven products having protrusions according to the
present invention are not yet used as disposable wet towels,
disposable wet tissues, handkerchiefs, makeup removers, dishwashing
sponges, dustcloths and so on, and thus the nonwoven towel having
protrusions according to the present invention is of a novel type
imparting expedience to daily life.
[0117] Also, the nonwoven towel having protrusions according to the
present invention is environmentally friendly thanks to the
reduction of the use of hydrophilic agent and detergent.
[0118] Below, examples of the nonwoven towel having protrusions
according to the present invention are described.
EXAMPLE 1
[0119] Hydrophobic PP spunbond nonwoven fabric having a basis
weight of 40 g/and not subjected to hydrophilic treatment was
punched at a speed of 10 m/min using a pin punch roll set, and thus
fibrous wrinkled protrusions of the elastic fibers of the nonwoven
fabric were formed on one surface of the nonwoven fabric, thereby
manufacturing an absorbent nonwoven towel having protrusions and
enhanced cleaning capacity. In the punching process, the pin punch
roll was heated to 120.degree. C., and the pocket roll was heated
to 110.degree. C. The pin punches of the pin punch roll had a
diameter of 1.9 mm, and the arrangement density of the pin punches
was about 13/.
EXAMPLE 2
[0120] As an absorbent layer, spunlace nonwoven fabric having an
average thickness of 200 was prepared, and then sandwiched between
the two nonwoven towels of Example 1 in which the fibrous wrinkled
protrusions thereof were disposed outwards. The three-layered
nonwoven composite was pressed using an ultrasonic sealer. The
embossing press of the embossing roll of the ultrasonic sealer had
a diamond line shape having one side 7 mm long and a line thickness
of 0.5 mm.
[0121] Through the pressing of the three-layered nonwoven composite
using the embossing roll of the ultrasonic sealer, unevenness was
imparted to the surface of the nonwoven fabric having the fibrous
wrinkled protrusions.
EXAMPLE 3
[0122] PP spunbond nonwoven fabric having a basis weight of 40
g/and subjected to hydrophilic treatment was punched as in Example
1 using a punching machine of a pin punch roll set. In the punching
process, the nonwoven fabric having absorbent fibrous wrinkled
protrusions on one surface thereof was passed through an ultrasonic
sealer, and thus a pressed portion by the uneven embossing pattern
of the embossing roll of the ultrasonic sealer was formed in the
surface of the nonwoven fabric having the fibrous wrinkled
protrusions. The pressed portion by the embossing roll had a
diamond line shape having one side 7 mm long and a line thickness
of 0.5 mm.
EXAMPLE 4
[0123] Nonwoven fabric having protrusions was manufactured in the
same manner as in Example 1, with the exception that the basis
weight of the nonwoven fabric was 25 g/.
[0124] Two layers of the nonwoven fabric having protrusions were
stacked one on another so that the fibrous wrinkled protrusions
thereof were disposed outwards and then pressed while forming the
pressed portion by the embossing pattern of the embossing roll of
an ultrasonic sealer. The pressed portion by the embossing roll had
a diamond line shape having one side 7 mm long and a line thickness
of 0.5 mm.
EXAMPLE 5
[0125] The nonwoven fabric having perforations of each of Examples
1 and 4 was subjected to corona treatment, thus enhancing
water-absorbing capacity.
EXAMPLE 6
[0126] The portion pressed by the embossing pattern of the
embossing roll of the ultrasonic sealer was formed in the nonwoven
fabric of Example 1 subjected to corona treatment. The portion
pressed by the embossing roll had a diamond line shape having one
side 7 mm long and a line thickness of 0.5 mm.
EXAMPLE 7
[0127] Use Example
[0128] The nonwoven fabric of each of Examples 1, 2, 3, 4, 5, 6 was
cut to a width of 30 cm and a length of 20 cm, and the nonwoven
towels having protrusions represented by Roman numerals I, II, III,
. . . corresponding thereto were manufactured.
[0129] The nonwoven towels I, II, III, . . . were used as
follows.
[0130] The nonwoven towels I, II, III, . . . were wet with water
and used as a wet facial cleansing wipe and a general wet
tissue.
[0131] When the face of a user was wiped with the nonwoven towel
having protrusions, oiliness and dirt were removed not only from
the surface of the skin but also from the facial wrinkles, thus
making the user feel cool. The surface texture of the wet towel was
good. Also, the user had the same feeling as when cleansing the
face using soap. In particular, facial dirt was mainly caught in
the fibrous wrinkled protrusions of the nonwoven fabric and also in
the perforations of the nonwoven fabric.
[0132] In addition, the face of a user was wiped using a
commercially available disposable nonwoven wet tissue.
[0133] Compared to the conventional nonwoven wet tissue having no
fibrous wrinkled protrusions, the frictional force and the cleaning
capacity of the nonwoven wet towel having fibrous wrinkled
protrusions were greater and the feel after cleansing was much
finer.
[0134] Compared to the single-layered nonwoven towel having
protrusions, the two- or three-layered nonwoven towel having
protrusions was more suitable for use as a facial cleansing wet
towel. The three-layered nonwoven towel having protrusions gave the
user a feeling like that of a woven wet towel.
[0135] The comparison test for wiping the excrement of an infant
using a commercially available disposable nonwoven tissue was
conducted. Compared to the commercially available wet tissue, the
nonwoven towel having fibrous wrinkled protrusions exhibited
superior cleaning effects.
[0136] When the nonwoven towels I, II, III, . . . were used as a
dishwashing sponge, good dishwashing effects were exhibited.
[0137] In the case of being used as a dishwashing sponge, the
cleaning effects were greater even without the use of a detergent.
Further, the nonwoven towel having protrusions was effective for
the removal of Kimchi stains from a plastic kitchen board, a
plastic storage container or the like. Upon cleaning of a frying
pan, there was no damage to the coating surface of the frying pan
and good surface cleaning capacity was exhibited.
[0138] When makeup was removed from the face of a user using the
nonwoven towels I, II, III, . . . , the makeup was removed well and
the use texture thereof was good. In particular, the makeup was
mainly caught in the fibrous wrinkled protrusions of the nonwoven
fabric.
[0139] When the nonwoven towel having protrusions was used as a
facial cleansing wet tissue after removal of the makeup, good
cleaning capacity was exhibited. Also, the nonwoven towels I, . . .
were used as an electrostatic dustcloth.
[0140] In this case, the same dust removal effects as when using a
commercially available electrostatic dustcloth made of spunlace
nonwoven fabric were exhibited.
[0141] The nonwoven towels I, . . . generated static electricity
greater than the commercially available dustcloth made of spunlace
nonwoven fabric, and exhibited hair cleaning effects superior to
the commercially available dustcloth made of spunlace nonwoven
fabric.
[0142] Both the surface of the nonwoven fabric having fibrous
wrinkled protrusions and the surface thereof having the
perforations were effective for the removal of dust. In particular,
much dust was caught in the surface having fibrous wrinkled
protrusions.
[0143] The nonwoven towel having protrusions had water-absorbing
capacity greater than the nonwoven towel having protrusions I.
[0144] The nonwoven towel having protrusions generated lint less
than the nonwoven towel having protrusions I.
EXAMPLE 8
[0145] As an absorbent layer, paper tissue having a basis weight of
20 g/was prepared, and then sandwiched between two nonwoven towels
having protrusions as shown in FIG. 6 so that the fibrous wrinkled
protrusions of the absorbent nonwoven fabric of Example 3 were
disposed outwards. The three-layered nonwoven composite was pressed
using an ultrasonic sealer, and pressed unevenness was formed.
[0146] The shape of the embossing laminator of the embossing roll
of the ultrasonic sealer was a diamond line having one side 7 mm
long and a line thickness of 0.5 mm.
[0147] The sandwich type nonwoven towel having protrusions was cut
to a width of 30 cm and a length of 30 cm, and then used as a
handkerchief.
[0148] When the wet hand of a user was wiped with the nonwoven
towel having protrusions, water was removed well.
EXAMPLE 9
[0149] External Appearance of Nonwoven Fabric
[0150] The average thickness of the PP spunbond nonwoven fabric
having a basis weight of 40 g/before punching in Examples 1 and 3
was about 300. After punching, the average thickness of the PP
spunbond nonwoven fabric having a basis weight of 40 g/was about
600.
[0151] The average thickness of the three-layered nonwoven
composite of Example 2 was about 1600, and was considerably
increased compared to about 800 which was the thickness before
punching.
[0152] As a thickness gauge, a digital thickness gauge available
from Mitutoyo was used. The thickness was measured in a state in
which the punched protrusions were slightly pressed.
[0153] Due to the increase in the thickness, the external
appearance of the nonwoven fabric gave a feel like that of a woven
wet towel.
[0154] As the thickness increased, the portion of the nonwoven
fabric which was not pin punched became soft and was reduced in
fiber density and increased in elasticity, which was confirmed with
the naked eye and the sense of touch.
[0155] Although preferred embodiments of the present invention have
been disclosed for illustrative purposes, those skilled in the art
will appreciate that various modifications, additions and
substitutions are possible, without departing from the scope and
spirit of the invention as disclosed in the accompanying
claims.
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